TM 5-3655-210-12
TECHNICAL MANUAL
OPERATOR AND ORGANIZATIONAL MAINTENANCE
MANUAL
CONVERSION, STORAGE AND
CHARGING UNIT CARBON DIOXIDE:
GASOLINE ENGINE OR ELECTRIC MOTOR
DRIVEN; SEMI-TRAILER MTD, 16, 000 LB.
CAPACITY: CARDIX MODEL E-46750
NSN 3655-00-062-7911
HEADQUARTERS, DEPARTMENT OF THE ARMY
10 JUNE 1976
TM 5-3655-210-12
WARNING
Take particular heed to specific cautions and warnings throughout this manual.
WARNING
Dry cleaning solvent, P-D-680 or P-S-661, used to clean parts is potentially dangerous to personnel and property. Use in
a well-ventilated area as the fumes are dangerous if inhaled. Avoid repeated and prolonged skin contact. Do not use
near open flame or excessive heat. Flash point of solvent is 100F. 138F. (38C. 59C.).
WARNING
Do not isolate sections of lines, components, or fittings not equipped with automatic pressure releases
without first releasing all residual gases.
WARNING
Personnel entering the conversion compartment must be equipped with a safety line securely attached. A safety guard
must be positioned to observed and assist persons working inside at all times.
SAFETY PRECAUTIONS
BEFORE OPERATION
Be sure the fire extinguisher is in place and in operating condition. Follow all lubrication and preventive maintenance
procedures with care, to avoid damaging the equipment. Shut down the engine before filling the fuel tank. Do not fill the
fuel tank while smoking, or within 50 feet of an open flame. Always provide a metal contact between the container and
tank when filling the fuel tank. Be sure trailer is properly grounded. Do not overfill a battery or splash electrolyte. Spilled
electrolyte will cause personal injury or equipment damage. Do not engage the starting motor for more than 30 seconds
at a time, without allowing a 3-minute cooling off period.
DURING OPERATION
When the refrigeration unit is operated manually install two pressure gages on the compressor; one on the suction side
and one on the discharge side, so that suction and discharge pressures may be checked. These pressures must not be
allowed to exceed their normal limits. Do not allow the cylinder filling unit to idle at charging pressures for long periods of
time. This will cause pressure buildup within the pressure vessels, and wear out the cylinder filling unit. Do not apply
power to drive shaft while personnel are positioned inside of operating compartment.
AFTER OPERATION
Shut the pressure off to any line, fitting, or valve before loosening the connections. Shut off the electrical power before
working on any electrical component. Disconnect the 220-volt power supply, disconnect one battery cable and set the
gasoline engine control switch to "manual" before performing any maintenance or service in the power compartment. If
this is not done, the equipment may start in response to the automatic controls. Before entering either pressure vessel,
be sure the compartment has been thoroughly ventilated. Never enter, or let personnel enter, the pressure vessels
unless personnel are stationed at the manway to observe continuously for signs of trouble caused by lack of air. While
carbon dioxide is not poisonous, large quantities can cause suffocation. Pump down the refrigerant from the refrigeration
compressor into the receiver before opening the compressor crankcase.
TM 5-3655-210-12
C1
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 23 October 1990
NO. 1
Operator and Organizational Maintenance Manual
CONVERSION, STORAGE AND CHARGING UNIT
CARBON DIOXIDE:
GASOLINE ENGINE OR ELECTRIC MOTOR DRIVEN;
SEMI-TRAILER MTD, 16, 000 LB.
CAPACITY: CARDIX MODEL E-46750
NSN 3655-04062-7911
Approved for public release; distribution is unlimited
TM 5-3655-210-12, 10 June 1976, is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the
margin. An illustration change is indicated by a miniature pointing hand.
Remove pages
Insert pages
2-27
3-9 and 3-10
4-3 and 4-4
2-27/2-28
3-9 and 3-10
4-3 and 4-4
2. Retain this sheet in front of manual for reference purposes.
By Order of the Secretary of the Army:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
HOMAS F. SIKORA
Brigadier General, United States Army
The Adjutant General
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 0502)
*TM 5-3655-210-12
TECHNICAL MANUAL
No. 56-3655-210-12
HEADQUARTERS,
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 10 June, 1976
OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL
CONVERSION, STORAGE AND CHARGING UNIT
CARBON DIOXIDE: GASOLINE ENGINE OR
ELECTRIC MOTOR DRIVEN; SEMI-TRAILER
MTD, 16, 000 LB. CAPACITY: CARDIX MODEL E-46750
NSN 3655-00-062-7911
REPORTING OF ERRORS
You can help to improve this manual by calling attention to errors and by recommending improvements.
Your letter, DA Form 2028 (Recommended Changes to Publications), and/or DA Form 2028-2
(Recommended Changes to Equipment Technical Manuals) may be used. Copies of DA Form 2028-2
are attached in the back of the manual for your use. Please mail your recommended changes directly to
Commander, U. S. Army Troop Support Command, ATTN: DRSTS-MPP, 4800 Goodfellow Blvd, St.
Louis, MO 63120. A reply will be furnished directly to you.
Paragraph
Chapter
Section
Chapter
Section
1.
I.
II.
2.
I.
II.
III.
Chapter
3.
Section
I.
II.
Chapter
III.
IV.
4.
Section
I.
II.
III.
IV.
LIST OF ILLUSTRATIONS
LIST OF TABLES
INTRODUCTION
General....................................................................................................1-1
Description and Data................................................................................1-6
OPERATING INSTRUCTIONS
Operating Procedures ..............................................................................2-1
Operation of Auxiliary Material
Used in Conduction with
Conversion and Storage Unit .............................................................2-17
Operation Under Unusual
Conditions .........................................................................................2-18
OPERATOR/CREW MAINTENANCE
INSTRUCTION
Lubrication Instructions ............................................................................3-1
Preventive Maintenance Checks
and Services (PMCS) ........................................................................3-4
Troubleshooting .......................................................................................3-6
Maintenance Procedures .........................................................................3-8
ORGANIZATIONAL MAINTENANCE
INSTRUCTIONS
Service Upon Receipt of
Material .............................................................................................4-1
Movement to a New Worksite ..................................................................4-6
Repair Parts, Special Tools and
Equipment ...............................................................................................4-8
Lubrication Instructions ............................................................................4-11
*This manual supersedes TM 5-865621012, 28 October 1968, including all changes.
Page
1-1
1-1
2-1
2-26
2-25
3-1
3-4
3-6
3-5
4-1
4-8
4-8
4-8
TM 5-3655-210-12
Paragraph
Section
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
XIV.
XV.
XVI.
XVII.
XVIII.
XIX.
XX.
XXI.
XXII.
Section XXIII.
Appendix
A
B
C
Index
Preventive Maintenance Checks
and Services......................................................................................4-14Troubleshooting .......................................................................................4-16
Radio Interference Suppression ...............................................................4-18
Maintenance of the Gasoline
Engine Fuel System ..........................................................................4-23
Gasoline Engine Lubrication
System and Valve Tappets ................................................................4-31
Exhaust System.......................................................................................4-35
Gasoline Engine Ignition
System ..............................................................................................4-38
24 Volt Electrical Systems
Engine and Vehicular.........................................................................4-41
220 Volt AC Electrical System .................................................................4-56
Engine and Power Compartment
Cooling System .................................................................................4-59
Wheels, Tires, Tubes, and
Bearings ............................................................................................4-65
Brake System ..........................................................................................4-69
Frame......................................................................................................4-80
Springs ....................................................................................................4-82
Body ........................................................................................................4-83
Refrigeration System ...............................................................................4-87
Clutches and Drive Belts..........................................................................4-91
Carbon Dioxide Transfer and
Cylinder Filling System ......................................................................4-93
Conversion Heater ...................................................................................4-106
REFERENCES ........................................................................................
MAINTENANCE ALLOCATION CHART ..................................................
BASIC ISSUE ITEMS LIST AND
ITEMS TROOP INSTALLED OR
AUTHORIZED ...................................................................................
..........................................................................................................
ii
Page
4-10
4-11
4-27
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4-43
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4-71
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4-90
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4-100
4-113
A-1
B-1
C-1
I-1
Figure
1-1
1-2
1-3
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3-1
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
TM 5-3655-210-12
LIST OF ILLUSTRATIONS
Title
Page
Conversion Storage and Charging Unit, 3/4 Left
Front View (TS 024476)....................................................................................................1-2
Conversion Storage and Charging Unit, Right
Rear View (TS 024477) ....................................................................................................1-3
Wiring Diagram (TS 024478) ..................................................................................................1-7
Power Compartment Valves and Controls
(TS 024479) .....................................................................................................................2-2
Engine Control Panel (TS 024480)..........................................................................................2-3
Clutch Controls, Installed View (TS 024481) ...........................................................................2-4
Liquid Level Gages, Pressure Vessels (TS 024482) ................................................................2-5
Conversion Heater, Installed View (TS 024483) ......................................................................2-6
Schematic Piping Diagram TS 024484) ..................................................................................2-7
Refrigeration Flow Diagram (TS 024485) ................................................................................2-8
CO2 Manifolds, Installed View (TS 024486 .............................................................................2-9
Electric Motor Starter and Reversing Switch
(TS 024487) .....................................................................................................................2-10
Governor Controls, Installed View (TS 024488).......................................................................2-11
Power Receptacles, Installed View (TS Q24489).....................................................................2-12
Refrigeration Compressor, Installed View
TS 024490).......................................................................................................................2-13
Normal Conversion Operation (TS 024491) ............................................................................2-14
Manway Access (TS 024492)..................................................................................................2-14
Manway Cover TS 024493).....................................................................................................2-14
Transfer of Liquid from the Conversion Pressure
Vessel to the Storage Pressure Vessel
(TS 024494) .....................................................................................................................2-15
Reduced Conversion Cycle (TS 024495) ................................................................................2-16
Storage Compartment, Face View (Serial Nos.
L-1475-T through L-1478-T) (TS 024496) .........................................................................2-17
Storage Compartment, Face View (Serial Nos.
L-1666-T through L-1668-T) (TS 024497) .........................................................................2-18
Filling Both Pressure Vessels with Liquid
Carbon Dioxide (TS 024498) ............................................................................................2-19
Transfer Operation Liquid Fill, Storage
Compartment Only (TS 024499) .......................................................................................2-20
Transferring Liquid from Both Compartments
(TS 024500) .....................................................................................................................2-21
Transfer of Liquid Carbon Dioxide from the
Storage Pressure Vessel (TS 024501) ..............................................................................2-22
Transfer of Liquid Carbon Dioxide from One
External Tank to Another External Tank
(TS 024502) .....................................................................................................................2-23
Cylinder Filling Operation (TS 024503) ...................................................................................2-24
Power Compartment Heating (TS 024504)..............................................................................2-26
Lubrication Chart (Sheet 1 of 2) (TS 024506)..........................................................................3-2
Lubrication Chart (Sheet 2 of 2) (TS 024506)..........................................................................3-3
Air Cleaner, Exploded View (TS 024507) ................................................................................3-6
Fuel Filter, Exploded View (TS 024508)..................................................................................3-7
Muffler and Exhaust Pipes (TS 024509)..................................................................................3-8
Engine Control Panel (TS 024510)..........................................................................................3-9
Taillight Removal (TS 024511)) ..............................................................................................3-10
Blackout Stop and Taillight, Exploded View (TS 024512) ........................................................3-11.
Clearance Light, Exploded View (TS 024513) .........................................................................3-11
Heater Compartment and Oome Lights, Installed
View (TS 024514) ............................................................................................................3-12
Electrolyte and Batteries Stored for Shipment
(TS 024615) .....................................................................................................................3-13
Batteries, Installed View (TS 024516) .....................................................................................3-14
iii
TM 5-3655-210-12
Figure
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
4-18
4-19
4-20
4-21
4-22
4-23
4-23
4-24
4-25
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4-27
4-28
4-29
4-30
4-31
4-32
4-33
4-34
4-35
4-36
4-37
4-38
4-39
4-40
4-40
4-41
4-42
4-43
Title
Page
Power Receptacles, Installed View (TS 024517) .....................................................................3-14
Landing Gear, Installed View (TS 024518) ..............................................................................3-1
Electric Motor Starter and Reversing Switch
(TS 024519) .....................................................................................................................3-16
Conversion Heater, Installed View (TS 024520) ......................................................................3-17
Clutch Controls, Installed View (TS 024521) ...........................................................................3-18
C02 Manifolds, Installed View (TS 024522).............................................................................3-19
Storage Compartment, Face View (TS 024523) ......................................................................3-20
Storage Compartment, Face View (Serial Nos.
L-1666-T through L-1668-T) (TS 024524) .........................................................................3-21
Conversion and Storage Unit Tie-Down and
Blocking (TS, 024525) ......................................................................................................4-2
Electrolyte and Batteries Stored for Shipment
(TS 024526) .....................................................................................................................4-3
Batteries, Installed View (TS 024527) .....................................................................................4-4
Refrigeration Compressor, Installed View
(TS 024528) .....................................................................................................................4-5
Axle with Brake System Parts, Removed (TS 024529)...........................................................4-9
Shut-Off Valve (TS 024530)....................................................................................................4-11
208V, AC Power Receptacle (TS 024531)...............................................................................4-12
Spark Plug, Removal (TS 024532)..........................................................................................4-12
Checking for Correct Breaker Point Gap (TS 024533)............................................................4-13
Flywheel Screen, Removal (TS 024534) .................................................................................4-14
Flywheel Timing Marks (TS 024535).......................................................................................4-14
Idle Adjusting Screw (TS 024536) ...........................................................................................4-15
Tappet Adjustment (TS 024537) .............................................................................................4-15
Choke Control Levers (TS 024538) .........................................................................................4-16
Pressure Switch Adjustment (TS 024539) ...............................................................................4-18
Clutch Adjusting Points (TS 024540).......................................................................................4-21
Pressure Gage (TS 024541) ...................................................................................................4-22
Cylinder Filling Operation (TS 024542) ...................................................................................4-22
Blower and Fuel Pump Removal (TS 024543) ........................................................................4-23
Fuel Line Removal (TS 024544) .............................................................................................4-24
Fuel Filter, Exploded View (TS 024545)..................................................................................4-25
Blower and Fuel Pump, Exploded View (TS 024546) ..............................................................4-26
Ignition Suppression Components (Sheet 1 of 2) (TS 024547) ...............................................4-27
Ignition Suppression Components (Sheet 2 of 2) (TS 024548) ...............................................4-24
Governor Controls, Installed View (TS 024549).......................................................................4-29
Governor Controls, Exploded View (TS 024550) .....................................................................4-30
Intake Manifold and Carburetor (TS 024551)...........................................................................4-31
Engine, Fuel System View (TS 024552)..................................................................................4-33
Air Cleaner, Exploded View (TS 024553) ................................................................................4-34
Governor, Partially Exploded View (TS 024554) .....................................................................4-35
CO2 Manifolds, Installed View (TS 0245555) ..........................................................................4-36
Fuel Filter, Exploded View (TS 024556)..................................................................................4-37
Governor Controls, Installed View (TS 024557).......................................................................4-38
Fuel Filter, Exploded View (TS 024558)..................................................................................4-39
Engine, Fuel System View (TS 024559)..................................................................................4-40
Intake Manifold and Carburetor (TS 024560)...........................................................................4-42
Oil Filter, Exploded View (TS 024561) ....................................................................................4-43
Valve Cover and Gasket (TS 024562).....................................................................................4-44
Tappet Adjustment (TS 024563) .............................................................................................4-45
Muffler and Exhaust Pipes (TS 024564)..................................................................................4-47
Ignition Suppression Components (Sheet 1 of 2) (TS 024565) ...............................................4-48
Ignition Suppression Components (Sheet 2 of 2) (TS 024566) ...............................................4-49
Flywheel Timing Marks (TS 024567).......................................................................................4-50
Magneto Gear Timing Marks (TS 024568) ..............................................................................4-50
Breaker Point Removal and Adjustment (TS 024569) .............................................................4-50
iv
TM 5-3655-210-12
Figure
4-44
4-45
4-46
4-47
4-48
4-49
4-50
4-51
4-52
4-53
4-54
4-55
4-56
4-57
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4-60
4-61
4-62
4-63
4-64
4-65
4-66
4-67
4-68
4-69
4-70
4-71
4-72
4-73
4-74
4-75
4-76
4-77
4-78
4-79
4-80
4-81
4-82
4-83
4-84
4-85
4-86
4-87
4-88
4-89
4-90
Title
Page
Condenser and Breaker Points, Exploded View (TS 024570) .................................................4-51
Trailer Running Light Wiring Schematic (TS 024571).............................................................4-52
Dome Light Schematic (TS 024572) .......................................................................................4-53
Engine Control Panel (TS 024573)..........................................................................................4-54
DC Control Wiring Schematic (TS 024574).............................................................................4-55
Batteries and Box, Exploded View (TS 024575) ......................................................................4-56
Starter and Solenoid Removal (TS 024576)............................................................................4-57
Generator and Regulator Removal (TS 024577) .....................................................................4-58
Generator Brush Installation (TS 024578) ...............................................................................4-59
Pressure Switch Adjustment (TS 024579) ...............................................................................4-60
Batteries, Installed View (TS 024580) .....................................................................................4-61
Control Panel Unit Removal (TS 024581) ...............................................................................4-62
Wiring Diagram (TS 024582) ..................................................................................................4-63
Gage Panel, Rear View (TS 024583) ......................................................................................4-64
Liquid Level Gages, Pressure Vessels (TS 024584) ...............................................................4-65
Alarm Bell, Partially Exploded View
(Serial NosL-1475-T through L-1478-T)
(Sheet 1 of 2) (TS 024585) ...............................................................................................4-66
Alarm Bell, Partially Exploded View
(Serial Nos.L-1666-T through L-1668-T)
(Sheet 2 of 2) (TS 024586) ...............................................................................................4-67
Taillight Removal (TS 024587) ...............................................................................................4-67
Blackout Stop and Taillight, Exploded View (TS 024588) .......................................................4 -68
Service Taillight, Exploded View (TS 024589)- .......................................................................4-68
Clearance Light, Exploded View-(TS 024590) .........................................................................4-69
Heater Compartment and Dome Lights, Installed
View (TS 024591) .............................................................................................................4-70
220 Volt Wiring Schematic (TS 024592) .................................................................................4-71
Electric Motor, Installed View (TS 024593)..............................................................................4-72
Rear Door Shutter Control Removal (TS 024594) ...................................................................4-73
Power Compartment Valves and Controls (TS 024595) .........................................................4-74
Wheel and Hub Removal (TS 024596)....................................................................................4-76
Wheel Mounting Details (TS 024597)......................................................................................4-77
Hub and Drum Assembly, Exploded View (TS 024598)..........................................................4-78
Air Brake System Layout (TS 024599) ....................................................................................4-79
Axle with Brake System Parts, Removed (TS 0245600).........................................................4-81
Slack Adjuster, Correct Travel (TS 0245601) ..........................................................................4-82
Wheel Brake Assembly (TS 0245602).....................................................................................4-83
Power Receptacles, Installed View (TS 0245603) ...................................................................4-85
Pintle Hook, Exploded View (TS 0245604)..............................................................................4-86
Storage Compartment, Face View (TS 0245605) ....................................................................4-87
Storage Compartment, Face View (Serial Nos.
L1666-T through L-1668-T) (TS 024606)...........................................................................4-88
Landing Gear, Installed View (TS 0245607) ............................................................................4-89
Torque Arm Adjustment and Removal-(TS 0245608)..............................................................4-90
Power Compartment Door, Exploded View (TS 024609) ........................................................4-91
Storage Compartment Door, Exploded View (TS 024610)......................................................4-93
Refrigeration Flow Diagram (TS 024611) ................................................................................4-94
Refrigeration Compressor, Installed View (TS 024612) ..........................................................4-96
C02 Manifolds Installed View (TS 024613)..............................................................................4-97
Refrigeration Receiver and Suction Valve (TS 024614) .........................................................4-98
Clutch Adjusting Points (TS 024615).......................................................................................4-99
Schematic Piping Diagram (TS 024616) .................................................................................4-101
CO2 Liquid Manifold, Exploded View (TS 024617)..................................................................4-102
v
TM 5-3655-210-12
Figure
4-91
4-92
4-93
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4-111
4-112
4-113
4-114
Title
Page
Power Receptacles, Installed View (TS 024618) .....................................................................4-103
Clutch Controls, Installed View (TS 024619) ...........................................................................4-104
C02 Manifolds, Installed View (TS 024620).............................................................................4-105
CO2 Vapor Manifold, Exploded View (TS 024621)..................................................................4-106
Generator and Regulator Removal (TS 024622) .....................................................................4-107
Cylinder Filling Manifold, Exploded View (TS 024623) ...........................................................4-108
Power Compartment Valves and Controls (TS 024624) .........................................................4-109
Gage Panel, View (TS 024625)...............................................................................................4-110
Strainer, Exploded View (TS 024626) .....................................................................................4-112
Conversion Heater, Installed View (TS 024627) ......................................................................4-113
Engine Control Panel (TS 0224628)........................................................................................4-114
Heater Wiring Diagram (TS024629)........................................................................................4-115
Heater Compartment and Dome Lights, Installed
View (TS 024630) .............................................................................................................4-116
Water Manifold, Exploded View (Serial Nos.
L-1475-T through L1478-T)(TS 024631)............................................................................4-118
Water Manifold, Exploded View (Serial Nos.
L-1666-T through L1668-T) (TS 024632)...........................................................................4-119
Blower and Fuel Pump Removal (TS 024633) ........................................................................4-120
Blower and Fuel Pump, Exploded View (TS 024634) ..............................................................4-121
Fuel Line Removal (TS 024635) .............................................................................................4-122
Fuel Filter, Exploded View (TS 024536)..................................................................................4-123
Fuel Manifold, Exploded View (TS 024637) ............................................................................4-124
Combustion Head, Exploded View (TS 024638)......................................................................4-125
Heater Compartment and Dome Lights, Installed
View (TS 024639) .............................................................................................................4-126
Heater Removal Points (Serial Nos. L1475-T
through L.1478-T) (TS 024640).........................................................................................4-128
Heater Removal Points (Serial Nos.
L-1666-through L-1668-T) (TS 02641).....................................................................................4 -129
vi
TM 5-3655-210-12
LIST OF TABLES
Number
2-1
3-1
3-2
4-1
4-2
4-3
4-4
4-5
4-6
Page
Valves ................................................................................................................................. 2-10
Operator/Crew Preventive Maintenance Checks and
Services ........................................................................................................................ 3-4
Troubleshooting................................................................................................................... 3-5
Separate Packed Items........................................................................................................ 4-1
Military Antifreeze Materials Used with Unit ......................................................................... 4-3
Maintenance and Operating Supplies .................................................................................. 4-6
Organizational Preventive Maintenance Checks
and Services ................................................................................................................. 4-10
Troubleshooting................................................................................................................... 4-11
Valves ................................................................................................................................. 4-25
vii
TM 5-3655-210-12
CHAPTER 1
INTRODUCTION
Section I. GENERAL
1-3.
Equipment Serviceability Criteria
This equipment is not covered by an ESC.
1-1.
Scope
These instructions are published for the use by
personnel to whom the Cardox Model E-46750
conversion, storage and charging unit is issued. They
provide information on the operation and organizational
maintenance of the equipment. Also included are
descriptions of main units and their functions in
relationship to other components.
1-4.
Destruction of Army Material to Prevent
Enemy Use Refer to TM 750-244-3 for instructions to
destroy material to prevent enemy use.
1-5.
Administrative Storage
Refer to TM 740-90-1 for instructions
administrative storage of this equipment.
1-2.
aintenance Forms and Records
Maintenance forms and records that you are required to
use are explained in TM 38-750.
on
the
Section II. DESCRIPTION AND DATA
1-6.
Description
a. The Cardox Model E-46750 carbon dioxide
liquid storage and conversion unit (figs 1-1 and 1-2) is
self-contained, and is designed for road transportation
by any suitable towing unit with air brake connections.
b. A cylindrical storage tank, located at the front of
the unit, is divided by a bulkhead into two hermetically
sealed pressure vessels: A 6-ton (5.4431 metric tons)
pressure vessel (front section) for the storage of liquid
carbon dioxide; and a 2-ton (1.8144 metric tons)
pressure vessel (rear section) for the conversion of solid
carbon dioxide (dry ice) into liquid carbon dioxide and
for storage of liquid carbon dioxide. After the unit has
been filled either liquid carbon dioxide or solid carbon
dioxide (the latter is reduced to a liquid through the use
of a heater), the temperature and pressure are
controlled by mechanical refrigeration.
The liquid
carbon dioxide in each pressure vessel is maintained at
a temperature of 17C. or OF., and a corresponding
vapor pressure of 295-305 psi (20.7385 to 21.4415 kg
per sq cm). Each pressure vessel is provided with a
safety vent assembly for protection against abnormally
high pressures. A manway cover is located at the top of
each pressure vessel. Blocks of insulation surround
each manway and must be kept in place to
prevent heat transmission. Pipe outlets on the tank
connect to the liquid fill lines, vapor equalizing lines,
pressure and capacity gages, refrigerator coil (storage
pressure vessel), and heater coil (a manway cover is
located at the top of the conversion vessel) (conversion
pressure vessel).
c. The power compartment is located at the rear
section of the trailer completely enclosed by the housing
and accessible through the doors at the rear of the
housing. The refrigeration unit for maintaining storage
tank temperature, automatic and semi-automatic
refrigeration controls, transfer pump, cylinder filling unit,
space heater, and drive units consisting of an electric
motor and a gasoline engine are all mounted in this
compartment. A countershaft with a one-way clutch is
driven by either power unit as desired, but not
simultaneously. The countershaft, through clutching, is
used to drive the refrigeration unit, cylinder filling unit,
and transfer pump.
Operational gages, control
equipment and valves are also located in this
compartment.
d. The storage compartment, located below the
storage tank in back of the landing gear, is completely
enclosed by housing and accessible through the doors
on either side of the compartment. The conversion
heater, cylinder scale, tool box, transfer hoses, power
cable, fire extinguisher, refrigerant
1-1
TM 5-3655-210-12
Figure 1-1. Conversion storage and charging unit, ¾ left front view.
cylinder, ground rod assembly and electrolyte are all
enclosed in this compartment.
e. The chassis and housing completely support
and cover the storage tank, power compartment, and
storage, compartment. External clearance lights are
provided on the housing for use during road
transportation. Internal dome lights are provided in the
power and storage compartments. The chassis is fitted
with air brakes that operate in conjunction with the
tractor towing the unit. Manually operated, two speed
landing jacks are provided to support the front end of
the unit. Removable lifting eye covers permits access
to the lifting eye holes at the top of the tank body. The
four tie-down rings are to be installed in the lifting eye
holes when using a crane to lift the unit.
1-7.
Tabulated Data
a. Identification. The conversion storage and charging
unit has four major identification plates. The information
contained on the plates is listed below:
(1) Engine plate.
Manufacturer............................. Wisconsin Motor Corp.
Model..................................................................MTHD
Size (bore; stroke)............................................ 3 x 3/, 4
(8.255 x 8.256 cm)
Specification No................................................ 147203
Serial No.................................................... as assigned
Additional....................................Operating instructions
1-2
TM 5-3655-210-12
Figure 1-2. Conversion storage ad charging unit right rear view.
1-3
TM 5-3655-210-12
(b) Dimensions and weights.
Overall length .................................................. 27 ft.
(810 cm)
Overall width...................................................... 8 ft.
(240 cm)
Overall height ......................................... 10 ft., 6 in.
(315.24 cm)
Trailer weight empty................................ 19, 500 lbs
(8775 kg)
Overall weight, loaded............................. 35, 000 lbs
(15750 kg)
Shipping cubage ......................................2315 cu ft.
(65553.855 cubic cm)
(c) Capacities.
Storage pressure vessel.................12, 000 lbs liquid
(843.6 kg per sq cm)
Conversion pressure vessel .... 5, 000 lbs solid-liquid
(2250 kg)
Gasoline fuel tank ......................... 20 gal (gallon) (s)
(76 liters)
Gasoline engine crankcase ............................. 32 qt.
(3.325 liters)
Refrigeration compressor crankcase ................ 22 qt
(2.375 liters)
Cylinder filling unit crankcase............................. 5 qt
(4.751 liters)
Conversion heater fluid ...................................10 gal
(38 liters)
Gasoline engine air cleaner................................. / pt
(.235 liters)
(2) Electric motor.
Manufacturer.............................General Electric Co.
Models .................... 5K215BG215 and 5K184BL219
Type........................................................... Induction
Horsepower..............................................................
Voltage ..........................................................220 ac
Phase.................................................................... :3
Cycles..................................................................... (
Amperes .............................................................. 15
Rated speed............................................. 1.745 rpm
Temperature rise................................................55C
........................( 1:1 F.)
(3) Gasoline engine.
(a) Identification.
Manufacturer.........................Wisconsin Motor Corp.
Model............................................................. MTHD
Specifications............... 142703 MIL-E-112751D and
326500 MIL-E-11275D
Horsepower................................. 11.7 at 1.8(10 rpm
Type....................................... 2 cylinder, 4-cycle, air
cooled .................................................... heavy duty.
Bore and stroke ................................. 3 ¾ x 3 1/4 in.
(8.255 x 8.255 cm)
Displacement ...cu................................................ in.
(88:3.421 cc)
(b) Starter.
Manufacturer....................................... Prestolite Co.
Model Nos.................... MBP-40()12-T MBP-4(019-T
Voltage ................................................................ 24
(2) Electric motor plate.
Manufacturer...................................... General Electric
Models .................. 5K215BG215 TP and 5K184BL219
Horsepower............................................................... 5
Phase..........................................................................
Volts...................................................................... 208
Cycles..................................................................... 60
RPM.....................................................................1745
AMP........................................................................ 15
Deg C rise............................................................... 55
Service factor............................................................ 1
Time rating...........................................................cont.
NEMA class design ................................................... B
Frame ................................................................... 215
Type.......................................................................... K
Code .........................................................................H
Shaft end brg AFBMA ................................ 35BC02XP
Opp end ...................................................... 25BC02/P
(3) Conversion, storage and charging unit data
plate.
Nomenclature......................... Conversion storage and
charging unit: C02
16, 000 lbs cap semi(7200 kg) trl mtd.
TM ...................................................... TM 5-3655-210
Stock No .........................................3655-00-062-7911
Make................................................................ Cardox
Model............................................................. E-46750
Serial Nos .................................. L-1475-T to L-1478-T
Date mfd ................................................. as applicable
Contract No.................................. DAAK01-67-C-1355
Serial Nos .................................. L-1666-T to L-1668-T
Contract No.................................. DSA700-69-C-H562
(4) (Transportation data plate.
Overall length ...................................................324 in.
(822.96 cm)
Overall height ...................................................126 in.
(320.04 cm)
Overall width.......................................................96 in.
(243.84 cm)
Shipping cubage ............................................. 2315 ft.
(69450 cm)
Shipping weight.......................................... 19, 500 lbs
(8775 kg)
Shipping tonnage ............................................. 10 tons
(9.0719 metric tons)
Additional..................................... Pictorial showing lift
and tie-down points,
center of gravity, and
axle and kingpin loads
(empty)
b. Tabulated Data
(1)
Carbon dioxide conversion, storage and
charging unit.
(a) Identification.
Manufacturer.................................................... Cardox
Model............................................................. E-46750
Type........................................................ Semi-tlr mtd.
Serial Nos ........................... L-1475-T to L-1478-T and
L-1666-T to L-1668-T
1-4
TM 5-3655-210-12
Valve clearance intake, cold
(Engine Spec 142703) ................... 0.012 in.
(.0305 cm)
(Engine Spec 326500..................... 0.008 in.
(.0203 cm)
Valve clearance exhaust, cold
(engine Spec 142703).................... 0.012 in.
(.0305 cm)
(Engine Spec 326500) ................... 0.016 in.
(.0406 cm)
Magneto breaker point gap................... 0.015 in.
(.0381 cm)
(I) Nut and bolt torque data.
Spark plugs to cylinder head24 to 26 ft-lb (foot-pounds)
(3.3192 - 3.5958 kgm)
Manifold .................................................. 26 ft-lb
(3.5958 kgm)
Cylinder head cap screw ................ 22 to 24 ft-lb
(3.0426 - 3.3192 kgm)
Governor and magneto .................. 16 to 18 ft-lb
(2.2128 - 2.4894 kgm)
(4) Cylinder filling compressor.
Manufacturer................................. Cardox Corp.
Part No .................... 17123 (Ser Nos. L-1475-T
through L-1478-T)
Part No ...................... 17117 (Ser Nos.L-1666-T
through L-1668-T)
Type....................... Single stage, single cylinder
Transfer capacity (300 psi (21.09 kg per sq cm)
suction pressure) 25 lb liquid C02 per minute
(1.7575 kg per sq cm)
Transfer capacity (200 psi (14.06 kg per sq cm)
suction pressure)20 lb liquid CO2 per minute
(1.406 kg per sq cm)
Discharge pressure .... 1, 200 psi min (minimum)
(84.36 kg per sq cm)
(5) Conversion heater.
Manufacturer....................Janitrol Aero Division,
Midland Ross Corp.
Model................................................. B 39 B8 1
Heater output .........90, 000 BTU/(British thermal
units) hour.
Fuel consumption.................... 0.85 gal per hour
(3.23 liters)
Voltage supply .................................. 24 volts dc
Heater fluid ...... MIL-A-11755C arctic anti-freeze
Fuel pressure ............................................32 psi
(c) Generator.
Manufacturer................. Delco-Remy Division of
General Motors Corp.
Model................................................... 1105970
Cold output ...................18 amps at 28.5 volts at
1, 775 rpm.
Field current at 24 volts.......... 0.91 to 0.98 amps
Brushes..............................................................
Frame size ........................................5 /18 in dia
(13.0175 cm)
Brush spring tension.................................. 28 oz
(784 grams)
Ground polarity .................................... Negative
(d) Generator regulator.
Manufacturer...........................................Cardox
Model..................................................... 559770
Voltage setting ................................ 27.5 to 29.5
Current limit ................................................... 18
Ground polarity .................................... Negative
Air gap (voltage and current unit) ......... 0.087 in.
(.2210 cm)
Air gap (cutout relay)............................ 0.048 in.
(.1219 cm)
(e) Magneto.
Manufacturer...........................Wico Electric Co.
Model.................................................... HS2390
Impulse range ...............................................29°
(f) Carburetor.
Manufacturer............. Zenith Carburetor Division
of Bendix Aviation Corp.
Model....................................................... 12288
Type....................................................... Updraft
Barrel size................................................... 1 in.
(2.54 cm)
Flange size .............................................. 7/8 in.
(2.2225 cm)
(g) Fuel pump.
Manufacturer..................... Blackstone Mfg. Co.
Model..................................................... LP1043
Type..................................................Diaphragm
(h) Air cleaner.
Manufacturer................... United Specialties Co.
Model...............T-12B-12 (Engine Spec 142703)
Model................... 12B12 (Engine Spec 326500)
Type.......................................................Oil bath
(i) Oil filter.
Manufacturer.................................... Fram Corp.
Model.......................F3P (Engine Spec 142703)
Model..................... F21P (Engine Spec 326500)
Type.................................Replacement element
(j) Fuel filter.
Manufacturer........... Tillotson Manufacturing Co.
Model.............OW-480-T (Engine Spec 142703)
(2.2496 kg per sq cm)
Spark gap .................................................... 0.125 in.
(.3175 cm)
(6) Circulating pump (conversion heater).
Manufacturer...................... Marine Products Co.
Model .............................. 3450 (Ser. Nos. L-1475-T
through L-1478-T)
Model ............................ 12204 (Ser. Nos. L-1666-T
through L-1668-T)
Type .........................................................Centrifugal
(7) Transfer pump.
Manufacturer ............... Smith Precision Products Co.
Model .......................................................MC-1044H
(k)Adjustment data.
Spark plug gap ............................................0.030 in.
(.0762 cm)
1-5
TM 5-3655-210-12
Model.................. 65950-8 (Ser. Nos. L-1666-T
through L-1668T)
Rating ......................................... 18, 000 lbs ea.
(8100 kg)
Track...................................................... 70½ in.
(179.07 cm)
Wheels......................................... Budd 66580-3
Type.................................................Rotary gear
Transfer capacity ................12, 000 lb liquid C02
(843.6 kg per sq cm)
minimum per hour
Discharge pressure (against a
head of 50 feet (1500 cm) of liquid CO2
at OF.) (-18C.) ........................... 300 psi min
(21.09 kg per sq cm)
(8) Refrigeration unit.
(b) Brakes.
Manufacturer............................. Shuler Axle Co.
Type................................................ Air actuated
Manufacturer........ Copeland Refrigeration Corp.
Model (Compressor)............................... 83, 000
Model (Condenser)26, 573 (Ser. Nos. L-1475-T
through L-1478T)
Model (Condenser)066-0010-00 (Ser. Nos. L-1666-T
through L-1668-T)
Model (Receiver).... K1670 (Ser. Nos. L-1475-T
through L1478-T)
Model (Receiver577-0004-00 (Ser. Nos. L-1666-T
through L-1668T)
Compressor cylinders....................................... 2
Bore and stroke................................. 3 ¼ x 3 in.
(8.265 - 7.62 cm)
Condenser cooling ................. Cross-finned tube
Receiver capacity (maximum)................. 19.3 lb
(1.3568 kg per sq cm)
(9) Compartment heater.
(c) Tires and tubes.
Size .................................................. 11.00 x 20
Rating ...................................................... 12 ply
Tire inflation ..............................................75 lbs
(5.2725 kg per sq cm)
(d) Landing jacks.
Manufacturer......... Austin Trailer Equipment Co.
Model......... JH-3250-1-312 (Ser. Nos. L-1475T
through L-1478-T)
Right hand leg... R1568SC (Ser. Nos. L-1666-T
through L-1668-T)
Left hand leg ..... R1550SC (Ser. Nos. L-1666-T
through L-1668-T)
Model No ....................................JH-320-15-312
(11) Electrical. Refer to Figure 1-3, wiring diagram.
Manufacturer....................... Evans Products Co.
Model...............HV220271 (Ser. Nos. L-1475-T
through L-1478-T)
Model...............HV220272 (Ser. Nos. L-1666-T
through L-1668-T)
Voltage .......................................................... 24
Type.................................................... Hot water
(10) Running gear.
(a) Tandem axle.
Manufacturer............................. Shuler Axle Co.
Model T-18C267-C27-CO0A-26 (Ser. Nos. L-1475-T
through
L-1478-T)
Model................C27FOA1 (Ser. Nos. L-1666-T
through L-1668-T)
Model.................. 66580-3 (Ser. Nos. L-1475-T
through L-1478-T)
1-8.
Difference in Models
This manual covers the Cardox Conversion, Storage
and Charging Units, Model E-46750, Serial Numbers L1475-T through L-1478-T, and Serial Numbers L-1666-T
through L-1668-T Any physical differences that exist
between the units resulting in alternate text coverage
are indicated in the text by the applicable serial
numbers. The absence of serial numbers in the text
means the instructions apply to all units.
1-6
TM 5-3655-210-12
Figure 1-3. Wiring diagram.
1-7
TM 5-3655-210-12
CHAPTER 2
OPERATING INSTRUCTIONS
WARNING
If equipment fails to operate, refer to troubleshooting
procedures in Chapter 3.
Section I. OPERATING PROCEDURES
g. Ammeter. The ammeter (1, fig. 2-2) indicates
the charging or discharging rate of the battery and is
located on the engine control panel. It is graduated in
divisions of 5 amperes and registers from 0 to 30
amperes on both charge and discharge sides.
h. Heater Fuel Pressure Gage. The heater fuel
pressure gage (19, fig. 2-5) is part of the conversion
heater and is located in the storage compartment. It
indicates the pressure of the heater fuel supplied by the
fuel pump to the combustion chamber. It is graduated in
one pound divisions and registers from 0 to 60 psi
(4.218 kg per sq cm).
Normal fuel pressure is
approximately 32 psi (2.2496 kg per sq cm).
i. Sight Glass, Expansion Tank. The sight glass
(3, fig. 2-5) is installed on the expansion tank (heater
fluid reservoir) is the storage compartment. It shows the
level of the heater fluid.
j. Refrigerant Sight Glass. The refrigerant sight
glass (1, fig. 2-12) is located in the line above the
refrigeration compressor. It indicates the refrigerant
flow.
k. Compressor Oil Level Sight Glass.
The
compressor oil level sight glass (5, fig. 2-12) is located
in the crankcase of the compressor. It shows the oil
level in the compressor.
l. Manual Control Valves. The control valves are
listed and identified in Table 2-1.
m. Light Switches. The dome light switch for the
storage compartment light is located on the light. The
toggle switch for the power compartment dome lights is
located on the gage panel in the power compartment.
These switches are single-pole, single-throw switches
and are manually operated.
n. Alarm Bell Cutout Switch. The alarm bell cutout
switch is mounted on the gage panel. It is a manually
operated toggle switch used to cut out the alarm bell.
o. Gage Line Heater Switch. The gage line heater
switches (6 and 7, fig. 2-2) used to turn on the gage 2-1
2-1.
General
This section describes, locates, illustrates, and furnishes
the operator/crew sufficient information pertaining to the
various controls and instruments provided for the proper
operation of the conversion and storage unit.
2-2.
Controls And Instruments
a. General.
The purpose of controls and
instruments and their reading are illustrated in Figures
2-1 to 2-11.
b. Shutter Control. The shutter control (7, fig.2-1)
is located above the refrigeration condenser. It is used
to ventilate the refrigeration system, allowing a flow of
cool air to be drawn through the condenser fins by the
fan.
c. Fuel Indicator. The fuel indicator (4, fig. 2-2) is
electrically operated. It is mounted on the engine
control panel. It shows the amount of gasoline in the
fuel tank, and is graduated from empty to full in fourths
of the tank capacity.
d. Cylinder Filling Pressure Gage. The cylinder
filling pressure gage is located in the power
compartment on the cylinder filling manifold, and
indicates the pressures at which the cylinder is being
filled. The gage registers from 0 to 2, 000 psi (140.6 kg
per sq cm) and is graduated in 20 pound (1.406 kg per
sq cm) divisions. Normal pressure is 800 psi, (56.24 kg
per sq cm) but variance will occur depending on
surrounding temperatures.
e. Liquid Level Gages (Pressure Vessels). Each
pressure vessel is provided with a liquid level gage (2
and 4, fig. 2-4). The gages are mounted on a panel
inside the power compartment. They can be viewed
through the window in the rear door. The gages indicate
the liquid level in each vessel and are graduated in
tenths of the vessel capacity.
f. Vessel Pressure Gages. Each pressure vessel
is provided with a pressure gage (1 and 3, fig. 2-4),
located on a panel which is viewed through the window
in the rear door, which indicates the pressure in each
vessel. The gages register from 0 to 600 psi (42.18 kg
per sq cm) in division of 20 pounds (1.406 kg per sq
cm).
2-1
TM 5-3655-210-12
TS 024479
1.
2.
3.
4.
5.
6.
7.
8.
Expansion valve adjusting screw
Expansion valve
low pressure gage line valve, conversion
Low pressure gage line valve, storage
Bleeder valve for carbon dioxide, conversion
Bleeder valve for carbon dioxide, storage
Shutter control
Relief valve for carbon dioxide, storage
9.
10.
11.
12.
13.
14.
15.
16.
Relief valve for carbon dioxide, storage
Safety vent switching valve, storage
Safety relief valve, transfer pump
High pressure gage line valve, conversion
High pressure gage line valve, storage
Relief valve for carbon dioxide, conversion
Safety vent switching valve, conversion
Relief valve for carbon dioxide, conversion
Figure 2-1. Power compartment valves and controls
line heaters in low temperatures to prevent the liquid
carbon dioxide in the lines from solidifying, are located
on the gasoline engine control panel.
p. Space Heater Switch. The space heater switch
(8, fig. 2-2) is located on the engine control panel. It is
a manually controlled switch controlling the heating of
the power compartment in low temperatures.
q. Conversion Heater Switch. The conversion
heater switch (9, fig. 2-2) is located on the engine
control panel.
It is a manually controlled switch
operating the conversion heater.
r. Toggle Switches (Momentary)..
These two
toggle switches are located on the engine control panel.
They are the gasoline engine START and STOP
switches (11 and 12, fig. 2-2). They are normally in the
OFF position and when moved to the ON position, will
spring back to OFF when pressure is released. These
switches are used to start and stop the engine when on
manual control.
2-2
TM 5-3655-210-12
1.
2.
3.
4.
5.
Ammeter
Electrical control switch (tractor or trailer)
Circuit breaker
Fuel indicator
Gage lines operating lights
6. Storage vessel gage line switch
7. Conversion vessel gage line switch
8. Compartment heater control switch
9
10
]1
12
13
14
15
Conversion heater control switch
Conversion heater failure light
Gasoline engine manual stop switch
Gasoline engine manual starter switch
Gasoline engine control switch for automatic or
manual
control
Gasoline engine failure light
Engine control panel
Figure 2-2. Engine control panel
s. Battery Selector Switch. This switch (2, fig. 22) is mounted on the engine control panel. It is a singlepole, double-throw switch to supply power to the unit,
from either the tractor or the trailer batteries.
t. Gasoline Engine Control Switch. The engine
control switch (13, fig. 2-2) is located on the engine
control panel. It is a double-pole, double-throw switch to
set the engine for either "manual" or "automatic"
starting.
u. Carburetor Priming Lever (Serial Nos. L-14
75Tthrough L-1478-T). The carburetor priming lever
(27, fig. 2-8) is located in the crankcase of gasoline
engine, on the right side at the governor mounting. It
primes the carburetor when starting the engine.
v. Electric Motor Starting Switch. The electric
motor starting switch (fig. 2-9) is located on the left wall
of the power compartment. This switch is used for
either manual or automatic starting of the electric motor.
A reset button is located below the operating switch, to
manually reset the switch should an overload occur.
w. Electric Motor Reversing Switch. The electric
motor reversing switch (fig. 2-9) is located on the
2-3
TM 5-3655-210-12
1. Transfer pump clutch shifter
2. Cylinder filling compressor clutch shifter
3. Refrigeration compressor clutch shifter
Figure 2-3. Clutch controls, installed views
side of the power compartment. It is a threepole, double-throw switch controlling the rotation of the
electric motor.
x. Conversion Heater Vibrator Switch.
The
vibrator switch (20, fig. 2-5) is located on the ignition
unit of the conversion heater. This switch is safety wired
at the factory. The vibrator is wired with two sets of
contacts. When the normal set of contacts have failed
the wire must be cut to pull the switch out. The vibrator
is then operating on the reserve contacts.
y. Battery Circuit Breaker. The battery circuit
breaker (3, fig. 2-2) is mounted on the engine control
panel and provides overload protection for voltage
sensitive components.
z. Clutch Shifters. The three clutch shifters are
mounted on the countershaft in the power compartment.
They are manual controls to engage the three clutches
which operate the transfer pump (1, fig.2-3),
refrigeration compressor (3) and the cylinder filling
compressor (2).
aa. Governor Controls. The governor control (24,
fig. 2-10) is located on the left side of the gasoline
engine. It controls the speed of the gasoline engine.
2-3.
Operation Under Usual Conditions
a. General.
Instructions in this section are
published for the use of the personnel responsible for
the operation of the conversion and storage unit.
2-4
TM 5-3655-210-12
1. Storage tank pressure gage
2. Conversion tank level gage
3. Conversion tank pressure gage
4. Storage tank level gage
Figure 2-4. Liquid level gages, pressure vessels.
b. It is essential that the operator know how to
perform every operation of which the conversion and
storage unit is capable. This section gives instruction on
starting and stopping the unit, and performing the
various operations of which it is capable.
(5.4431 metric tons) pressure vessel and into both
pressure vessels simultaneously convert solid carbon
dioxide (dry ice) in the two ton (1.8144 metric tons)
pressure vessel into liquid carbon dioxide, transfer liquid
carbon dioxide from the six ton (5.4431 metric tons)
pressure vessel or both pressure vessels simultaneously
into an external tank or transfer liquid carbon dioxide
from one external tank into another external tank.
c. The unit can be used to fill high pressure
cylinders with carbon dioxide, transport liquid and solid
carbon dioxide transfer liquid carbon dioxide from the
two ton (1.8144 metric tons) pressure vessel to the six
ton (5.4431 metric tons) pressure vessel, transfer liquid
carbon dioxide from an external source into the six ton
2-5
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Filler cap
Union nut
Sight glass
Expansion tank
Saddle stand clamp
Cap screw
Nut
Anti-freeze bleed-off petcock
Compartment heater diversion valve
Tube nut
11.
12.
13.
14.
15.
16.
17.
18.
19.
Conversion heater diversion valve
Anti-freeze bleed-off petcock
Nut
Gasket
Cap screw
Spark plug
Coupling nut
Tube nut
Fuel pressure gage
20.
21.
22.
23.
24.
25.
26.
27.
28.
Vibrator switch
Heater fluid line
Saddle stand
Drain cock
1/3 union
1/3 union
Nipple
Elbow
Nipple
Figure 2-5. Conversion heater, installed view.
d. Since it is intended that the electric motor be
used as the power source whenever electric power is
available, circuitry has been installed to prevent the
gasoline engine operating if the conversion and storage
unit is connected to 208 volt power. Operation of the
gasoline engine, under either manual or automatic
control, requires that the power cable be disconnected.
rapidly, due to the drop in pressure and temperature, it
forms C02 snow. This snow, when compressed into
blocks or cubes, forms dry ice. Dry ice, in solid forms
and at atmospheric pressure sublimates, remaining at
110F. (-76C) until it has disappeared. It is excellent for
certain refrigeration purposes, because it will neither
support combustion nor form explosive mixtures, C02 is
of the chief fire extinguishing agents in use today. It is
also used for inflatable equipment and as a propellant or
expelling agent. Since C02 in addition to being heavier
than air, is both invisible and odorless, it presents a
particular hazard.
It will tend to collect in low,
unventilated places. The fact is obvious that the more
of any gas, poisonous or not, that is present, the less
breathable oxygen there will be present. Men going into
these conditions or places, or left there run the risk of
e. C02 gas, when pure, is colorless, odorless, and
1.52 times as heavy as air. It is the by product of the
combustion of all materials containing carbon. It can be
condensed into a colorless liquid and stored in this state,
under pressure, in cylinders. The pressure of the C02 in
the cylinders is relative to the surrounding temperature.
Liquid C02 will return to a gaseous state at a
temperature of 87.7F. (31C.). It cannot be a liquid
above this temperature, regardless of the pressure that
is applied. When CO2 liquid is allowed to expand
2-6
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Figure 2-6. Schematic piping diagram.
Tank pressure control switch (conversion heater)
28.
Dehydrator by-pass valve
Alarm pressure switch conversion
29.
Transfer pump bleed-off valve
Pressure gage (conversion)
30.
Transfer pump
Pressure gage (storage)
31.
Transfer hose bleed-off valve (by-pass pump)
Tank pressure control switch (gasoline engine)
32.
Safety relief valve (transfer pump discharge)
Tank pressure control switch (electric motor)
33.
Liquid fill line valve (by-pass pump)
Alarm pressure switch (storage)
34.
Liquid shut-off valve (storage)
Liquid level gage (storage)
35.
Liquid shut-off valve to cylinder fill compressor
Low pressure gage line valve (storage)
36.
Strainer bleed-off valve
High pressure gage line valve (storage)
37.
Cylinder filling unit
Fire valve
38.
Cylinder filling hose bleed-off valve
Conversion pressure vessel
39.
Cylinder filling hose bleed-off valve
Storage pressure vessel
40.
Transfer hose bleed-off valve (vapor)
Bleeder valve for C02 (storage)
41.
Vapor equalizing line valve
Relief valve for CO
(storage)
42.
Cylinder filling hose
Relief valve for C02 (storage)
43.
Cylinder filling valve
Safety vent switching valve (storage)
44.
Cylinder filling valve
Liquid line shut-off valve (conversion)
45.
Cylinder filling pressure gage
Bleeder valve for C02 (conversion)
46.
Pressure regulating valve (cylinder fill)
Relief valve for C02 (conversion)
47.
Vapor return valve (conversion)
Relief valve for C02 (conversion)
48.
Vapor return valve (storage)
Safety vent switching valve (conversion)
49.
High pressure vapor return valve
Dehydrator
50.
Safety relief valve cylinder fill
Liquid equalizing line valve
51.
Strainer
Vapor relief valve (liquid line)
52.
High pressure gage line valve (conversion)
Transfer hose bleed-off valve (thru pump)
53.
Low pressure gage line valve (conversion)
Liquid fill line valve (thru pump)
54.
Liquid level gage conversion
2-7
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
Discharge service valve
Condenser
Evaporator coil
Expansion valve
Suction pressure switch (gas and electric)
Receiver
Refrigerant
8.
9.
10.
11.
12.
13.
14.
Sight glass
Receiver inlet valve
Dehydrator
Receiver liquid outlet valve
Discharge pressure switch (gas and electric)
Compressor
Suction service valve
Figure 2-7. Refrigeration flow diagram.
smothering to death. Small percentages of C02 will
cause tiredness and perhaps headaches. Three percent
in the air doubles breathing efforts, and five percent
causes panting.
Eight percent will cause marked
distress and ten percent causes unconsciousness very
quickly.
Turn the reversing switch to one of the
ON positions only long enough to observe the rotation of
the shaft. The shaft should rotate counterclockwise when
viewed from the shaft end of the motor. If the shaft
rotates in the proper direction, turn the motor starting
switch to the AUTOMATIC position, and return the
reversing switch to the same ON position. If the shaft
rotates in the wrong direction, turn the motor starting
switch to the alternate ON position. The position of the
reversing switch must not be changed unless a power
source of different phase sequence is used. With the
above steps performed, the electric motor will start
whenever the high tank pressures close the tank pressure
switch, which controls the electric motor.
2-4.
Electric Motor Operation
a. Automatic Operation. Make certain the motor
starting switch and the reversing switch are in the OFF
position; and the power line is connected to the trailer
208 VAC-power receptacle (1, fig. 2-11). Disengage
the three countershaft clutches (1, 2, and 9, fig. 2-3).
Turn the motor starting switch (fig. 2-9) to the HAND
position.
2-8
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Strainer bleed-off valve
Cylinder filling compressor liquid shut-off valve
Liquid equalizing line valve
Dehydrator by-pass valve
Refrigeration suction valve
Transfer pump bleed-off valve
Liquid fill line valve thru pump
Receiver tank inlet line
Dehydrator
Union nut
Liquid line shut-off valve, conversion
Transfer hose bleed-off valve (thru pump),
Cylinder filling valve
Tube nut
Cylinder fill pressure regulating valve
Safety relief valve cylinder fill
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Union nut
Cylinder filling valve
Transfer hose bleed-off valve
Vapor return valve, conversion
Transfer hose bleed-off valve vapor
Liquid line vapor relief valve
Vapor equalizing line valve
High pressure vapor return valve
Fire protection valve
Vapor return valve, storage
Carburetor priming lever (ser. Nos. L-1475-T through L1478-T)
Stop pin (ser. Nos. L-1475-T through L-1478-T)
Liquid fill line valve, by-pass pump
Liquid shut-off valve to cylinder filling compressor
Figure 2-8. CO, manifolds, installed view;.
b. Manual Operation. Make certain the motor
starting switch (fig. 2-9) and the reversing switch are in
the OFF position; and the power line connected to the
trailer. Disengage all countershaft shifters (1, 3 and 3,
fig. 2-3). Turn the motor starting switch (fig. 2-9) to the
HAND position. Turn the reversing switch to one of the
ON positions only long enough to observe the rotation of
electric motor shaft.
The shaft should turn
counterclockwise when viewed from the shaft end of the
motor. If the shaft rotates in the proper direction, return
the motor starting switch to the OFF position, turn the
reversing switch to the proper ON position. The electric
motor can now be manually operated when the motor
starting switch is turned to the HAND position. To stop
the electric motor, throw the motor starting switch and
the reversing switch to the OFF position.
2-5.
Gasoline Engine Operation
a. Automatic
Operation. The
tractor-trailer
toggle switch (2, fig. 2-2) is located on the engine
control panel. It should be in the trailer position. The
circuit breaker (3), mounted on the control panel should
be ON or in the up position. On serial number units L1475-T through L-1478-T, prime the engine
2-9
TM 5-3655-210-12
Table 2-1. Valves
Tag
Description
No.
Figure 2-9.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
18
19
20
21
22
23
24
25
26
27
28
29
Electric motor starter and reversing
switch
carburetor by working the priming lever (27, fig. 2-8) up
and down until the carburetor is full. This is indicated by
a reduction of pressure on the priming lever. It takes
approximately 24 strokes to fill the carburetor. Close
the manual-automatic toggle switch (13, fig. 2-2) on the
engine control panel to the AUTOMATIC position. The
gasoline engine will now start when high tank pressures
close the circuit to the tank pressure switch.
b. Manual Operation. The tractor-trailer toggle
switch (2) on the engine panel should be in the trailer
position. The circuit breaker (3), mounted on the engine
control panel should be ON or in the up position. On
serial number units L-1475-T through L-1478-T, prime
the carburetor (a. above). Hold the gasoline engine
START switch (12) mounted on the engine control panel
up, until the engine starts, then release the switch. To
stop the engine hold the engine STOP switch (11) up
until the engine is completely stopped.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
2-10
Liquid fill line (storage compartment, thru pump)
Liquid shut-off (storage)
Liquid fill line (by-pass pump)
Liquid line shut-off (conversion)
Liquid equalizing line
Dehydrator by-pass
Vapor equalizing line
Vapor return (conversion)
Vapor return (storage)
Transfer pump bleed-off
Low pressure gage line (conversion)
Liquid shut-off to cylinder fill compressor
High pressure vapor return
Pressure regulating valve
Strainer bleed-off
Cylinder valve
Cylinder fill hose bleed-off
Cylinder valve
Cylinder fill hose bleed-off
Cylinder valve
Cylinder fill hose bleed-off
Low pressure gage line (storage)
High pressure gage line (conversion)
High pressure gage line (storage)
Safety vent switching valve (conversion)
Safety vent switching valve (storage)
Fire valve
Transfer hose bleed-off (by-pass pump)
Transfer hose bleed-off (thru pump)
Transfer hose bleed-off (vapor)
Relief valve--3/4 male (1.905 cm)-341 psi (23.9723
kg per sq cm) (storage)
Relief valve-3/4 male (1.905 cm)-341 psi (23.9723kg
per sq cm) (storage)
Relief valve--3/4 male (1.905 cm)-341 psi (23.9723
kg per sq cm) (conversion)
Relief valve-3/4 male (1.905 cm)-341 psi (23.9723 kg
per sq cm) (conversion)
Bleeder valve-3/8 female (.9525 cm)-330 psi (23.199
kg per sq cm) (conversion)
Bleeder valve-3/8 female (.9525 cm)-330 psi (23.199
kg per sq cm) (conversion)
Vapor line relief
Safety relief (pop type) 375 psi (26.3625 kg per sq
cm) (transfer pump discharge)
Safety relief disc-1500 psi (105.45 kg per sq cm)
3 way valve (conversion heater coil)
3 way valve (compartment heater)
Expansion valve, refrigeration system
Air tank bleed-off (brakes)
Heater fluid pump bleed-off (outlet)
Refrigerator compressor suction valve
Refrigerator compressor discharge valve
Receiver tank shut-off (outlet)
Receiver tank shut-off (inlet)
Heater fluid pump bleed-off (inlet)
TM 5-3655-210-12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Exhaust manifold
Nut
Lockwasher
Saddle washer
Capscrew
Lockwasher
Adjusting needle screw
Adjusting nut
Governor control rod
Tube nut
Fuel tube
Support pin
Cotter pin
Governor control lever
15
15
16
17
18
19
20
21
22
23
24
25
26
Screw ser. nos, L1475-T through L-1478-T)
Screw (ser. nos, L-1666-T through L-1668-T)
Carburetor
Spring
Cross shaft lever
Chain
Setscrew
Stop collar
Air cleaner mounting bracket
Locknut
Governor control
Choke rod
Cylinder block
Figure 2-10. Governor controls, installed view
2-6.Normal Conversion Operation
Perform the following steps when converting solid
carbon dioxide in the conversion pressure vessel into
liquid carbon dioxide. If the storage pressure vessel
contains liquid, set the refrigeration controls for
automatic operation, and engage the refrigeration clutch
(9, fig. 2-3). If the storage pressure vessel is empty,
refrigeration is not required.
a. Position the valves as indicated in Figure 2-13.
Refer to Table 2-1 for valve identification.
b. When the pressure in the conversion pressure
vessel is 0 psi, close valve 8.
c. Open the manway on the conversion pressure
vessel.
(1) Unlatch the four locks (4, fig. 2-14) securing
the hatch cover (1) to the platform (3).
(2) Lift up the hatch and pull out the block of
insulation (2).
(3) Hold the cover and loosen the two nuts (3,
fig. 2-15), flatwashers (4), two clamps (5), and the two
bolts (6) securing the cover (1).
(4) Tilt the cover sideways, and pull the cover
and the gasket (2) away from the vessel.
d. Inspect the threads and report any damage to
proper authority. Inspect and replace a damaged
gasket.
e. Pack the vessel with approximately 4,000
pounds (1800 kg) of solid carbon dioxide.
f. Reseal the manway by:
2-11
TM 5-3655-210-12
1. 208 v, ac power receptacle
2. Vapor equalizing line
3. Liquid fill line (pump by-pass)
4. 24 v, de receptacle
5. Liquid fill line
6. Blackout stop and taillight
Figure 2-11 .
7. Pintle hook
8. Capscrew
9. Stop and taillight, service
Power receptacles, installed view.
soap and water to the hatch seal. Bubbles will indicate
a leak.
i. After conversion is completed, turn off the
conversion heater control switch (9, fig. 2-2) and if the
liquid is to be transferred to the storage pressure vessel,
transfer as follows: (1) Set the driving unit for manual
operation by placing toggle switch (2, fig. 2-2) in the
trailer position. The circuit breaker (3), mounted on the
engine control panel should be ON or in the up position.
Prime the carburetor. Hold the gasoline engine START
switch (12) mounted on the engine control panel up,
until the engine starts, then release the switch. To stop
the engine hold the engine STOP switch (11) up until
the engine is completely stopped.
Disengage all
clutches (1, 2, and 3, fig. 2-3).
(2) Set the valves as indicated in figure 2-16
and start the driving unit. Refer to Table 2-1 for valve
identification.
(3) Close valves 1, 3, 5 and 10 (fig. 2-16).
Open valve 4. Open valves 2 and 10. When liquid
carbon dioxide appears at valve 10, close the valve and
engage the clutch to the transfer pump.
(4) Continue to operate the transfer pump until
the conversion pressure vessel is empty, as indicated by
the liquid level gage (2, fig. 2-4).
(1) Install the gasket (2, fig. 2-15) on the
cover (1).
(2) Position the cover in the vessel.
(3) Position the bolts (6), clamps (5),
flatwashers (4), and secure with the nuts (3).
(4) Replace the block of insulation (2, fig. 214).
(5) Lower the hatch (1), and secure with locks
(4).
g. Turn on the conversion heater switch (9, fig.
2-2), mounted on the direct current control panel to start
the conversion heater.
h. The conversion heater will cycle on and off
during the initial stages of conversion. This will occur
since the heater fluid circulating through the coil is not
sufficiently cooled by the carbon dioxide, and causes the
heater thermostat switch to open and close. The heater
will continue to operate until the temperature of the
heating fluid, returning to the heater, reaches 73.9C.
(165F.). The heater will remain off until the fluid
temperature reduces to 65.6C. (150F.). The conversion
cycle will continue until the pressure in the conversion
pressure vessel reaches 275 psi (19.3325 kg per sq cm).
At this pressure, the tank pressure control switch will
open the circuit, to stop the heater. During the use of
the conversion vessel the hatch cover should be
periodically leak tested by applying a solution of
2-12
TM 5-3655-210-12
refrigeration for the contents of both pressure vessels,
and to equalize the liquid levels and pressures.
1.
2.
3.
4.
Refrigerant sight glass
Suction valve
Freon charging port
Suction valve shut-off
5.
6.
7.
8.
2-7. Reduced Conversion Cycle
a. This operation can be performed only when
liquid carbon dioxide is present in the storage pressure
vessel. Perform the following steps when converting
solid carbon dioxide into the conversion pressure
vessel. The refrigeration controls should be set for
automatic operation as follows: Make certain the motor
starting switch and the reversing switch are in the OFF
position; and the power line is connected to the trailer
208 VAC power receptacle (1, fig. 2-11). Disengage
the three countershaft clutches (1, 2, and 3, fig. 2-3).
Turn the motor' starting switch (fig. 2-9) to the HAND
position. Turn the reversing switch to one of the ON
positions only long enough to observe the rotation of the
shaft. The shaft should rotate counterclockwise when
viewed from the shaft end of the motor. If the shaft
rotates in the proper direction, turn the motor starting
switch to the AUTOMATIC position, and return the
reversing switch to the same ON position. If the shaft
rotates in the wrong direction, turn the motor starting
switch to the alternate ON position. The position of the
reversing switch must not be changed unless a power
source of different phase sequence is used. With the
above steps performed, the electric motor will start
whenever the high tank pressures close the tank
pressure switch, which controls the electric motor. The
refrigeration clutch (3, fig. 2-3) engaged.
b. Position the valves as indicated in figure 2-17.
Refer to Table 2-1 for valve identification.
c. When the pressure in the conversion pressure
vessel is 0 psi, close valve 8. Open the manway on the
conversion pressure vessel and pack the vessel with
approximately 4,000 pounds (1800 kg) of solid carbon
dioxide. Reseal the manway as follows:
(1) Install the gasket (2, fig. 2-15) on the
cover (1).
(2) Position the cover in the vessel.
(3) Position the bolts (6), clamps (5),
flatwashers (4), and secure with the nuts (3).
(4) Replace the block of insulation (2, fig. 214).
(5) Lower the hatch (1), and secure with locks
(4).
d. Turn on the switch, (9, fig. 2-2), mounted on the
dc control panel, to start the conversion heater.
e. To reduce the conversion cycle time, close
valve 7 (fig. 2-17) and then open valves 8 and 9. Keep
the valves in this position until the conversion pressure
vessel pressure increases to 60 psi (4.218 kg per sq
cm), or the storage pressure vessel pressure reduces to
150 psi (10.545 kg per sq cm). When either of these
Oil level sight glass
Receiver tank inlet line
Receiver
Oil filler plug
Figure 2-12. Refrigeration compressor, installed view.
(5) Disengage the transfer pump clutch and
close valves 2 and 9.
(6) Set the unit for automatic operation, and
engage only the refrigeration clutch (3, fig. 2-3).
With all the liquid contained in the storage pressure
vessel, the valves should be in the normal position as
indicated in figure 2-13.
(7) If liquid was contained in the storage
pressure vessel during conversion, close valve 7 (fig. 213) and then open valves 5, 8 and 9 to provide
2-13
TM 5-3655-210-12
Figure 2-13 . Normal conversion operation .
1. Hatch cover
2.Insulation block
3. Platform
4. Locks
1. Cover
2. Gasket
3. Nut
Figure 2-14 . Manway access .
4. Washer, flat
5. Clamp
6. Bolt
Figure 2-15. Manway cover
2-14
TM 5-3655-210-12
Figure 2-16. Transfer of liquid from the conversion pressure
vessel to the storage pressure vessel.
values are indicated, close valves 8 and 9, and then
open valve 7. This will allow liquid carbon dioxide to
cover the heater coils at the bottom of the conversion
pressure vessel, and prevent the heater thermostat
switch from opening as often as in a normal conversion
operation.
f. The conversion heater will cycle on and off
during the initial stages of conversion. This will occur
since the heater fluid circulating through the coil is not
sufficiently cooled by the carbon dioxide, and causes the
heater thermostat switch to open and close. The heater
will continue to operate until the temperature of the
heating fluid, returning to the heater, reaches 73.9C.
(165F.). The heater will remain off until the fluid
temperature reduces to 65.6C. (150F.). The conversion
cycle will continue until the pressure in the conversion
pressure vessel reaches 275 psi (19.3325 kg per sq cm).
At this pressure, the tank pressure control switch will
open the circuit, to stop the heater.
g. After conversion is complete, turn off the
conversion heater switch (9, fig. 2-2) and if the liquid is
to be transferred to the storage pressure vessel, transfer
as follows:
(1) Set the driving unit for manual operation
and disengage all clutches (1, 2, and 3, fig. 2-3).
(2) Set the valves as indicated in Figure 2-16
and start the driving unit. Refer to Table 2-1 for valve
identification.
(3) Close valves 1, 3, 5, and 10 (fig. 2-16).
Open valve 4. Open valves 2 and 10. When liquid
carbon dioxide appears at valve 10, close the valve and
engage the clutch to the transfer pump.
(4) Continue to operate the transfer pump until
the conversion pressure vessel is empty, as indicated by
the liquid level gage (6, fig. 2-4).
(5) Disengage the transfer pump clutch and
close valves 2 and 9.
(6) Set the unit for automatic operation, and
engage only the refrigeration clutch (3, fig. 2-3). With
all the liquid contained in the storage pressure vessel,
the valve should be in the normal position as indicated
in Figure 2-13. If the liquid level and pressure is to be
equalized in both tanks, close valve 7 and then open
valves 5, 8 and 9. This will provide refrigeration for the
contents of both pressure vessels.
2-15
TM 5-3655-210-12
Figure 2-17 .
Reduced conversion cycle .
b. Set the valves as indicated in Figure 2-16 and
start the driving unit. Refer to Table 2-1 for valve
identification.
c. Close valves 1, 3, 5, and 10 (fig. 2-16). Open
valve 4. Open valves 2 and 10. When liquid carbon
dioxide appears at valve 10, close the valve and engage
the clutch to the transfer pump.
d. Continue to operate the transfer pump until the
conversion pressure vessel is empty, as indicated by the
liquid level gage (2, fig. 2-4).
e. Disengage the transfer pump clutch and close
valves 2 and 10.
f. Set the unit for automatic operation, and engage
only the refrigeration clutch (3, fig. 2-3). With all the
liquid contained in the storage pressure vessel, the
valves should be in the normal position as indicated in
Figure 2-13.
2-8. Transfer of Liquid from the Conversion
Pressure Vessel to the Storage Pressure
Vessel
a. Set the driving unit for manual operation as
follows: Make certain the motor starting switch (fig. 29) and the reversing switch are in the OFF position; and
the power line connected to the trailer. Disengage all
countershaft shifters (1, 2, and 3, fig. 2-3). Turn the
motor starting switch (fig. 2-9) to the HAND position.
Turn the reversing switch to one of the ON positions
only long enough to observe the rotation of electric
motor shaft. The shaft should turn counterclockwise
when viewed from the shaft end of the motor. If the
shaft rotates in the proper direction, return the motor
starting switch to the OFF position, turn the reversing
switch to the proper ON position. The electric motor can
now be manually operated when the motor starting
switch is turned to the HAND position. To stop the
electric motor, throw the motor starting switch and the
reversing switch to the OFF position. Then' disengage
all clutches (1, 2, and 3, fig. 2-3).
2-9. Filling Both Pressure Vessels With Liquid
Carbon Dioxide
a. Set the driving unit for manual operation and
disengage all clutches as follows: The tractor-trailer
2-16
TM 5-3655-210-12
appears at valve 10, close the valve and engage the
transfer pump clutch. Continue to pump liquid into the
pressure vessels until they are full. To determine when
the tank is full, check as follows:
(1) Determining Liquid Level While Pumping.
(a) Liquid Level Gage. The unit is equipped so
that the liquid level gages (2 and 4, fig. 2-4) indicate the
contents of the pressure vessels (in tenths of capacity)
even during pumping. Thus the contents can be
determined by reading the gages and allowing for slight
time lag.
(b) Liquid in Vapor Equalizing Line. When
filling the pressure vessels, it is usually desirable to fill
them completely. The normal course of the carbon
dioxide during filling is for liquid to enter at the bottom of
the vessels while carbon dioxide vapor flows out at the
top of the vessels, returning to the tank from which the
liquid is being pumped. When the liquid level in the
pressure vessel rises until it reaches the bottom of the
vapor equalizing dip tube inside the vessel, the tank is
at full capacity.
toggle switch (2, fig. 2-2) on the engine panel should be
in the trailer position. The circuit breaker (3), mounted
on the engine control panel should be ON or in the up
position. Prime the carburetor. Hold the gasoline
engine START switch (12) mounted on the engine
control panel up, until the engine starts,; then release
the switch. To stop the engine hold the engine STOP
switch (11) up until the engine is completely stopped.
b. Set the valves as indicated in Figure 2-13 and
start the driving unit. Refer to Table 2-1 for valve
identification.
c. Remove the caps and connect the liquid and
vapor transfer hoses (5 and 10, fig. 2-18) or (5 and 10,
fig. 2-19) (stored in the storage compartment) to the
liquid fill line (5, fig. 2-11) and vapor equalizing line (2)
at the rear of the trailer, and to the liquid supply unit.
d. Close valves 1, 3, 10, 27, and 28 (fig. 2-20).
Open the liquid fill and vapor equalizing valves on the
liquid supply unit.
e. Open valves 1, 2, 7, and 10. When liquid
1. Bracket
2. Nut
3. Brace
4
4
6
Capscrew
Transfer hose (vapor)
Freon tank
7
8
9
Fire extinguisher
Quick release clamp
Holder
10 Transfer hose (liquid)
11 Cylinder filling hoses
12 Scales
Figure 2-18. Storage compartment, face view (ser . nos . L-1475-T
through L-1478-T) .
2-17
TM 5-3655-210-12
1. Bracket
2. Nut
3. Brace
4. Capscrew
5. Transfer hose (vapor)
6. Freon tank
Figure 2-19 .
7. Fire extinguisher
8. Quick release clamp
9. Holder
10. Transfer hose (liquid)
11. Cylinder filling hoses
12. Scale
Storage compartment, face view (ser. nos . L-1666-T through L-1668-T) .
dioxide. Be alert for the indications outlined in (b) and
(c) above, several minutes before this time has elapsed.
Stop the pump immediately when either indication is
observed.
NOTE
If pumping is continued after capacity is
reached, liquid carbon dioxide will enter
the vapor equalizing line instead of
vaporous carbon dioxide. The cold liquid
in the vapor equalizing line will cause that
line to accumulate frost, and indicate that
complete filling has been obtained.
(c) Pressure Gage. Another method of
determining when the tank is full is to observe the
pressure gages (1 and 3, fig. 2-4). As long as liquid
enters the bottom of the vessel and vapor returns
through the vapor equalizing line, the pressure will
remain approximately constant. As soon as the liquid
level reaches the vapor equalizing dip tube and liquid is
forced into the vapor equalizing line, the pressure will
suddenly begin to rise.
(d) Amount of Carbon Dioxide Required to Fill
Tank. If the pumping rate is known, it can be
determined from the liquid level gage reading before
pumping is started how much carbon dioxide will be
required to fill the tank and approximately how long it
will take to pump this amount of carbon
(2) Checking for Overfilling.' It is important that the
level of the liquid carbon dioxide inside the pressure
vessel be kept no higher than the bottom of the vapor
equalizing line dip tube. After complete filling of the
pressure vessel and after the hoses have been
disconnected, open the vapor equalizing line valve (23,
fig.
2-8) slightly to discharge carbon dioxide to
atmosphere. If the discharge is clear or only slightly
foggy, the tank has not been overfilled. However, if the
discharge is a dense, white cloud containing particles of
dry ice, the liquid level in the tank is too high. To
remedy this, carbon dioxide discharge from the vapor
equalizing line connection should be allowed to continue
slowly until the dense white discharge changes to a
clean or blue fog discharge.
2-18
TM 5-3655-210-12
TS 024498
Figure 2-20. Filling both pressure vessels with liquid carbon dioxide.
f. Disengage the clutch to the transfer pump.
Close the liquid fill and vapor equalizing line valves on
the liquid supply unit.
g. Close valves 1 and 7. Open valves 27 and 28
to bleed off the carbon dioxide trapped in the transfer
hoses, and then disconnect the transfer hoses. Open
valve 7 slightly to check for overfilling. If no liquid
carbon dioxide appears, close the valves. If the liquid
carbon dioxide appears through the valve, leave the
valve open until the discharge changes to a clean or
blue fog discharge.
h. Set the unit for automatic operation and engage
only the refrigeration clutch. Position the valves in the
normal positions as indicated in Figure 2-13.
(stored in the storage compartment) to the liquid fill line
and vapor equalizing line at the rear of the trailer, and to
the liquid supply unit.
d. Close valves 1, 3, 5, 8, 10, 27, and 28 (fig. 221). Open valves 2 and 7. Open the liquid fill and
vapor equalizing line valves on the liquid supply unit.
e. Open valves 1 and 10. When liquid appears at
valve 10, close the valve and engage the transfer pump
clutch.
Continue to pump liquid into the storage
pressure vessel until it is full. To determine when the
pressure vessel is full, check as follows:
(1) Determining Liquid Level While Pumping.
(a) Liquid Level Gage. The unit is equipped so
that the liquid level gages (2 and 4, fig. 2-4) indicate the
contents of the pressure vessels (in tenths of capacity)
even during pumping. Thus the contents can be
determined by reading the gages and allowing for slight
time lag.
(b) Liquid in Vapor Equalizing Line. When
filling the pressure vessels, it is usually desirable to fill
them completely. The normal course of the carbon
dioxide during filling is for liquid to enter at the bottom of
the vessels while carbon dioxide vapor flows out at the
top of the vessels, returning to the tank from which the
liquid is being pumped. When the liquid level in the
pressure vessel rises until it
2-10.
Filling The Storage Pressure Vessel With
Liquid Carbon Dioxide (Both Pressure
Vessels Empty)
a. Set the driving unit for manual operation, and
disengage all clutches.
b. Set the valves as indicated in Figure 2-21 and
start the driving unit. Refer to Table 2-1 for valve
identification.
c. Connect the liquid and vapor transfer hoses
2-19
TM 5-3655-210-12
TS 024499
Figure 2-21 .
Transfer operation liquid fill, storage compartment
only .
reaches the bottom of the vapor equalizing dip tube
inside the vessel, the tank is at full capacity.
has elapsed. Stop the pump immediately when either
indication is observed.
(2) Check for Overfilling. It is important that the
level of the liquid carbon dioxide inside the pressure
vessel be kept no higher than the bottom of the vapor
equalizing line dip tube. After complete filling of the
pressure vessel and after the hoses have been
disconnected, open the vapor equalizing line valve (23,
fig.
2-8) slightly to discharge carbon dioxide to
atmosphere. If the discharge is clear or only slightly
foggy, the tank has not been overfilled. However, if the
discharge is a dense, white cloud containing particles of
dry ice, the liquid level in the tank is too high. To
remedy this, carbon dioxide discharge from the vapor
equalizing line connection should be allowed to continue
slowly until the dense white discharge changes to a
clear or blue fog discharge.
f. Disengage the transfer pump clutch, and close
the liquid fill and vapor equalizing line valves on the
liquid supply unit.
g. Close valves 1, 2, and 9. Open valves 27 and
28 to bleed off the carbon dioxide trapped in the transfer
hoses, and then disconnect the transfer hoses. Check
for overfilling.
NOTE
If pumping is continued after capacity is
reached, liquid carbon dioxide will enter the
vapor equalizing line instead of vaporous
carbon dioxide. The cold liquid in the vapor
equalizing line will cause that line to
accumulate frost, and indicate that complete
filling has been obtained.
(c) Pressure Gage.
Another method of
determining when the tank is full is to observe the
pressure gages (1 and 3, fig. 2-4). As long as liquid
enters the bottom of the vessel and vapor returns
through the vapor equalizing line, the pressure will
remain approximately constant. As soon as the liquid
level reaches the vapor equalizing dip tube and liquid is
forced into the vapor equalizing line, the pressure will
suddenly begin to rise.
(d) Amount of Carbon Dioxide Required to Fill
Tank.
If the pumping rate is known, it can be
determined from the liquid level gage reading before
pumping is started how much carbon dioxide will be
required to fill the tank and approximately how long it
will take to pump this amount of carbon dioxide. Be
alert for the indications outlined in (b) and (c) above,
several minutes before this time
2-20
TM 5-3655-210-12
empty, or sufficient liquid has been pumped into the.
receiver unit.
f. Disengage the clutch to the transfer pump.
Close the liquid fill and vapor equalizing line valves on
the receiver unit.
g. Close valves 3, 6, and 7. Open valves 26 and
28 to bleed off carbon dioxide trapped in the transfer
hoses, and then disconnect the transfer hoses.
h. Set the valves for the normal position as
indicated in Figure 2-13. Set the controls for automatic
operation, and engage the refrigeration clutch only if
liquid carbon dioxide is remaining in the pressure
vessels.
h. Set the unit for automatic operation, and engage
only the refrigeration clutch.
With all the liquid
contained in the storage pressure vessel, set the valves
in the normal position as indicated in figure 2-13.
2-11. Transfer of Liquid Carbon Dioxide from Both
Pressure Vessels Simultaneously.
a. Set the driving unit for manual operation, and
disengage all clutches.
b. Set the valves as indicated in figure 2-22 and
start the driving unit. Refer to table 2-1 for valve
identification.
c. Connect the liquid and vapor transfer hoses
(stored in the storage compartment) to the liquid fill line
and vapor equalizing line at the rear of the trailer, and to
the receiver unit.
d. Close valves 1, 3, 10, 26, and 28 (fig. 2-22).
Open the liquid fill and vapor equalizing line valves on
the receiver unit.
e. Open valves 3, 6, 7, and 10. When liquid
appears at valve 10, close the valve and engage the
transfer pump clutch. Continue to pump liquid into the
receiver unit until the pressure vessels are
2-12.
Transfer Of Liquid Carbon Dioxide From The
Storage Pressure Vessel (Liquid In The
Storage Pressure Vessel Only)
a. Set the driving unit for manual operation, and
disengage all clutches.
b. Set the valves as indicated in Figure 2-23 and
start the driving unit. Refer to Table 2-1 for valve
identification.
c. Connect the liquid and vapor transfer hoses
(stored in the storage compartment) to the liquid fill
TS 024500
Figure 2-22 .
Transferring liquid from both compartments .
2-21
TM 5-3655-210-12
TS 024501
Figure 2-23 .
Transfer of liquid carbon dioxide from the storage
pressure vessel .
line and vapor equalizing line at the rear of the trailer,
and to the receiver unit.
d. Close valves 1, 3, 7, 8, 10, 26, and 28. Open
the liquid fill and vapor equalizing line valves on the
receiver unit.
e. Open valves 3, 6, 7, 9, and 10. When liquid
appears at valve 10, close the valves and engage the
transfer pump clutch. Continue to pump liquid into the
receiver unit until the storage pressure vessel is empty,
or sufficient liquid has been pumped into the receiver
unit.
f. Disengage the clutch to the transfer pump.
Close the liquid fill and vapor equalizing line valves on
the receiver unit.
g. Close valve 3, 6, 7, and 9. Open valves 26 and
28 to bleed off carbon dioxide trapped in the transfer
hoses, and then disconnect the transfer hoses.
h. Set the valves for the normal position as
indicated in Figure 2-13. Set the controls for automatic
operation, and engage only the refrigeration clutch if
liquid remains in the storage pressure vessel.
2-13. Transfer Of Liquid Carbon Dioxide From
One External Tank Into Another External Tank
(Liquid In Both Pressure Vessels)
a. Set the driving unit for manual operation, and
disengage all clutches.
b. Set the valves for the normal position as
indicated in Figure 2-13 and start the driving unit. Refer
to Table 2-1 for valve identification.
c. Connect the liquid and vapor transfer hoses to
the liquid fill line (5, fig. 2-11) and liquid fill line (pump
by-pass) (3) at the rear of the trailer. Connect one liquid
fill line to each external tank, and connect the vapor
equalizing line to both external tanks.
d. Close valves 1, 3, 10, 26, and 27 (fig. 2-24).
Open the liquid fill and vapor equalizing line valves oi
both external units.
e. Open valves 1, 3, and 10. When liquid appears
at valve 10, close the valves and engage the transfer
pump clutch (1, fig. 2-3). Continue operation of the
transfer pump until sufficient liquid has been' pumped
from one external tank into the other.
2-22
TM 5-3655-210-12
TS 024502
Figure 2-24 .
Transfer of liquid carbon dioxide from one external
tank to another external tank .
b. Set the driving unit for manual operation and
disengage all the clutches.
c. Set the valves as indicated in Figure 2-25.
Refer to Table 2-1 for valve identification.
d. Place the cylinder to be filled on the scales (12,
fig. 2-18) or (12, fig. 2-19), and connect the cylinder
filling hose to the cylinder and to valve(l3 or 18, fig.
2-8). A fiber gasket must be placed between the hose
and cylinder being filled. Record the weight of the
empty cylinder. Add to this weight, the weight
necessary to fill the cylinder. This figure is the total
weight. Close the cylinder filling valve 17 or 19 on the
filling hose (fig. 2-25) when the scale indicates this
weight.
e. Open valves 12, 13, 14, and 15 (fig. 2-25).
When liquid appears at valve 15, close the valve, and
engage the clutch to the cylinder filling compressor (2,
fig. 2-3).
f. Slowly adjust the pressure regulating valve 14
(fig. 2-25), until a charging pressure of 600 to 800 psi
(42.18 to 56.24 kg per sq cm) is indicated on the
pressure gage in cool weather; 800 to 1000 psi (56.24 to
70.3 kg per sq cm) is suitable pressure in hot weather.
However, experience on the part of the
f. Open valves 26 and 27 to bleed off carbon
dioxide trapped in the liquid fill lines, and disconnect the
hoses. Bleed off the interconnecting vapor line between
the external tanks, and then disconnect the hose.
g. Set the valves for the normal position as
indicated in Figure 2-13. Set the controls for automatic
operation, and engage refrigeration clutch (3, fig. 2-3).
2-14.
Cylinder Filling Operation (Liquid in Both
Pressure Vessels)
a Before performing any steps involving the
storage tank, purge the cylinders completely to reduce
pressure. Pressurized cylinders will slow up the filling
time. Purge the cylinders just prior to the filling, as
released vapor will cool the cylinder and reduce the
filling time. Difficulty during filling may be experienced
because of water in the cylinder. Open the cylinder
valve, allow the cylinder to warm up and then invert to
remove the water. After all pressure and water are
removed, perform the following steps.
2-23
TM 5-3655-210-12
regulating valve may remain constant until all cylinders
have been filled. This will reduce packing wear.
CAUTION
Do not allow the cylinder filling unit to idle at
charging pressure for long periods of time.
This will cause pressure build-up within the
pressure vessels and wear to the cylinder
filling unit.
j. After the cylinder filling operations are
complete, adjust valve 14 (fig. 2-25) counterclockwise
to reduce the gage pressure to approximately 300 psi
(21.18 kg per sq cm). Disengage the cylinder filling unit
clutch (2, fig. 2-3) and set the valves for the normal
position as indicated in Figure 2-13. Set the controls for
automatic operation, and engage the refrigeration clutch
(3) (fig. 2-3). Remove the cylinder filling hoses, and
replace in the storage compartment.
2-15. Determining Liquid Level While Pumping
a. Liquid Level Gage. The unit is equipped so that
the liquid level gages (2 and 4, fig. 2-4) indicate the
contents of the pressure vessels (in tenths of capacity)
even during pumping. Thus the contents can be
determined by reading the gages and allowing for slight
time lag.
b. Liquid in Vapor Equalizing Line. When filling
the pressure vessels, it is usually desirable to fill them
completely. The normal course of the carbon dioxide
during filling is for liquid to enter at the bottom of the
vessels while carbon dioxide vapor flows out at the top
of the vessels, returning to the tank from which the
liquid is being pumped. When the liquid level in the
pressure vessel rises until it reaches the bottom of the
vapor equalizing dip tube inside the vessel, the tank is
at full capacity.
NOTE
If pumping is continued after capacity is
reached, liquid carbon dioxide will enter
the vapor equalizing line instead of
vaporous carbon dioxide. The cold liquid
in the vapor equalizing line will cause that
line to accumulate frost, and indicate that
complete filling has been obtained.
TS 024503
Figure 2-25.
Cylinder filling operation .
operator will determine a suitable charging pressure.
g. Open valve on cylinder to be filled and
corresponding valve 16 or 18 (fig. 2-25).
NOTE
As the empty cylinder starts filling, the
charging pressure, indicated on the pressure
gage, will decrease and gradually regain the
charging pressure as the cylinder fills.
h. Allow the cylinder to fill until the proper v/eight
is reached. When the cylinder is full, close the valve on
the cylinder and the corresponding valve 16 or 18.
Bleed off pressure trapped in the hose through valve 17
or 19. Do not overfill the cylinder. The total weight of a
completely charged cylinder is stamped on the cylinder.
CAUTION
If a cylinder is overfilled, discharge the
excess carbon dioxide so that the
frangible disc on the cylinder is not
ruptured.
i. If cylinders of the same size are being filled
alternately, in pairs, with continuous charging taking
place, one connection is used for filling and the other
connection is used for attaching or removing the second
cylinder. Setting of the pressure
c. Pressure Gage. Another method of determining
when the tank is full is to observe the pressure gages (1
and 3, fig. 2-4). As long as liquid enters the bottom of
the vessel and vapor returns through the vapor
equalizing line, the pressure will remain approximately
constant. 'As soon as the liquid level reaches the vapor
equalizing dip tube and liquid is forced into the vapor
equalizing line, the pressure will suddenly begin to rise.
2-24
TM 5-3655-210-12
dioxide inside the pressure vessel be kept no higher
than the bottom of the vapor equalizing line dip tube.
After complete filling of the. pressure vessel and after
the hoses have been disconnected, open the vapor
equalizing line valve (23, fig. 2-8) slightly to discharge
carbon dioxide to atmosphere. If the discharge is clear
or only slightly foggy, the tank has not been overfilled.
However, if the discharge is a dense, white cloud
containing particles of dry ice, the liquid level in the tank
is too high. To remedy this, carbon dioxide discharge
from the vapor equalizing line connection should be
allowed to continue slowly until the dense white
discharge changes to a clear or blue fog discharge.
d. Amount of Carbon Dioxide Required to Fill
Tank.
If the pumping rate is known, it can be
determined from the liquid level gage reading before
pumping is started how much carbon dioxide will be
required to fill the tank and approximately how long it
will take to pump this among of carbon dioxide. Be alert
for the indications outlined in (b) and (c) above, several
minutes before this time has elapsed. Stop the pump
immediately when either indication is observed.
2-16.
Checking For Overfilling It is important that
the level of the liquid carbon
Section ll. OPERATION OF AUZILIARY MATERIAL
USED IN CONJUNCTION WITH CONVERSION AND STORAGE UNIT.
ide upon contact with the air turns into gas which has a
smothering effect on fire.
b. Operation. Open the quick release clamp and
lift out the extinguisher. Pull the pin which locks the
handle, point the nozzle at the base of the fire and
squeeze the handle to discharge the contents of the
extinguisher at the fire. As soon as possible after use,
recharge the extinguisher as instructed: NOTE
Do not put the extinguisher back in place in the
equipment after use without recharging it.
2-17. Fire Extinguisher
a. Description. The conversion and storage unit is
equipped with a 15 pound (1.0545 kg per sq cm) carbon
dioxide fire extinguisher (7, fig. 2-18) or (7, fig. 2-19)
located in the left side of the storage compartment. It is
held in with a quick release clamp (8) for easy access.
Fifteen pounds (1.0545 kg per sq cm) of liquid carbon
dioxide is held in the cylinder at 800 psi (56.24 kg per sq
cm) at 70F. (21C.). When the extinguisher valve is
opened, the carbon dioxide is released. The liquid
carbon diox-
Section lll. OPERATION UNDER UNUSUAL
CONDITIONS
grease. For lubrication at low temperatures refer to LO
5-3655-210-12.
c. Operating Precautions. Avoid all unnecessary
shocks when operating the equipment. Metal becomes
brittle at very low temperatures, and its ability to
withstand shock becomes less as the temperature
drops.
d. Low Temperature Operation. Perform the
steps given below when liquid carbon dioxide is
contained in both pressure vessels, and the surrounding
temperature is below -38.9C. (20F.). If the unit has
been subject to low temperatures for considerable time,
install warm, fully charged batteries.
(1) Position the valves as indicated in Figure 226. Valves 38 and 39 are open to the compartment
heater (valve handles turned 900 clockwise from
2-18. Operation In Extreme Cold
a. General. Operating the conversion and storage
unit in extreme cold temperatures presents special
problems. Careful inspection is necessary, particularly
for the lubrication and electrical systems. Spend more
time performing such operations as preventive
maintenance and take extra care with pre-starting
precautions. Failure to give this extra service may
result in starting failures, inefficient operation, and
serious or permanent damage to the unit.
b. Lubrication.
At extreme low temperatures,
lubricants that are too heavy a grade can make the
operating machinery difficult to start or to operate.
Operating with too heavy a grade of grease or oil will
cause rapid wear of the moving parts, as they receive
no initial lubricating from heavy cold oils or
2-25
TM 5-3655-210-12
TS 024504
Figure 2-26.
Power . Power compartment heating .
closed position). Refer to Table 2-1 for valve
identification.
(2) Turn on the switch (9, fig. 2-2) to the
conversion heater and the CONVERSION and
STORAGE switches (6 and 7) to the gage line heaters.
(3) After the conversion heater is operating, turn on
the SPACE switch (8) to the space heater.
(4) Turn valve 38 to the normal position (90°
counterclockwise from the position indicated in step (1)).
This will allow the heater fluid to circulate through the
piping in the conversion pressure vessel and to the
space heater in the power compartment.
(5) When the power compartment is warmed
sufficiently to perform transferring and filling operations,
turn valve 39 to the normal position (90°
counterclockwise from the position indicated in step (1)
above) and turn off the SPACE switch.
(6) The conversion heater is now warming up the
carbon dioxide in the tank and will continue to operate
until the pressure in the tank reaches 275 psi (19.3325
kg per sq cm). At this pressure, the tank pressure
control switch will open the circuit to stop the heater.
2-19.
Operation Under High Humidity Conditions
High moisture content in the air will cause the most
difficulty in electrical system. The spark plug and
breaker box wiring often becomes unserviceable due to
high humidity. The parts that are affected must be
removed and dried. If this does not remedy the trouble,
report to the proper authority.
2-20.
Operation In Extreme Heat
a. General. The operation of the conversion and
storage unit in extreme heat will be the same as under
normal conditions if care is taken t6 prevent
overheating. The automatic controls will operate to
keep the carbon dioxide liquid in the pressure vessels at
the required pressure, and the entire unit will operate
successfully at +130F. (54.4C.).
b. Cooling. Give extra care and service to the
power compartment, for efficient operation.' Open the
refrigeration shutter and the compartment doors. If
necessary, install a circulating fan on the 220-volt
circuit.
2-26
TM 5-3655-210-12
c. Air. Over a period of time, oil, dust, and
dirt will collect on the condenser fins. Remove by using
a long bristle brush. Keep any obstacles which might
obstruct the flow of air between the condenser fins,
away from the power compartment.
d. Lubrication.
When operating under
extreme heat, check the level of the oil, and the
lubrication points frequently. Keep oil levels as close to
the proper level as possible. For lubrication under
extreme heat, refer to LO 5-3655-210-12.
2-21.
Operation Under Dusty Or Sandy Conditions
a. General. Operation of the conversion arid
storage unit under conditions of extreme dust or sand
will cause wear, shorten the service life of the unit, and
increase the servicing periods to keep the unit
operating. Perform careful and frequent servicing.
b. Lubrication. Lubricate more frequently
than specified in LO 5-3655-210-12, depending upon the
amount of sand and dust in the area. Keep the covers
on lubrication points tightly closed. When lubricating,
make sure that no sand or dirt has entered lubrication
point.
c.
(4) Batteries.
Increase frequency of
battery PMCS. Use distilled water or a good grade of
drinking water (excluding mineral water).
d. Cleaning. Thoroughly clean and lubricate
the entire unit as soon as possible, after exposure to
severe dusty or sandy conditions.
2-22.
Operation In High Altitude
a. The gasoline engine power output will
gradually decrease as the operating altitude above sea
level increases. This is due to less air being drawn into
the cylinders, resulting in a richer fuel mixture and
incomplete combustion. It may be necessary to readjust
the carburetor for proper operation.
b.
properly.
2-23.
Be sure the air cleaner is operating
Operation In Salt Water Areas
a. General. Salt water has a very corrosive
action on metal. Avoid contact with salt water whenever
possible.
b. Lubrication. Clean all lubricating points
thoroughly. Refer to LO 5-3655-210-12 for proper
lubricants.
Protective Measures.
(1) Keep the air cleaner in the best
operating condition.
(2) Keep the doors and shutters closed
when possible, to keep excessive dust and sand from
entering compartments.
(3) Seal instrument edges with masking or
scotch tape to keep dust from entering.
c. Electrical System.
Keep all electrical
equipment clean and free from corrosion. Clean the
spark plug terminals frequently.
d. Protection. If the conversion and storage
unit is stored in an area where salt water spray is in the
air, use a tarpaulin or other suitable cover for protection.
Change 1 2-27/(2-28 Blank)
TM 5-3655-210-12
CHAPTER 3
OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Section I. LUBRICATION INSTRUCTIONS
clean of lubricants. Before lubricating the
storage and charging unit, wipe all lubrication
points free of dirt and grease. Clean all
lubrication points after lubricating to prevent
accumulation of foreign matter.
3-1.
General
Keep all lubricants in closed containers
and store in a clean, dry place away from
external heat. Allow no dust, dirt, or other
foreign material to mix with lubricants. Keep
all lubrication equipment clean and ready to
use.
3-3.
Points of Lubrication
Service the lubrication points at proper
intervals as shown in figure 3-1.
3-2.
Cleaning
Keep all external parts not requiring
lubrication
3-1
TM 5-3655-210-12
Figure 3-1. Lubrication order (sheet 1 of 2).
3-2
TM 5-3655-210-12
Figure 3-1. Lubrication order (sheet 2 of 2).
3-3
TM 5-3655-210-12
Section II. PREVENTIVE MAINTENANCE
CHECKS AND SERVICES (PMCS)
Table 3-1. Operator/Crew Preventive
Maintenance Checks and Services
3-4.
General
To insure that the conversion and
storage unit is ready for operation at all times,
it must be inspected systematically so that
defects may be discovered and corrected
before they result in serious damage or failure.
Defects discovered during operation of the unit
shall be noted for future correction, to be made
as soon as operation has ceased.
Stop
operation immediately if a deficiency is noted
which would damage the equipment if
operation were continued. All deficiencies and
shortcomings will be recorded together with
the corrective action taken On DA Form 2404
(Equipment Inspection and Maintenance
Worksheet)
at
the
earliest
possible
opportunity.
D-Daily
Total Man-Hours Required: 3.0
Internal
and
Sequence
No.
D
1
2
3
3-5. Daily
Preventive
Maintenance
Services
This paragraph contains an illustrated
tabulated listing of preventive maintenance
services which must be performed by the
operator.
The item numbers are listed
consecutively and indicate the sequence of
minimum requirements. Refer to Table 3-1 for
the daily preventive maintenance services.
4
5
6
7
Item to be Inspected
Procedure
W
W-Weekly
Work
Time
(M/H)
GASOLINE ENGINE CRANKCASE
Service per L05-3655-210-12.
FUEL PUMP FILTER (SERIAL NOS.
L-1475-T THROUGH L-1478-T)
Inspect filter through glass bowl.
Remove any foreign matter from
screen.
DRIVE BELTS
Check that transfer pump belt tension permits only about 1 in. (2.54
cm) deflection under thumb pressure
at midpoint between pulleys; tension
of other belts, about 1 1/2 in.
(3.81 cm) deflection under the same
test.
GASTANK
Fill with REGULAR grade
gasoline, 74 octane preferred.
CYLINDER FILLING UNIT
Service crankcase per figure 3-1.
REFRIGERATION COMPRESSOR
Service crankcase per figure 3-1.
CONTROLS AND INSTRUMENTS
With the unit operating inspect
for improper operation. Normal
operating ranges for instruments
are as follows:
DC Ammeter (on engine
control panel)
0-20 amps
Fuel Gage
"E" to "F"
NOTE
During operation observe for any unusual noise or vibration.
3-4
1.0
0.2
0.2
0.3
0.5
0.5
0.3
TM 5-3655-210-12
Section III. TROUBLESHOOTING
3-6.
Table 3-2. Troubleshooting
General
a.
This
section
contains
troubleshooting
information for locating and correcting most of the operating
troubles which may develope in the conversion and storage
unit. Each malfunction for an individual component, unit, or
system is followed by a list of tests or inspections which will
help to determine probably causes and corrective action to be
taken. Perform the tests/inspections and corrective actions in
the order listed.
Malfunction
Test or Inspection
Corrective Action
1.
GASOLINE ENGINE FAILS TO START
Step 1. Check for an empty fuel tank.
Fill the gasoline tank.
Step 2. Check for loose or broken wiring.
Tighten connections or replace defective
wiring.
Step 3. Check for dirty spark plugs.
Clean or replace plugs.
2.
ENGINE MISFIRING
Check for dirty spark plugs.
Clean the plugs.
3.
ENGINE KNOCKS
Check for lack of oil
Refill.
4.
POWER LOSS IN ENGINE
Check for a dirty air cleaner.
Clean and refill air cleaner (para 3-10).
b.
This manual cannot list all malfunctions that
may occur, nor all tests or inspections, and corrective action.
If a malfunction is not listed or is not corrected by tested
corrective actions, notify your supervisor.
3-7.
Operator Maintenance Troubleshooting
Refer to Table 3-2 for troubleshooting pertaining to
operator's maintenance.
Section IV. MAINTENANCE PROCEDURES
(2) Put oil cup, with gasket (5, fig. 3-3) back
General
on bracket (7) and add oil, of the same grade used in the
This section contains maintenance procedures that
crankcase, to the OIL LEVEL line.
are the responsibility of the operator as allocated by the
(3) Replace gasket (3), cap and filter
maintenance allocation chart and which are not covered
assembly and wingnut.
elsewhere in this manual.
(4) Check that check ball (serial nos. L-1475T through L-1478-T) or reed (serial nos. L-1666-T through
3-9.
Engine Assembly
L1668-T) in breather (11) is free in breather body. Wash
Refer to LO 5-3655-210-12 and service engine
breather in solvent and reinstall.
assembly.
3-8.
3-11.
3-10
Air Cleaner
a.
Removal and Disassembly.
(1) Remove wingnut (2, fig. 3-2) and lift off oil
cup assembly (4) from bracket (7). Do not tilt, as oil will spill
from oil cup.
(2) Take cap and filter assembly (1) and
gasket (3) from oil cup. Leave gasket (5) on bracket (7), and
dispose of old oil from oil cup. Remove breather (11).
b.
Inspection and Service.
(1) Wash filter assembly and oil cup in
solvent.
Fuel Filter Service (Ser. Nos. L-1475-T Through L1478-T)
Refer to Figure 3-3 and service fuel filter as follows:
a.
Turn shut-off valve (1) fully in to shut off fuel
flow.
b.
Loosen thumbnut (17) enough to free sediment
bowl (18), and while holding bowl from dropping
3-5
TM 5-3655-210-12
Muffler And Exhaust Pipe Inspection
Refer to Figure 3-4 and inspect the muffler (1) for leaks or
signs of rusting through the metal.
NOTE
Surface rusting, if it doesn't weaken the muffler to the point of
causing structural failure, is not enough to justify replacement
of the muffler.
3-12.
Inspect muffler, elbows (2), pipes (3, 4, and 14) for security of mounting,
tight joints, and freedom from corrosion.
3-13.
Cooling System Inspection
Refer to Figure 3-4 and inspect the cooling air shroud (5) and
related sheet metal ducting for security of attachment and freedom from
damage. Check flywheel cover (6) for any obstruction to air flow, such as
dust accumulation.
3-14.
Engine Control Panel Inspection
Refer to figure 3-5 and check that fuel gage (4) indicates
quantity of fuel in tank (should be full before operation), and ammeter (1)
indicates zero. Check for loose or damaged panel components.
3-15.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Cap and filter assembly
Wingnut
Gasket
Oil cup assembly
Gasket
Stud
Air cleaner bracket
Machine bolt
Lockwasher
Gasket
Breather
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Lights
a.
Stop and Taillights.
(1)
To remove either blackout or service stop and
taillights (11 and 15, fig. 3-6) uncouple wire connectors (14) and tag
leads for identification, then remove capscrews (12) and lockwashers (13)
to free blackout units, or screws and nuts attaching service units.
Reverse this procedure to install.
(2)
To replace lamps, loosen screws, remove door (1,
fig. 3-7) and remove defective lamp by pressing in while turning lamp to
left, to disengage lamp base from socket, then remove lamp. Install new
lamp by reversing removal procedure above.
NOTE
Procedure above is typical for both service and blackout
taillights.
Gasket
Hose clamp
Hose
Nut
Screw
Gasket
Breather
Washer
Screw
Preformed packing
b.
Clearance Lights. To replace lamp (3, fig. 3-8) remove
screws (11), door (1), lens (2) and press and turn lamp left to release.
Reverse these steps to complete operation. To replace entire light
assembly proceed as follows:
(1)
Remove door and lens as given above. Inside
trailer body, at light to be replaced, disconnect electrical connector by
pressing two halves together while twisting them.
(2)
Remove screws (7) and take off clearance light
and gasket (9). Reverse this procedure to install light.
c.
Dome Lights.
(1)
To remove dome lights, disconnect wire connector
(10, fig. 3-9), remove three screws (2) holding base (4) to roof of
compartment. Reverse procedure to install.
Figure 3-2. Air cleaner, exploded view.
swing bail (16) aside. Remove bowl, gasket (19) and screen (20).
c.
Clean screen of accumulated dirt, and reassemble,
using a new gasket (19).
d.
Open shut-off valve and check for leaks at gasket.
Tighten thumbnut until any leak stops.
3-6
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Shut-off valve and packing nut
Packing
Cover
Elbow
Pipe nipple
Fuel pump
Gasket
Tube nut
Fuel tube
Spring
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Preformed packing
Primer lever
Pin
Lockwashers
Capscrew
Ball
Thumbnut
Sediment bowl
Gasket
Screen
Figure 3-3. Fuel filter, exploded view.
3-7
TM 5-3655-210-12
TS 024509
Figure 3-4. Muffler and exhaust pipes.
3-8
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
Muffler
Elbow
Pipe nipple
Pipe coupling
Shroud
Flywheel cover
Machine screw
8.
9.
10.
11.
12.
13.
14.
Lockwasher
Capscrew
Battery lead
Lockwasher
Capscrew
Bracket
Tailpipe tube
15.
16.
17.
18.
19.
20.
Belt tightener mounting
Capscrew
Nut, terminal, lower
Lockwasher
Lead
Lead
21.
22.
23.
24.
25.
26.
Nut, terminal, upper
Lead
Nut, U-bolt clamp
Bracket
Clamp (U-bolt)
Solenoid
Figure 3-4 - Continued.
1.
2.
3.
4.
5.
6.
7.
8.
Ammeter
Electrical control switch (tractor or trailer)
Circuit breaker
Fuel indicator gage
Gage lines operating lights
Storage vessel gage line switch
Conversion vessel gage line switch
Compartment heater control switch
9.
10.
11.
12.
13.
14.
15.
(2) To replace lamp, loosen two
screws (3) holding lens (5) to base (4), turn
lens to remove it, and replace lamp.
Reposition lens and tighten screws.
d. Failure and Gage Line Lights
(1) Removal. Tag the wires of the
light to be removed. Then remove the nut and
lockwasher securing the light to the panel and
slide the assembly out the front of the panel.
(2) Cleaning,
Inspection,
and
Repair.
Conversion heater control switch
Conversion heater failure light
Gasoline engine manual stop switch
Gasoline engine manual starter switch
Gasoline engine control switch for automatic or manual
control
Gasoline engine failure light
Engine control panel
WARNING
Dry cleaning solvent, P-D-680 or PS661 used to clean parts is
potentially dangerous to personnel
and property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F. - 138F.
(38C. - 59C.).
3-9
TM 5-3655-210-12
1.
2.
3.
4.
5.
Frame
Bumper assembly
Nut
Bracket
Lockwasher
6.
7.
8.
9.
10.
Capscrew
Machine bolt
Nut
Bracket
Bracket
11.
12.
13.
14.
15.
16.
Service stop and taillight
Capscrew
Lockwasher
Connector
Blackout stop and taillight
Nut
Figure 3-6. Taillight removal.
Clean with a cloth dampened in a cleaning
solvent. Inspect for damaged threads, cracked
or broken glass, or any other damage.
Replace damaged parts. Reverse removal
procedure to reinstall.
(3) Replacing. To replace a burned
out lamp, unscrew the lens from the front of the
light, replace the lamp and screw the lens back
in place.
(1) Place the two batteries (8, fig.
3-11) in position in the battery holder with the
negative (-) terminals (1) on each battery
nearest the rear of the unit.
3-16. Batteries
a. Removal.
(3) Position the connector lead (4)
with one end on the positive (+) terminal (5) of
one battery and the other end on the negative
terminal (1) of the other battery.
(1) Remove the band (4, fig. 3-10)
holding the boxes (3) together.
(2) Remove the boxes from the
storage compartment. Open the boxes and lift
out the batteries and electrolyte containers.
(2) Place the two holddown bars (9)
in position on the holddown rods (10) and
secure with the four flatwashers (11) and nuts
(12).
(4) Place the ground lead (2) on
the negative terminal (1) nearest the side wall
and the solenoid lead cable (7) on the positive
terminal (5) of the other battery.
(5) Secure the cables to the four
terminals with the four nuts (6).
b. Installation.
NOTE
Do not mix military batteries and
maintenance-free batteries.
Under
charge or over charge will result.
NOTE
Use an electrolyte with a specific gravity
of 1.280. Do not use tropical electrolyte,
which will reduce battery reserve
capacity.
(6) Remove the twelve cell caps
from the batteries and add the electrolyte to
each of the cells.
Change 1 3-10
TM 5-3655-210-12
1. Door assembly
2. Machine screw
3. Retaining ring
4.
5.
6.
Gasket
Lamp
Lamp
7.
8.
9.
Socket and wiring assembly
Machine screw
Eyelet
10.
11.
12.
Grommet
Connector
Body
10.
11.
Spring nut
Screw
Figure 3-7. Blackout stop and taillight, exploded view.
1. Door
2. Lens
3. Lamp
4.
5.
6.
Screw
Washer
Wiring assembly
7.
8.
9.
Screw
Base
Gasket
Figure 3-8. Clearance light, exploded view.
3-11
TM 5-3655-210-12
Figure 3-9. Heater compartment and dome lights, installed view.
3-12
TM 5-3655-210-12
1.
2.
3.
4.
5.
Coolant line
Machine screw
Machine screw
Dome light base
Dome light lens
6.
7.
8.
9.
10.
Housing
Coolant line
Tube nut
Bracket
Connector
11.
12.
13.
14.
15.
Coolant line
Pipe plug
Nipple
Tee
Nipple
16.
17.
18.
19.
20.
Pipe union
Saddle stand
Capscrew
Coolant pump
Coolant pump lead
21.
22.
23.
24.
25.
Wiring harness
U-bolt
Bracket
Nut
Machine screw
26.
27.
28.
29.
Limit switch
Limit switch cover
Lockwasher
Coolant line
Figure 3-9 - Continued.
3-18.
Tires And Tubes
Inspect tires for wear, cuts which damage the cords of the
carcass fabric, and inflation pressure, which should be 75 pounds per
square inch (5.2725 kg per sq cm).
3-19.
Pintle
Check that pintle assembly (7, fig. 3-12) unlatches readily and latches
easily and securely. Clean as necessary to free up sticky mechanism.
3-20.
Landing Gear
Wash or steam clean landing gear for inspection. Check for
loose screws and nuts, damaged threads, corrosion, physical damage,
leaking lubricant from gear box (7, fig. 3-13). Refer maintenance beyond
lubrication to organizational maintenace.
3-21.
Winterization Equipment
Operate conversion and storage gage line heater switches (6
and 7, fig. 3-5). If operating lights (5) do not light, replace bulbs as
follows: To replace a burned out lamp, unscrew the lens from the front of
the light, replace the lamp and screw the lens back in place.
3-22.
Data Plates and Instruction Holders
Inspect data, plates for security of mounting and legibility of
data. Inspect instruction holders for condition and that current copies of
applicable instructions are installed.
3-23.
Motor Starter and Protective Devices
Inspect exterior of starter (fig. 3-14) and reversing switch for general
condition, loose attaching parts and condition of external wiring.
3-24.
1. Landing jack brace,
mounting bracket
2. Capscrew
3. Packing boxes
4.
5.
6.
7.
Gages, Lines, and Fittings
Inspect instruments and gages for proper indication as
described, security of mounting and freedom from leakage (if applicable).
Inspect gages and associated lines for physical damage.
3-25.
Conversion Heater
Inspect heater fluid lines (fig. 3-15) and their fittings for leaks.
Check sight glass indications for quantity of heater fluid in tank. Operate
heater and check that exhaust from combustion is free of smoke.
3-26.
Cylinder Filling Compressor
a.
Service compressor (26, fig. 3-16) according to LO 53655-210-12.
Band
Landing jack brace
Tool box'
Band
Figure 3-10. Electrolyte and batteries stored for shipment
Electrolyte must cover the plates by at least /4 inch (.635 cm).
WARNING
Do not overfill the batteries or splash electrolyte as it is
an acid and can cause personal injury.
(7)
Replace the twelve cell caps and wash off any
acid that may have spilled.
3-17.
Power Transfer Equipment
Check that transfer pump drive belt can be deflected no more
than 1 in. (2.54 cm) at midpoint by thumb pressure; all other belts, no
more than 1/2 in (3.81 cm). Lubricate in accordance with LO 5-3655210-12.
3-13
TM 5-3655-210-12
1.
2.
3.
4.
Negative terminal
Ground lead
Battery filler cap
Connector lead
5.
6.
7.
8.
Positive terminal
Nut
Battery to solenoid lead cable
Battery
9.
10.
11.
12.
Battery holddown bar
Bracket holddown rod
Washer
Nut
Figure 3-11. Batteries, installed view.
1. 208 v, ac power receptacle
2. Vapor equalizing line
3. Liquid fill line (pump by-pass)
4.
5.
6.
24 v, dc receptacle
Liquid fill line
Blackout stop and taillight
7.
8.
9.
Pintle hook
Capscrew
Stop and taillight, service
Figure 3-12. Power receptacles, installed view.
3-14
TM 5-3655-210-12
(fig. 3-17) for leaks, or damage. See that each
valve bears a numbered identification tag.
b. Inspect all hoses, lines, and fittings
for leaks, security of attachment and general
physical condition. Look for spurts of C02
snow from compressor packing nut during
operation. Tighten nut if necessary.
c.
3-27. Fire Extinguisher
Check that the weight of the hand fire
extinguisher (7, fig. 3-18) or (7, fig. 3-19)
corresponds to the "full weight" stamped on
the body.
Inspect C02 manifolds, piping and
valves
1.
2.
3.
4.
5.
6.
7.
8.
Shaft support
Crankshaft
Lockwasher
Nut
Nut
Lockwasher
Gear box
Fitting
9.
10.
11.
12.
13.
14.
15.
16.
Crank assembly
Crank holder
Cross brace
Machine bolt
Foot
Nut
Washer
Capscrew
Figure 3-13. Landing gear, installed view.
3-15
17.
18.
19.
20.
21.
22.
23.
Diagonal brace
Plate
Gasket
Screw
Landing jack leg
Capscrew
Bracket
TM 5-3655-210-12
Figure 3-14. Electric motor starter and reversing switch.
3-16
TM 5-3655-210-12
Figure 3-15. Conversion heater, installed view.
3-17
TM 5-3655-210-12
Figure 3-16. Clutch controls, installed view.
3-18
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Strainer
Street elbow
Pipe nipple
Union nut
Hose
Hose nut
Transfer pump clutch shifter
Cylinder filling compressor clutch shifter
Refrigeration compressor clutch shifter
Strainer bleed-off valve
Tube nut
Bleed-off tube strainer
Refrigeration compressor
Capscrew
Nut
Lockwasher
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Bevel washer
U-bolt
Frame
Nut
Bevel washer
Transfer pump bleed-off tube
Bracket
Lockwasher
Transfer pump bleed-off valve
Cylinder filling compressor
Nut
Bracket
U-bolt
Liquid shut-off valve cylinder fill compressor
Coupling
Cylinder filling pressure gage
Figure 3-16 - Continued.
TS 024522
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Strainer bleed-off valve
Cylinder filling compressor liquid shut-off valve
Liquid equalizing line valve
Dehydrator by-pass valve
Refrigerator suction valve
Transfer pump bleedoff valve
Liquid fill line valve thru pump
Receiver tank inlet line
Dehydrator
Union nut
Liquid line shut-off valve, conversion
Transfer hose bleed-off valve (thru pump)
Cylinder filling valve
Tube nut
Cylinder fill pressure regulating valve
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Safety relief valve cylinder fill
Union nut
Cylinder filling valve
Transfer hose bleed-off valve
Vapor return valve, conversion
Transfer hose bleed-off valve vapor
Liquid line vapor relief valve
Vapor equalizing line valve
High pressure vapor return valve
Fire protection valve
Vapor return valve, storage
Carburetor priming lever
Stop pin
Liquid fill line valve, by-pass pump
Liquid shut-off valve to cylinder filling compressor
Figure 3-17. CO2 manifolds, installed view.
3-19
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
Bracket
Nut
Brace
Capscrew
Transfer hose (vapor)
Freon tank
7.
8.
9.
10.
11.
12.
Fire extinguisher
Quick release clamp
Holder
Transfer hose (liquid)
Cylinder filling hoses
Scales
Figure 3-18. Storage compartment, face view.
3-20
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
Bracket
Nut
Brace
Capscrew
Transfer hose (vapor)
Freon tank
7.
8.
9.
10.
11.
12.
Fire extinguisher
Quick release clamp
Holder
Transfer hose (liquid)
Cylinder filling hose
Scale
Figure 3-19. Storage compartment face view (ser. nos. L-1666-T
through L-1668-T).
3-21
TM 5-3655-210-12
CHAPTER 4
ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Section I. SERVICE UPON RECEIPT OF MATERIAL
4-1.
Unloading New Conversion And Storage Unit
a.
General. The conversion and storage units are shipped
on railroad flatcars, securely blocked (fig. 4-1) and lashed with 1/2 inch
(1.27 cm) steel cable or 2 inch (5.08cm) X 0.050 inch (0.127cm) high
tension bands. They are completely assembled. To prevent possible loss
in transit, the freon gas charge is pumped down from the refrigeration unit
to the receiver tank. The crankcases of the gasoline engine, cylinder
filling unit, and refrigerating unit are filled to the proper level. The tool box,
with tools, and the electrolyte for the batteries, are secured in the storage
compartment. The pressure vessels are drained of carbon dioxide liquid
and filled with carbon dioxide vapor at 3 to 5 psi (pounds per square inch)
(.2109 to .3515 kg per sq cm).
b.
Unloading With Lifting Device.
(1)
Remove the cables or bands (fig. 4-1) securing
the rear of the unit to the flatcar.
(2)
Remove the cables or bands securing the front of
the trailer.
(3)
Remove the blocking from the side of the wheels
and the blocking from in front of, and behind the wheels.
(4)
If a crane is to be used remove the four lifting eye
covers by removing twelve sheet metal screws and lockwashers securing
each cover to the tank body.
(5)
Remove the insulation blocks from under the
covers.
(6)
Unscrew four tie-down rings from the trailer and
install them in the lifting eye holes at the top of the tank body.
(7)
Attach the slings and carefully remove the unit
from the flatcar with a crane of ample lifting capacity.
(8)
Remove the slings, replace the insulation and
secure each cover with the twelve sheet metal screws and lockwashers.
c.
Unloading By Use of Ramp.
(1)
Place an unloading ramp at the end of the flatcar.
(2)
Block the flatcar wheels with 6 x 6 inch (15.24 x
15.24cm) timbers on each side.
(3)
Lower the landing jacks to support the weight of
the front of the trailer, and remove all tie-down cable or bands, wheel and
body blocks, and other bracing.
(4)
Back an air brake equipped tractor up to the ramp
to the trailer, and couple the tractor air and electrical connections to the
trailer. Be sure the condensation drain petcock on the air reservoir is
closed, and carefully tow the unit off the flatcar.
4-2.
Unpacking New Conversion And Storage Unit
Accessories
a.
General. Table 4-1 contains a list of separate packed
items that are furnished with and are
Table 4-1. Separate Packed Items
National
Stock
Number
6140-00-057-2554
6150-00-435-2322
Description
Quantity
Furnished
w/equipment
Battery, storage, 12V
Cable, electrical, main-power,
100 ft. (3000cm) w/conn
(90129)x8702-17
Chock, wheel (07464) 3597
Dichlorodifluoromethane, fed.
BB-F-671, type 12,
25 LB. (11.25kg) cylinder.
Ground, rod assembly w/ wire lug
and clamp (07464) 3598.
2 ea.
1 ea.
3655-00-084-0464
Hose assembly, C02, cylinder
filling 1/4"x6" (.635 x 15.24cm)
(07464) 126200
2 ea.
3655-00-653-5713
Hose assembly, C02, transfer,
1" (2.54cm), ID, 50' (1500cm)
Ig. with 1/2" (1.27cm) captive adapter.
Hose assembly, C02, transfer,
1-1/2"(3.81cm) ID, 50' (1500cm)
Ig. with 3/4" (1.905cm) captive
adapter
Scale, dial indicating,
400 LB (180 kg)
(07464) 559381.
Sulfuric acid, electrolyte
1 ea.
2540-00-421-1521
6830-00-292-0147
5975-00-369-9710
4720-00-653-5717
6670-00-084-0530
6810-00-249-9354
4-1
2 ea.
1 ea.
1 ea.
1 ea.
1 ea.
4 gal.
(15.2
liters)
TM 5-3655-210-12
Figure 4-1. Conversion and storage unit tie-down and blocking.
4-2
TM 5-3655-210-12
c.
1. Landing jack brace,
mounting bracket
2. Capscrew
3. Packing boxes
4.
5.
6.
7.
Band
Landing jack brace
Toolbox
Band
Figure 4-2. Electrolyte and batteries stored for shipment.
required to complete an operational end item. This table does not
constitute authority for requisitioning purposes.
For requisitioning
authority, refer to TM 5-3655-210-201 (when printed). The batteries are
shipped dry charged. The batteries and electrolyte are packed in
separate containers and stored in packing boxes secured in the storage
compartment (fig. 4-2).
b.
Removal.
(1)
Remove the steel band (7, fig. 4-2) securing the
boxes and attached to the landing jack braces (5).
(2)
Remove the band (4) holding the boxes (3)
together.
(3)
Remove the boxes from the storage compartment.
Open the boxes and lift out the batteries and electrolyte containers.
Installation.
NOTE
Do not mix military batteries and maintenance-free batteries.
Under charge or over charge will result.
(1)
Place the two batteries (8, fig. 4-3) in position in
the battery holder with the negative (-) terminals (1) on each battery
nearest the rear of the unit.
(2)
Place the two hold-down bars (9) in position on the
holddown rods (10) and secure with the four flat washers (11) and nuts
(12).
(3)
Position the connector lead (4) with one end on the
positive (+) terminal of one battery and the other end on the negative
terminal of the other battery.
(4)
Place the ground lead (2) on the negative terminal
(1) nearest the side wall and the solenoid lead cable (7) on the positive
terminal (5) of the other battery.
(5)
Secure the cables to the four terminals with the
four nuts (6).
NOTE
Use an electrolyte with a specific gravity of 1.280. Do not use
tropical electrolyte, which will reduce battery reserve capacity.
(6)
Remove the twelve cell caps from the batteries
and add the electrolyte to each of the cells. Electrolyte must cover the
plates by at least 1/4 inch (.635 cm).
WARNING
Do not overfill the batteries or splash electrolyte as it is an acid
and can cause personal injury.
(7)
Replace the twelve cell caps and wash off any
acid that may have spilled.
d.
Removal of Protective Material and Devices. All the
exterior trailer lights and reflectors, and the rear window in the power
compartment are covered with masking tape. Remove the tape carefully.
Remove the strap securing the rear door.
e.
Services for Cold Weather Operation. Refer to LO 53655-210-12, note 1 and Table 4-2.
Table 4-2. Military Antifreeze Materials Used with Unit.
NOTE
This fluid is used full strength to transfer heat from the
conversion heater to the solid carbon dioxide in the conversion
pressure vessel during conversion cycle of the unit. This fluid
is used at all ambient temperatures, due to the extreme cold of
the solid carbon dioxide being converted to liquid. Under no
circumstances is this fluid to be diluted with water or any other
substance. In this manual, references to 'heater fluid' refer to
MIL-A-11755C Arctic Type Antifreeze.
Change 1 4-3
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
Negative terminal
Ground lead
Battery filler cap
Connector lead
Positive terminal
Nut, 5/16-18
7.
8.
9.
10.
11.
12.
Battery to solenoid lead cable
Battery.
Battery hold-down bar
Bracket hold-down rod
Washer, flat, 4/16 in.
Nut, 5/16-18
Figure 4-3. Batteries installed view.
4-3.
Inspecting And Servicing The Equipment
a.
Make a complete inspection of the gasoline
engine unit, visually checking for loss or damage which may
have occurred in shipment. Inspect the magneto, spark
plugs, cables, governor and linkage connections.
b.
Check the tension of the belts. Tension is
correct when the belts can be depressed by thumb pressure
approximately 1-1/2 inches (3.81cm) at the center.
c.
With the ignition off, turn the engine over by
hand, to make sure that the crank shaft, connecting rods,
pistons, and bearings move freely.
d.
Make a complete visual check of the electric
motor for loss or damage which may have occurred during
Shipment.
e.
Inspect all electrical terminals for tightness,
make certain ground rod assembly is installed.
f.
Turn the electric motor over by hand to make
sure that all moving parts turn freely.
g.
Check the condenser to make sure that all air
circulating openings are free from dirt, dust, or other debris.
h.
Make a complete inspection of the carbon
dioxide transfer pump for loss or damage that may have
occurred during shipment.
i.
Turn the transfer pump by hand to make sure
that all parts turn freely.
j.
Inspect the cylinder filling unit for loss or
damage during shipment.
k.
Turn the cylinder filling unit pulley by hand to
make sure that it turns freely.
¶U.S. GOVERNMENT PRINTING OFFICE: 1991
4-4
l.
Inspect the power train for damage.
m. Check the clutches for ease of operation.
n.
Inspect the scale, fire extinguisher, freon tank,
and transfer and cylinder filling hoses for damage during
shipment.
o.
Check the tools and toolbox for loss or damage.
p.
Check the conversion heater and expansion
tank for damage.
q.
Check all the gages for any damage that may
have occurred during shipment.
r.
Report any loss or damage on DD Form 6
(Report of Damage or Improper Shipment) or report to the
proper authority.
4-4.
Installation
a.
General. Move the conversion and storage unit
to its operating location with a suitable tractor. If the
equipment is located on marshy ground or ground with a high
sand content, wood platforms should be constructed under
the trailer wheels and under the landing jacks. Disconnect the
tractor air lines and electrical cable from the trailer. When the
tractor air lines are disconnected the trailer is in emergency
braking condition and should not be moved. Release the
towing pintle and remove the tractor. Remove the wheel
chocks from the fenders and position them under the trailer
wheels. Lower the landing jacks, if necessary, to level the
trailer as the liquid level gages will not work if the trailer is not
level.
b.
Refrigeration System. Remove valve cover
caps and open all valves necessary to allow refrigerant to
554-123/20075
PIN: 025570-001
TM 5-3655-210-12
circulate through the refrigeration system.
Observe the refrigerant sight glass (1, fig. 44), after approximately five minutes of
operation the sight glass should not show arty
gas bubbles. Bubbles indicate an insufficient
charge of refrigeration.
c. Check carefully for wear of the
pillow block bearing, frayed or excessive wear
of the drive belts, and defective gages. Check
thoroughly for loose lines and bolts. Check the
electrical wiring for wear or loose connections.
Check all valves and piping for damage.
Check the batteries for proper electrolyte level.
Check battery cables for looseness or
excessive wear.
4-5. Maintenance And Operating Supplies
A list of maintenance and operating
supplies required for initial operation of the
conversion, storage and charging plant are
contained in Table 4-3.
1.
2.
3.
4.
Refrigerant sight glass
Suction valve
Freon charging port
Suction valve shut-off
5.
6.
7.
8.
Oil level sight glass
Receiver tank inlet line
Receiver
Oil filler plug
Figure 4-4. Refrigeration compressor, installed
view.
4-5
TM 5-3655-210-12
Table 4-3. Maintenance and Operating Supplies
(1)
Component
application
(2)
National
Stock
Number
CRANKCASE
9150-00-265-9435
(2)
9150-00-265-9428
(2)
9150-00-242-7603
(2)
AIR CLEANER
FUEL TANK
CONVERSION
VESSEL
HEATER EXPANSION
TANK
CYLINDER FILLING
COMPRESSOR CRANK
CASE
(4)
Quantity
required
f/initial
operation
OIL, LUBRICATING
5 gal (19 liters)
can as follows:
OE-30
9130-00-160-1818
(2)
6830-00-160-1818
(2)
9150-00-292-9657
(2)
6850-0174-1806
9150-00-265-9435
(2)
9150 0265-9428
(2)
9150-00-242-7603
(2)
(5)
Quantity
required
F/8 hrs
operation
3-1/2 qt
(3.325 liters)
(3)
OE-10
3-1/2 qt
(3)
OES
3-1/2 qt
(3)
½
(.475 liters)
(3)
OIL LUBRICATING (4)
6830-00-292-0142
REFRIGERANT
COMPRESSOR
CRANKCASE
(3)
Description
FUEL, GASOLINE:
Bulk as follows:
Automotive combat
Grade 91A
20 gal(5)
(76 liters)
18 gal
(68.4 liters)
4,000 lbs(5)
(1800 kg)
CARBON DIOXIDE:
Solid 50 lbs
(22.5 kg)
blocks
CARBON DIOXIDE:
50 lb cylinders
(22.5 kg)
LUBRICATING OIL:
Refrigerant compressor RC02
12,000 lbs
(5400 kg)
ANTIFREEZE: artic
Grade 55 gal
(209 liters)
drum
OIL, LUBRICATING:
5 GAL (19 liters)
drum as follows:
OE-30
OE-10
OES
4-6
2-1/2 qt
(2.375 liters)
10 gal
(38 liters)
(3)
5 qt
(4.75 liters)
5 qt
(3)
(3)
(6)
Notes
(1) Includes
quantity of oil to fill engine
oil system
as follows:
3-1/2 qt crankcase 1 qt
(.95 liters) Oil
Filter.
(2) See C9100-11
for additional
data and requisitioning procedure.
(3) See current
L.O. for grade
application and
replenishment
intervals.
(4) Use oil as
prescribed in
Item 1.
(5) Tank capacity.
TM 5-3655-210-12
(1)
Component
application
(2)
National
Stock
Number
GREASE PAINTS
9150-00-526-4502
(2)
REFRIGERATION
SYSTEM
9150-0190-0905
(2)
6830-0(-292-0147
(3)
Description
(4)
Quantity
required
f/initial
operation
GREASE, BALL AND
BEARING: 1 lb (.45 kg)
can as follows:
BR, 1 lb (.45 kg)
GREASE, AUTOMOTIVE
AND ARTILLERY:
5 lb (2.25 kg)
can as follows:
GAA, 5 lb (2.25 kg)
(5)
Quantity
required
F/8 hrs
operation
(3)
(3)
DICHLORODILFLUOROMETHANE: Refrigerant Type R12 25
lbs (11.25 kg) Fed
BB-F-671 lb cyl
4-7
(6)
Notes
TM 5-3655-210-12
Section II. MOVEMENT TO A NEW WORKSITE
4-7.
4-6.
Dismantling for Movement
a.
The conversion and storage unit is completely
self-contained and required no disassembly in moving to a
new location.
b.
Stow the transfer hoses, electrical power supply
extension cable, ground rod assembly and tools in the storage
compartment.
c.
Couple the towing tractor to the trailer and
connect the air and electrical lines of the tractor to the trailer.
d.
Raise the landing jacks.
e.
Check the brakes and lights to see if they
function properly.
f.
Remove the chocks from under the trailer
wheels and stow them in the storage racks located on the
fenders.
g.
Close and secure the doors and shutters.
h.
The unit is now ready to be moved to a new
work site.
Reinstallation After Movement
a.
General. Move the conversion and storage unit
to its operating location with a suitable tractor. If the
equipment is located on marshy ground or ground with a high
sand content, wood platforms should be constructed under
the trailer wheels and under the landing jacks. Disconnect the
tractor air lines and electrical cable from the trailer. When the
tractor air lines are disconnected the trailer is in emergency
braking condition and should not be moved. Release the
towing pintle and remove the tractor. Remove the wheel
chocks from the fenders and position them under the trailer
wheels. Lower the landing jacks, if necessary, to level the
trailer as the liquid level gages will not work if the trailer is not
level.
b.
Refrigeration System. Remove the caps and
open the inlet line (6, fig. 4-4) and outlet shut-off valve on the
receiver tank (7) to allow the refrigerant to circulate through
the refrigeration system. Check that the refrigerant sight
glass (1) is full of refrigerant, indicating an adequate charge.
Section III. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT
maintenance of the conversion, storage and charging unit.
4-8.
Tools And Equipment
Tools, equipment and repair parts issued with or
authorized for the conversion, storage, and charging unit are
listed in TM 5-3655-210-20P.
4-10
Maintenance Repair Parts
Repair parts and equipment are listed and illustrated
in the repair parts and special tools list covering
organizational maintenance for this equipment in TM 5-3655210-20P.
4-9.
Special Tools And Equipment
No special tools or equipment are required by
organizational
maintenance
personnel
for
the
Section IV. LUBRICATION INSTRUCTIONS
b.
Cleaning.
Clean the lubrication fittings,
breathers, and other points by wiping with a cloth dampened
in a cleaning solvent before lubrication. In making repairs,
clean all parts with a cleaning solvent, and dry before they are
lubricated.
c.
Points of Lubrication. Service the lubrication
points at proper intervals as illustrated in current lubrication
order.
d.
OES Oil
(1) Crankcase oil level must be checked
frequently, as oil consumption may increase.
(2) Oil may require changing more frequently
than usual because contamination by dilution and sludge
formation will increase under cold weather
4-11.
General Lubrication Information
This section contains lubrication instructions which
are supplemental to and not specifically covered in the
lubrication order.
4-12.
Detailed Lubrication Information
a.
Care of Lubricants.
When lubricating the
conversion and storage unit, care must be taken in handling
and applying the various lubricants. The containers which
house the lubricants must be free of dust, dirt, and water.
Clean the lubrication equipment before and after it is used.
Close the containers tightly after use, and keep in a protected
place.
4-8
TM 5-3655-210-2
the proper lubricant to the level of the sight glass (5) and
replace the filler plug.
(3) Open the inlet (6) and outlet shut-off valves
on the receiver tank (7) to allow the refrigerant to
recirculate through the system.
(4) Place the unit in operation and inspect the
oil level in approximately 30 minutes. Add more oil, if
necessary, using the above procedure.
operation conditions. Apply the lubricant as directed by
figure 3-1.
e. Refrigeration System. The refrigerant must
be pumped down into the receiver tank before adding or
changing the compressor crankcase lubricating oil.
f. Adding or Changing the Compressor
Crankcase Lubricating Oil.
CAUTION
Pump down the compressor before
opening the crankcase filler plug.
4-13.
(1) To drain the oil, remove one of the bottom
capscrews and remove the filler plug (8, fig. 4-4) to
allow the oil to drain freely.
(2) After the oil has drained, replace the
capscrew in the bottom of the compressor. Fill with
Brake
System
Information
Detailed
Lubrication
Sparingly grease friction surfaces of camshaft (fig. 4-5),
cam roller and cam, and anchor pins by direct
application of grease to camshaft supports, fittings as
shown.
Figure 4-5. Axle with brake system parts removed
4-9
TM 5-3655-210-12
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
4-14.
General
Q-Quarterly
Total man-hours required. 9.0
To insure that the conversion and storage unit is
ready for operation at all times, it must be inspected
systematically so that defects may be discovered and
corrected before they result in serious damage or
failure.
The necessary preventive maintenance
services to be performed are listed in Table 4-4. Item
numbers indicate the sequence of minimum inspection
requirements. Defects discovered during operation of
the unit shall be noted for future correction to be made
as soon as operation has ceased. Stop operation
immediately if a deficiency is noted which would
damage the equipment if operation were continued. All
deficiencies and shortcomings will be recorded together
with the corrective action taken on DA Form 2404
(Equipment Inspection and Maintenance Worksheet) at
the earliest possible opportunity.
4-15.
Preventive
Services
Maintenance
Checks
Sequence
number
2
2
2
3
And
a. This paragraph contains an illustrated
tabulated listing of preventive maintenance services
which must be performed by organizational
maintenance personnel at quarterly intervals.
A
quarterly interval is equal to 3 calendar months, or 250
hours of operation, whichever occurs first.
4
5
6
b. The item numbers are listed consecutively
and indicate the sequence of minimum requirements.
Refer to Table 4-4 quarterly preventive maintenance
services.
7
Table 4-4. Organizational Preventive Maintenance
Checks and Services.
8
Q-Quarterly
Total man-hours required: 9.0
Sequence
number
1
Item to be inspected
procedure
BATTERIES:
Test and service batteries
per TM96140-200-15.
9
Work
time
(M/H)
0.4
4-10
Item to be Inspected
procedure
ENGINE GOVERNOR:
Check and adjust governor setting.
(para 4-25)
IGNITION SYSTEM
Clean, adjust or replace
breaker points Set timing Set spark plug
gap to 0.030 in (.0762cm)
GASOLINE ENGINE:
Refer to paragraph 4-64 and remove
shrouding Clean crankcase
passages, shrouds, fan and cooling
fins with dry compressed air.
ELECTRIC MOTOR:
Report overheating or noises to direct
support maintenance Adjust belt tension
to 1-1/2 in (3.81cm) max deflection
at midspan.
EXPANSION TANK:
Maintain level Add MIL-A-11755C
Artic Type Antifreeze only.
COUNTERSHAFT CLUTCHES:
Test operation Adjust as required
(para 4-91).
GENERATOR:
Adjust belt tension to 1-1/2 in.
(3.81cm) deflection at midspan.
(apply thumb pressure)
REFRIGERATION UNIT:
Clean dirt from condenser fins
with dry compressed air.
CYLINDER FILLING UNIT:
Adjust packing nut, if leaking.
Adjust belt tension to 1-1/2 in.
(3.81cm) deflection at midspan
by applying thumb pressure 9
STORAGE VESSEL LINES, FITTINGS
AND VALVES:
Pressure test storage vessels, lines,
fittings and valves by pressurizing
with gaseous carbon dioxide and
isolating by closing all valves.
A drop of pressure registered on
pressure gages will indicate a leak.
Work
time
(M/H)
0.5
1.0
1.0
1.5
0.8
1.0
1.5
0.8
0.5
TM 5-3655-210-12
Section VI. TROUBLESHOOTING
4-16.
General
a. This section contains troubleshooting
information for locating and correcting most of the
operating troubles which may develop in the conversion,
storage and charging unit. Each malfunction for an
individual component, unit, or system is followed by a
list of tests or inspections which will help to determine
probable causes and corrective actions to be taken.
Perform the tests/inspections and corrective action in
the order listed.
b. This manual cannot list all malfunctions that
may occur, not all tests or inspections and corrective
actions. If a malfunction is nor listed or is not corrected
by listed corrective action, see your supervisor.
4-17. Organizational Maintenance Troubleshooting.
Refer to Table 4-5 for troubleshooting pertaining
to organizational maintenance.
Table 4-5. Troubleshooting
Malfunction
Test or Inspection
Corrective Action
1.
GASOLINE ENGINE FAILS TO START (SER.
NOS. L1475T thru L-1478T).
Figure 4-6. Shut-off valve.
Malfunction
Test or Inspection
Corrective Action
b. Adjust plug by bending the electrode up or
down as necessary until 0.030 in. feeler
gage fits the gap.
Step 1. Check to see if the fuel valve (1, fig. 4-6)
(located in the fuel filter assembly mounted on
the fuel pump) is open.
Close the fuel valve.
Step 2. Check for an empty fuel tank by adding fuel.
Fill the tank.
Step 3. See if the 208-volt power cable is not connected
to the receptacle (1, fig. 4-7).
Connect the cable.
Step 4. Check for loose and broken wiring.
Tighten connections or replace defective wiring
(para. 4-39).
Step 5. Test and inspect spark plugs as follows: au Use
a feeler gage and see if plugs have the
proper gap. Plugs should indicate an 0.030 in.
(.0762cm) gap.
b. Remove the four coupling nuts (2, fig. 4-8)
and spark plugs (1). Visually inspect plugs for
carbon, corrosion and excessive dirt deposits.
c. Test spark plugs by holding the plug about
1/4 in. (0.64cm) away from cylinder head. A
bright blue spark should jump from tip of plug to
the cylinder head.
Clean, adjust or replace the spark plugs as
follows:
a,
Clean
by
sand
blasting.
c.
Install new plug(s) (1, fig. 4-8) and secure
with nuts (2).
Step 6. Inspect the magneto for cracks and
distortion. Try to start the engine and observe
any spark indicating a shorted wire. Remove
cover from magneto and loosen the screw (1,
fig. 4-9); turn the rotor (2) so the points are fully
open and insert an 0.015 in. (.0381cm) feeler
gage (3)
Replace magnet and wiring or adjust
points, refer to paragraph 4-40.
NOTE
If a new magneto is installed, it will have to be timed to
the engine (para 4-40).
2.
ENGINE MISFIRING
Step 1. Inspect for broken wiring.
See malfunction 1.
Step 2. Check for fouled or cracked spark plug.
See malfunction 1.
Step 3. Check for sticking or out of adjustment points.
See malfunction 1.
4-11
TM 5-3655-210-12
1. 208v. receptacle
Figure 4-7. 208v, AC power receptacle
TS 024532
2.NUT
1. PLUG
Figure 4-8. Spark plug, removal.
4-12
TM 5-3655-210-12
1. Screw
2. Rotor
3. Feeler gage
Figure 4-9. Checking for correct breaker point gap.
Malfunction
Test or Inspection
Corrective Action
3. ENGINE KNOCKS
Step 1. Check to see if oil level is low.
Refill.
Step 2. Check panel to see if engine is operating under
heavy load at low speed.
Adjust the governor, paragraph 4-27.
Step 3. Check for the running spark advance mark
being advanced too far by removing screws (1,
fig. 4-10) and screen (2). Observe timing mark
(1, fig. 4-11) Time the magneto, paragraph 4-40.
Step 4. Check for a loose flywheel by removing the
screen (fig. 4-10) and checking for a loose nut
or key out of position.
Place key in position in slot and tighten
flywheel nut (2, fig. 4-11).
Test or Inspection
Corrective Action
4. ENGINE BACKFIRES
Step 1. Listen for irregular engine performance and
check exhaust for excessive black smoke
indicating gasoline mixture being too lean.
Adjust the carburetor by turning idle
adjusting screw (1, fig. 4-12) as needed to
get smoothest idle possible.
Step 2. Listen for sticking inlet valves (missing engine)
(chattering noise) and check for possible
backfire.
Adjust valves as follows:
a. Turn the crankshaft over by hand until
the lifter (6, fig. 4-13) that is to be adjusted is
at its lowest position.
b. Insert 0.012 in. (.0305cm) feeler gage (5)
between the valve stem (8) and lifter screw
(7). Hold lifter (6) with wrench, and turn lifter
adjusting screw into or out of the lifter with
Malfunction
4-13
TM 5-3655-210-12
Malfunction
Test or Inspection
Corrective Action
another wrench until the correct
clearance is obtained. A slight drag
should be felt as the feeler gage is
moved back and forth.
Step 3. Test and inspect spark plugs as follows:
a Use a feeler gage and see if plugs have the
proper gap. Plugs should indicate an 0.030 in.
(.0762cm) gap.
b. Remove the four coupling nuts (2, fig. 4-8)
and spark plugs (1). Visually inspect plugs for
carbon, corrosion and excessive dirt deposits.
c. Test spark plugs by holding the plug about
1/4 in. (0.63cm) away from cylinder head. A
bright blue spark should jump from the tip of
plug to the cylinder head.
Clean, adjust or replace the spark plugs as
follows:
a, Clean by sand blasting.
b. Adjust plug by bending the electrode up
or down as necessary until 0.030 in. feeler
gage fits the gap.
c. Install new plugs (1, fig. 4-8) and secure
with nuts (2).
1. Running spark advance mark
1. Screw
2. Screen
TS 024534
Figure 4-10. Flywheel screen, removal.
2. Flywheel nut
Figure 4-11. Flywheel timing marks
4-14
TM 5-3655-210-12
1. Screw
1.
2.
3.
4.
5.
TS 024536
Figure 4-12. Idle adjusting screw.
Head
Air shroud heat deflector
Valve cover
Gasket
Feeler gage
6.
7.
8.
9.
Valve lifter
Adjusting screw
Valve stem
Block
Figure 4-13. Tappet adjustment.
4-15
Malfunction
Test or Inspection
Corrective Action
5.
Engine Overheats
Step 1. Check engine for hard starting or blow back
indicating possible ignition spark out of time.
Re-time the engine (para. 4-40).
Step 2. Check for part of the air shroud removed from the
engine.
Replace missing parts (para. 4-64).
Step 3. Check for restrictions in the exhaust.
Clean or replace the muffler and the exhaust pipe
(para. 4-36).
6.
Compression Low
Step 1. Inspect for a loose or broken spark plug.
Tighten spark plug. Replace a broken spark plug
by removing the coupling nut (2, fig. 4-8) and
removing plug (1).
Step 2. Check the valve adjustment with an 0.012 in.
(0.0305cm) feeler gage.
Adjust the valves as follows:
a. Turn the crankshaft over by hand until the lifter
(6, fig. 4-13) that is to be adjusted is at its lowest
position.
b. Insert 0.012 in. (.0305cm) feeler gage (5)
between the valve stem (8) and lifter screw (7).
Hold lifter (6) with wrench, and turn lifter
adjusting screw into or out of the lifter with
another wrench until the correct clearance is
obtained. A slight drag should be felt as the
feeler gage is moved back and forth.
7.
Power Loss In Engine
Step 1. Check for a partly closed carburetor choke.
Open choke as follows:
a. Loosen the clamp screw (1, fig. 4-14) slightly
so that there is still enough drag to rotate the
choke control shaft.
b. Lift up on the control lever (2) until the
carburetor choke control lever (3) is in the up, or
closed position.
c. Tighten the clamp screw (1).
d When the lever (2) is released it should go back
to the intermediate position.
Step 2. Inspect for dirty air cleaner parts.
Remove, disassembly and clean or replace parts
as necessary (para. 4-26).
Step 3. Check instruments and observe sluggish engine
running (overload).
Correct operation of cylinder filling unit
8.
Pressure Vessel Pressure Too High, Alarm Bell
Does Not Ring
Step 1. Inspect tank alarm pressure switch out of adjustment
(The correct setting is 305 on the high side (knob 5) and 295
on the low side (knob 6).
Adjust setting of the pressure switch as follows:
Adjust the tank pressure switches (4, fig. 4-15) by
turning the adjusting knobs (5 and 6) to the desired
setting on the scale. Set the pressure switch (8),
connected to the conversion heater, at 275 on the
high side and 260 on the low side.
TM 5-3655-210-12
Malfunction
Test or Inspection
Corrective Action
circulate through the refrigeration system Check that
the refrigerant sight glass (1) is full of refrigerant,
indicating an adequate charge.
Step 2. Check head pressure being too high due to air in the
system.
Discharge old refrigerant to air, and recharge
system as follows:
a Install a discharge pressure gage in the
discharge service valve.
b. Connect a full freon cylinder to the gage
port (3, fig. 4-4), using a charging hose with
dehydrator, and a vacuum-pressure gage.
c.
Before tightening the charging hose
connection at the compressor, crack the
cylinder valve slightly to purge air from the
hose.
d Close the suction service valve (2) one
turn.
e. Start the compressor, and slowly admit
freon from the supply cylinder until the sight
glass appears full of refrigerant.
CAUTION
If the compressor pounds, or frost forms on the cylinder
head, throttle down the rate of the flow of refrigerant with
the freon cylinder valve.
Step 3. Check for refrigeration compressor switch being out
of adjustment. The compressor pressure switches (1
and 2, fig. 4-15).
Set the suction pressure switch (2) to open at
zero psi to shut off the engine or electric
motor. The low pressure suction switches
reset to allow operations to resume when the
suction pressure rises to 12 psi (.8436 kg per
sq cm). Set the discharge switches (high
pressure) (1) to open at 240 psi (16.872 kg
per sq cm) to stop the electric motor or
gasoline engine. The high pressure switches
close to resume operation when the pressure
drops to 210 psi (14.763 kg per sq cm).
Adjust the switches to the correct settings as
indicated on the dial by using a screw driver
on the adjusting screw.
10.
Pressure Vessel Pressure Too High, Refrigeration
Unit Operates Continuously.
Step 1. Check to see if belts or clutches are slipping.
Adjust the belts or clutches as follows:
a. Clutch adjustment.
(1) Loosen the setscrew (11, fig. 4-16) in the
adjustment nut (12).
(2) Release the clutch as far as possible.
(3) Unscrew the adjusting nut (12) until the
clutch can easily be engaged.
(4) Turn the adjusting nut (12) clockwise as
far as possible by hand.
(5) Release the clutch and tighten the
adjusting nut 1/8 turn.
Figure 4-14. Choke control levers.
Malfunction
Test or Inspection
Corrective Action
Step 2. Check for loose connection in tank alarm circuit.
Tighten all loose connections.
9.
Pressure Vessel Pressure Too High, Refrigeration
Unit Operates In Short Cycles
Step 1. Check head pressure being too high due to service
valves being partly closed.
Completely open all refrigeration system
service valves as follows:
Remove the caps and open the inlet line (6,
fig. 4-4) and outlet shut-off valve on the
receiver tank (7) to allow the refrigerant to
4-16
TM 5-3655-210-12
Malfunction
Test or Inspection
Corrective Action
13.Refrigeration Compressor Knocking
Step 1. Check for lack of oil in the crankcase.
Add oil (fig. 3-1).
Step 2. Check for oil or liquid refrigerant in the piston
chamber.
Add oil compressor (fig. 3-1).
14.Carbon Dioxide Cylinder Filling Unit Capacity Low
Step 1. Check for obstruction in valves or loose nuts and
crossed or worn valve threads.
Remove and clean or replace the defective
valves (para. 4-96).
Step 2. Test the pressure regulating valve charging pressure
by slowly operating valve and checking the pressure
gage (fig. 4-17).
Slowly adjust the pressure
regulating valve 14 (fig. 4-18), until a charging
pressure of 600 to 800 psi (42.18 to 66.24 kg per sq
cm) is indicated on the pressure gage (1, fig. 4-17) in
cool weather; 800 to 1,000 psi (56.24 to 70.30 kg per
sq cm) is suitable in hot weather.
Step 3 Check for slipping clutch belts.
Adjust belts to a tension permitting 1-1/2 inch
(3.81cm) deflection under firm' thumb pressure
midway between pulleys. All belts are tensioned
by loosening the connected unit on its base,
moving it Ls required, and tightening the base
fasteners to hold the tension.
Step 4. Check for a clogged strainer.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to
clean parts is potentially dangerous to
personnel and property. Use in a well-ventilated
area as the fumes are dangerous if inhaled.
Avoid repeated and prolonged skin contact. Do
not use near open flame or excessive heat.
Flash point of solvent is 100F.-138F. (38C.59C.).
Malfunction
Test or Inspection
Corrective Action
(6) Secure the adjusting screw in this
position with the setscrew (11).
NOTE
If the clutch shows a tendency to slip when load is applied,
tighten adjusting nut as above until there is no slippage.
b. Belts Adjustment All belts are adjusted to a
tension permitting 1-1/2 inch (3.81cm) deflection
under firm thumb pressure midway between
pulleys, except the transfer pump belt, for which
1 inch (2.54cm) deflection is specified. All belts
are tensioned by loosening the connected unit on
its base, moving it as required, and tightening
the base fasteners to hold the tension.
Step 2. Check the sight glass to see if refrigeration system is
low on freon.
Recharge system as follows:
a. Install a discharge pressure gage In the
discharge service valve.
b. Connect a full freon cylinder to the gage port
(3, fig. 4-4), using a charging hose with
dehydrator, and a vacuum-pressure gage.
c.
Before tightening the charging hose
connection at the compressor, crack the cylinder
valve slightly to purge air from the hose.
d Close the suction service valve (2) one turn.
e. Start the compressor, and slowly admit freon
from the supply cylinder until the sight glass
appears full of refrigerant.
CAUTION
If the compressor pounds, or frost forms on the cylinder
head, throttle down the rate of the flow of refrigerant with
the freon cylinder valve.
11 Pressure Vessel Low, Refrigeration Unit Operates On
Automatic Control
Check for tank alarm pressure switch being out of
adjustment (The correct setting is 305 on the high
side (knob 5) and 295 on the low side (knob 6).
Readjust the tank alarm pressure switch as
follows:
Adjust the tank pressure switches (4, fig.
4-15) by turning the adjusting
knobs (5 and 6) to the desired setting on
the scale. Set the pressure switch (8),
connected to the conversion heater at
275 on the high side and 260 on the low
side.
12.Pressure Vessel Pressure Too Low, Refrigeration Unit
Not Operating
Step 1. Check for no liquid carbon dioxide in the storage
tank.
Fill the storage tank.
Step 2. Check for the tank being recently filled with relatively
cold carbon dioxide.
Wait for newly installed carbon dioxide to
warm up.
Wash all parts in a cleaning solvent, Fed.
Spec P-D-680 or P-S-661. Clean the gasket
mating surfaces thoroughly.
15. Cylinder Filling Unit Compressor Knocking
Step 1. Check for a loose pulley by applying hand pressure
back and forth.
Tighten the pulley bolts.
Step 2. Check for empty cylinder.
Stop the unit and prime, paragraph 2-14.
16. Liquid Level Gage Reads Low Or High
Step 1. Check the liquid level gage shutoff valve for leaks
(water seepage).
Tighten the packing glands with valves
partially open until the leakage stops.
4-17
TM 5-3655-210-12
1.
2.
3.
4.
5.
Compressor pressure switch (discharge)
Compressor pressure switch (suction)
Connector
Tank pressure switch
Adjusting knob, high side
6.
7.
8.
9.
10.
Adjusting knob, low side
Alarm bell pressure switch
Tank pressure switch low pressure
Receiver shut-off (inlet)
Receiver outlet line
Figure 4-15. Pressure witch adjustment.
4-18
TM 5-3655-210-12
Malfunction
Test or Inspection
Corrective Action
Wash out with solvent (Fed. Spec. P-D-680 or PS-661).
Step 2. Check for the clutch slipping (observe delayed
operating and noise).
Adjust clutch as follows:
a. Loosen the setscrew (11, fig. 4-16) in the
adjustment nut (12).
b. Release the clutch as far as possible.
c. Unscrew the adjusting nut (12) until the
clutch can easily be engaged.
d Turn the adjusting nut (12) clockwise as far
as possible by hand.
e.
Release the clutch and tighten the
adjusting nut 1/8 turn.
f. Secure the adjusting screw in this position
with the setscrew (11, fig. 4-16).
NOTE
If the clutch shows a tendency to slip when load is
applied, tighten adjusting nut as above until there
is no slippage.
19.Lack Of Spark In Conversion Heater
Step 1. Visually inspect contact points worn for %Pull
vibrator switch or replace vibrator as follows:
The vibrator (28, fig. 4-19) has two sets of
contact points. The switch (32) is safety wired at
the factory. If the vibrator inoperative and the
switch is still wired, cut the wire and pull the
switch out. If the lockwire (33) has been cut, the
switch pulled out and the vibrator is inoperative,
install a new as follows:
a. Unplug the disconnect plug (31).
b. Loosen the thumbscrew (27) and push
the bail downward.
c. Pull the vibrator (28) from the ignition
unit (3).
d. Push the switch (3?) in, and secure
with the lockwire (33).
e. Position the new vibrator (28, fig. 419) in the ignition unit (3) and secure
with the bail and thumbscrew (27).
f. Plug in the disconnect plug (31).
Step 2. Visually check for a dirt) or cracked spark plug.
Clean plug or replace it as follows:
a. Pull the disconnect plug (31, fig. 4-19).
b. Remove the spark plug cable (21, fig.
4-20) by loosening tie nut (20).
c. Unscrew the two tube nuts (14) securing
the fuel tube (17) and remove the tube.
d. Remove the three capscrews (7) and
lockwashers securing the combustion head
(6) and gasket to the heater assembly and lift
off the head and gasket.
Step 3 Check for broken wiring and cracked ignition unit.
Replace wiring or ignition unit (para. 4-114).
Malfunction
Test or Inspection
Corrective Action
Step 2. Inspect for leakage from gage line panel liquid supply
piping (water seepage).
Tighten until leakage stops.
Step 3. Check for a too tight piston rod packing gland (won't
loosen normally).
Loosen packing gland.
17. Counter Shaft Clutches Slipping
Step 1. Check to see if the clutch adjusting nut (12, fig. 4-16)
is tightened to a 1/8 turn.
Readjust the clutch as follows:
a. Loosen the setscrew (11, fig. 4-16 in
the adjustment nut (12).
b. Release the clutch as far as possible.
c. Unscrew the adjusting nut (12) until
the clutch can easily be engaged. & Turn
the adjusting nut (12) clockwise as far as
possible by hand.
e. Release the clutch and tighten the
adjusting nut 1/8 turn.
f. Secure the adjusting screw in this
position with the setscrew (11, fig. 4-16).
NOTE
If the clutch shows a tendency to slip when load is
applied, tighten adjusting nut as above until there is
no slippage.
Step 2. Visually check to see if there is lubricant between
clutch disk plates.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used
to clean parts is potentially dangerous to
personnel and property. Use in a wellventilated area as the fumes are dangerous if
inhaled. Avoid repeated and prolonged skin
contact. Do not use near open flame or
excessive heat. Flash point of solvent is
.100F.-138F. (38C.Clean disks with solvent (Fed. Spec. P-D680 or P-D-661.
18. Clutch Running Hot
Step 1. Visually check or observe feel indicating a drag
between clutch disk plates.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used
to clean parts is potentially dangerous to
personnel and property. Use in a wellventilated area as the fumes are dangerous if
inhaled. Avoid repeated and prolonged skin
contact. Do not use near open flame or
excessive heat. Flash point of solvent is
100F.-138F. (38C.-59C.).
20. Lack of Fuel At Conversion Heater
Step 1. Check for a clogged nozzle tip.
4-19
TM 5-3655-210-12
Malfunction
Test or Inspection
Corrective Action
f. Remove the four capscrews (24)
securing the pump (10). Remove the
fuel pump from the heater.
Malfunction
Test or Inspection
Corrective Action
WARNING
Dry cleaning solvent, P-D-680 or PS661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-138F. (38C.-59C.).
21. No Combustion Air Or Low Air Pressure
Step 1. Check for a cracked or broken motor.
Replace motor (fig. 4-22).
Step 2. Rotate blower fan to see if it is slipping on shaft.
Tighten fan lock screw.
Step 3 Check for a clogged blower housing.
WARNING
Dry cleaning solvent, P-D-680 or PS661, used to clean parts is
potentially dangerous to personnel
and property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
Clean tip with solvent (Fed. Spec. P-D680 or P-S-661).
Step 2. Check for a dirty or clogged fuel filter.
Replace fuel filter element as follows:
Refer to figure 4-21 and disassemble the
fuel filter.
Step 3. Check for an air leak in fuel line.
Tighten or replace defective line.
Step 4. Inspect solenoid valve for cracks, breaks and
wear.
Replace solenoid valve (para. 4-111).
Step 5. Check for a cracked, broken, or leaking fuel
pump.
Replace fuel pump as follows:
a. Pull the disconnect plug (30, fig.
4-19).
b. Remove the four capscrews (11)
that secure the plate (13) to the
combustion head.
c Remove the four machine screws
and washers securing the blower (15)
to the pump (10) and slide the blower
(15), plate (13), and gasket (14) out
and away from the heater.
d. Remove the two fuel tubes (6 and
7).
e. Disconnect and tag the taped
leads (19).
Wash all parts in a cleaning solvent (Fed.
Spec. P-D-680 or P-S-661).
22. Conversion Heater Overheating Condition
Step 1. Check for low coolant level.
Add coolant.
Step 2. Check for loose wires in disconnect plug.
Tighten all loose connections.
Step 3 Check for a cracked or broken water
temperature switch.
Replace the switch (para. 4-113).
4-20
TM 5-3655-210-12
1.
2.
3.
4.
5.
Transfer pump
Adapter
Tube nut
Tube
Union nut
6.
7.
8.
9.
10.
1/3 union
Clutch arm
Capscrew
Clutch arm
Clutch drive ring
11.
12.
13.
14.
15.
Setscrew
Adjusting nut
Drive belt
Frame
Capscrew
Figure 4-16. Clutch adjusting points.
4-21
16.
17.
18.
19.
Line assembly
Safety relief valve
Elbow
Pipe plug
TM 5-3655-210-12
TS 024542
Figure 4-18. Cylinder filling operation.
1. Pressure gage
Figure 4-17. Pressure gage.
4-22
TM 5-3655-210-12
1.
2.
3.
4
5.
6.
7.
8.
9.
10.
11.
Wiring harness
Capscrew
Ignition unit
Spark plug cable
Machine screw
Fuel tube
Fuel tube
Machine screw
Tube nut
Fuel pump
Capscrew
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Lockwasher
Plate
Gasket
Blower
Self-tapping screw
Plate
Blower wheel
Taped lead
Screw
Screw
Fuel tube
Figure 4-19. Blower and fuel pump, removal
4-23
23.
14.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Solenoid valve
Capscrew
Fuel manifold
Fuel gage
Thumbscrew
Vibrator
Control box
Disconnect plug
Disconnect plug
Switch
Lockwire
TM 5-3655-210-12
TS 02544
1.
2.
3.
4.
5.
6.
7.
Water temperature limit switch
Hex nut
Hex nut
Machine screw
Machine screw
Combustion head
Capscrew
8.
9.
10.
11.
12.
13.
14.
Bail
Nozzle assembly
Self-tapping screw
Cover
Capscrew
Nut, No.
Tube nut
Figure 4-20. Fuel line, removal
4-24
15.
16.
17.
18.
19.
10
21.
Adapter
Thumb nut
Fuel tube
Gasket
Spark plug
20. Nut
Cable
TM 5-3655-210-12
Table 4-6. Valves
Tag No. Description
1
Liquid fill line (storage compartment, thru
pump).
2
Liquid shut-off (storage)
3
Liquid fill line (by-pass pump)
4
Liquid line shut-off (conversion)
5
Liquid equalizing line
6
Dehydrator by-pass
7
Vapor equalizing line
8
Vapor return (conversion)
9
Vapor return (storage)
10
Transfer pump bleed-off
11
Low pressure gage line (conversion)
12
Liquid shut-off to cylinder fill compressor
13
High pressure vapor return
14
Pressure regulating valve
15
Strainer bleed-off
16
Cylinder valve
17
Cylinder fill hose bleed-off
18
Cylinder valve
19
Cylinder fill hose bleed-off
20
Low pressure gage line (storage)
21
High pressure gage line (conversion)
22
High pressure gage line (storage)
23
Safety vent switching valve (conversion)
24
Safety vent switching valve (storage)
25
Fire valve
26
Transfer hose bleed-off (by-pass pump)
27
Transfer hose bleed-off (thru pump)
28
Transfer hose bleed-off (vapor)
29
Relief valve-3/4 male-341 psi (23.9723 kg per
sq cm) (storage)
30
Relief valve-3/4 male-341 psi (storage)
31
Relief valve-3/4 male-341 psi (conversion)
32
Relief valve-3/4 male-341 psi (conversion)
33
Bleeder valve-3/8 female-330 psi (23.199 kg
per sq cm) (conversion)
34
Bleeder valve-3/8 female-330 psi (conversion)
35
Vapor line relief
36
Safety relief (pop type) 375 psi (26.3625 kg per
sq cm) (transfer pump discharge).
37
Safety relief disc-1500 psi (105.45 kg per sq
cm)
38
3 way valve (conversion heater coil)
39
3 way valve (compartment heater)
40
Expansion valve, refrigeration system
41
Air tank bleed-off (brakes)
42
Heater fluid pump bleed-off (outlet)
43
Refrigerator compressor suction valve
44
Refrigerator compressor discharge valve
45
Receiver tank shut-off (outlet)
46
Receiver tank shut-off (inlet)
47
Heater fluid pump bleed-off (inlet)
TS 024545
1. Adapter elbow
2. Bushing
3. Machine bolt
4. Washer
5. Filter head
6. Gasket
7. Gasket'
8. Element
9. Washer
10. Flatwasher
11. Spring
12. Body
13. Machine screw
14. Clamp
15. Lockwasher
16. Nut
Figure 4-21. Fuel filter, exploded view .
4-25
TM 5-3655-210-12
11.
12.
13.
14.
15.
16.
17.
18.
19.
1. Plate
2. Blower wheel
3. Machine screw
4. Housing
5. Lockwasher
6. Nut
7. Nut
8. Cap
9. Brush
10. Adapter
Fuel pump
Machine screw
Washer
Motor
Machine screw
Bracket
Setscrew
Washer
Self-tapping screw
Figure 4-22. Blower and fuel pump, exploded view.
4-26
TM 5-3655-210-12
Section VII. RADIO INTERFERENCE SUPPRESSION
4-18. Definitions
a. Interference. The term "interference" as used
herein applies to electrical disturbances in the radio
frequency range which are generated by the conversion
and storage unit and which may interfere with the proper
operation of radio receivers or other electronic
equipment, or enable the enemy to locate the
equipment.
b. Interference Suppression. The term “interference
suppression” as used herein applies to the methods
used to eliminate or effectively reduce radio interference
generated by the conversion and storage unit.
4-19. General Methods Used To Attain Proper
Suppression.
Essentially, suppression is attained by providing a.
low resistance path to ground for the stray currents. The
methods used to attain suppression include shielding the
ignition and high-frequency wires, grounding the frame
with bonding straps, and using capacitor and resistors
where necessary.
4-20. Interference Suppression Components
a. Gasoline Engine Spark Plugs and Ignition Cables.
The gasoline engine is equipped with shielded spark
plugs (1, fig. 4-23 1) and shielded ignition cables (3).
Braided metal covering woven around the insulation on
high tension leads are grounded through the magneto to
provide a low resistance path for grounding interference
generated in the circuit.
1.
2.
3.
4.
5.
6.
7.
NOTE
Do not pull on cable or twist braided
shielding. Gently work cable from
side to side and free the rubber seal.
Do not use sharp tools to install
rubber seals.
Shielded spart plug
Nut
Shielded ignition cable
Clip
Screw
Magneto assembly
Capscrew
8. IE toothed lockwasher
9. Nut
10. Capscrew
11. Timing gear cover
12. Cylinder block
13. Cylinder head
Figure 4-28. Ignition suppression components (sheet 1
of 2).
b. Magneto. The magneto (6, fig. 4-23 1) is
completely inclosed by a metal housing which is
grounded by the mounting. Electrical contact between
the mounting surfaces is accomplished by the use of
internal-external tooth lockwashers (8).
Shielded
ignition cables (3) carry current from the magneto (6) to
the shielded spark plugs (1).
c. Heater Spark Plug and Igniter Cable. The
conversion heater is equipped with a shielded spark plug
(6, fig. 4-23 2) and igniter cable (3). Braided metal
around the high tension lead grounds interference from
the circuit.
d. Ignition Unit. The ignition unit (13) is inclosed by
a metal housing, grounded to the mounting. Internalexternal tooth lockwashers (9) make electrical contact
between the mounting surfaces. Suppressor
(14) on the ignition unit eliminates radio interference by
the ignition unit.
e. Conversion Heater. The conversion heater base
(8) is grounded by the mounting to the housing.
Electrical contact between mounting surfaces is
accomplished by the use of internal-external tooth
lockwashers (12). The pump and blower motor circuit is
suppressed by suppressors (14) on the motor.
4-21. Replacement Of Suppression Components
Refer to figure 4-23 and replace suppression
components.
4-27
TM 5-3655-210-12
4-22. Testing Of Radio Interference Suppression
Components
The suppression components used on the equipment
are not rated in measurable values by which failure can
be determined. All shielding should indicate continuity
with chassis ground of the trailer when tested with a low
voltage ohmmeter. If interference is suspected, replace
suppression components by trial-and-error method until
trouble. Is corrected.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Nut
Machine screw
Shielded ignition cable
Clip
Combustion head
Shielded spark plug
Nut
Heater base
IE toothed lockwasher
Capscrew
Housing
IE toothed lock washer #10
Ignition unit
Radio interference suppressor
Figure 4-23. Ignition suppression components (sheet 2 of 2).
4-28
TM 5-3655-210-12
Section VIII. MAINTENANCE OF THE GASOLINE ENGINE FUEL SYSTEM
4-23. Description
The gasoline engine fuel system consists of a fuel tank,
fuel pump, fuel filter (Serial Nos. L-1475-T through L1478-T), carburetor, and fuel lines. The fuel tank is
located under the right fender of the trailer. On Serial
Nos. L-1475-T through L-1478-T units, the shut-off
valve is located in the fuel filter assembly mounted on
the fuel pump. An air cleaner is provided to protect the
carburetor air intake from dirt and grit.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
4-24. Governor Controls
a. Removal and Disassembly.
(1) Remove the cotter pin (13, fig. 4-24) securing the
chain (19) to the governor control (24).
Exhaust manifold
Nut
Lockwasher
Saddle washer
Capscrew
Lockwasher
Adjusting needle screw
Adjusting nut
Governor control rod
Tube nut
Fuel tube
Support pin
Cotter pin
Governor control lever
Screw
Carburetor
Spring
Cross shaft lever
Chain
Setscrew
Stop collar
Air cleaner mounting bracket
Locknut
Governor control
Throttle rod
Cylinder block
Figure 4-24. Governor controls, installed view.
4-29
TM 5-3655-210-12
(2) Loosen the setscrew (20) securing the stop
collar (21) to the throttle rod (25). Slide the stop collar
(21) from the rod.
(3) Remove the locknut (23) securing the governor
control to the air cleaner bracket (22). Slide the control
out of the bracket.
(4) Remove the spring (17) from the lever (18).
(5) Remove the cotter pin (13) and the washer
securing the lever (14) to the lever support pin (12).
Remove the assembly from the pin.
(6) Remove the spring (1, fig. 4-25) from the screw
(2).
(7) Unscrew the adjusting nut (8) from the screw
(2). Remove the screw from the swivel pin (6) in the
lever (5) and remove the spring (4) and the cotter pin (3)
from the screw.
(8) Remove the machine screw (9) from the lever
(5), releasing the chain (10).
(9) Remove the setscrew (11) from the collar
(12) and press the swivel pin (6) from the lever (5).
Remove the cotter pin (3) from the chain (10).
1.
2.
3.
4.
5.
6.
7.
8.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-138F. (38C.-59C.).
b. Cleaning, Inspection and Repair. Clean all parts
in a cleaning solvent. Check all screws for damaged
threads. Check the lever and control rods for bends or
breaks. Check the springs for damage or loss of
tension. Replace all damaged or badly worn parts.
c. Reassembly and Installation.
(1) Place the setscrew (11, fig. 4-26) in the stop
collar (12).
(2) Press the swivel pin (6) into place on the lever
(5).
(3) Position the cotter pin (3) in the screw (2). Slide
the spring (4) on the screw and slide the screw into the
swivel pin. Secure with the adjusting nut
(8).
(4) Position the cotter pin (3) in the chain (10) and
move it into place in the lever (5), securing it with the
machine screw (9).
(5) Place the spring (1) in position on the screw
(2).
(6) Position the lever assembly on the support pin
(12, fig. 4-25) on the engine and secure with the washer
and cotter pin (13).
Spring
Rod screw
Cotter pin
Spring
Lever
Swivel pin
Washer, flat
Adjusting nut
9.
10.
11.
11.
12.
13.
14.
15.
Machine screw
Chain
Setscrew
Setscrew
Stop collar
Nut
Shakeproof washer
Governor control
Figure 4-25. Governor controls, exploded view.
(7) Position the governor control in the air cleaner
bracket (22) and secure with the lockwasher and the nut
(23).
(8) Position the stop collar (21) on the governor
control (24) and secure with the setscrew (20).
(9) Position the chain (19) on the governor control
(24) and secure with the cotter pin (13).
(10) Place the spring (17) in position on the lever
(18).
4-25. Throttle And Choke Controls
a. Removal and Disassembly.
(1) Remove the cotter pin securing the throttle
control rod (10, fig. 4-26) to the lever.
(2) Remove the throttle rod from the lever and
unscrew it from the carburetor throttle lever.
(3) Remove the nut (4, fig. 4-27) securing the
choke control lead (3) to the choke control (5).
(4) Remove the two cotter pins (10)'(ser. nos. L1475-T through L-1478-T) or two clips (10) (ser. nos.L1666-T through L-1668-T) securing the choke control
rod (11) to the automatic choke control lever (9) and the
carburetor choke lever (13). Remove the rod (11).
4-30
TM 5-3655-210-12
TS 024551
1. Intake manifold
2. Gasket
3. Machine bolt
4. Lockwasher
5. Saddle washer
6. Lockwasher
7. Nut
8. Adapter
9. Carburetor
10. Throttle rod
11. Cotter pin
12. Gasket
13. Plug
Figure 4-26. Intake manifold and carburetor.
4-31
TM 5-3655-210-12
Figure 4-27. Engine, fuel system view.
4-32
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
Oil filter assembly
Oil filter inlet hose
Choke control lead
Nut
Automatic choke control
Machine screw
Exhaust pipe, nipple
Machine screw
Choke control lever
10.
10.
11.
12.
13.
14.
15.
16.
17.
Cotter pin
Clip
Choke control rod
Hose clamp screw
Carburetor choke lever
Hose clamp
Hose
Oil filler and gage
Oil filler body
18.
19.
20.
21.
22.
23.
24.
25.
26.
Oil filler nipple
27.
Street tee fitting 28.
Plug (timing)
29.
Timing gear cover 30.
IET lockwasher
31.
Nut
32.
Capscrew
33.
Lockwasher
34.
Machine bolt
Machine bolt
Lockwasher
Breather
Air cleaner mounting bracket
Oil filter mounting bracket
Machine bolt
Oil filter outlet hose
Hose nut
Figure 4-27 - Continued.
(2) Loosen the hose clamp screw (12, fig. 4-27)
securing the clamp (14) and hose (15) to the carburetor
(16, fig. 4-24).
(3) Remove the two machine bolts (27, fig. 4-27)
and lockwashers (28) securing the air cleaner bracket
(30) to the timing gear cover (21) and lift off the air
cleaner assembly and gasket (fig. 4-28).
(4) Remove the wing nut (2, fig. 4-28) securing the
cap and filter unit assembly (1) and lift off cap
assembly.
(5) Lift the cup assembly (4) with the gasket (3)
from the bracket (7).
(6) Remove the gasket (5) and unscrew the stud (6)
from the bracket.
(7) Loosen the hose clamp screw (16) and remove
the hose (14) from the bracket.
(8) Remove the two hose clamps (13) from the
hose (14).
(9) Remove the gasket (12) from the bracket (7).
(10) On all serial nos. L-1475-T through L-1478-T
units, remove the breather (11) and the gasket (10) from
the bracket (7).
(11) On serial nos. L-1666-T through L-1668-T
units, remove four screws (20) and washers (19)
securing breather (18) to air cleaner bracket (7).
Remove breather (18), gasket (17), and performed
packing (21).
Lines 7, 8 and 9 are superseded as follows: "for leaks or
breaks, and on serial nos. L-1475-T through L-1478-T
units, clean the hole in the timing gear breather plug.
Replace all damaged parts. Replace gaskets".
WARNING
Dry cleaning solvent, P-D)-680 or P'-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the fumes
al-e dangerous if inhaled. Avoid repeated
and prolonged skin contact. Do not use
near open flame or0 excessive heat.
Flash point of solvent is 1OOF.-138F.
(38C.-59C.).
b. Cleaning, Inspection and Repair. Empty the oil
from the oil cup and remove the gasket from the cup.
(5) Remove the two machine screws (6) securing
the automatic choke control (5) to the exhaust pipe (7)
and lift off the choke control (5).
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in -a well-ventilated area as the
fumes are dangerous if inhaled.
Avoid repeated and prolonged skin
contact. Do not use near open flame
or excessive heat. Flash point of
solvent is 100F.-138F. (38C.-59C.).
b. Cleaning, Inspection and Repair. Wipe off the
choke control with a rag dampened in cleaning solvent.
Check for a damaged case or mounting plate. If the
control is damaged it must be replaced. Check the
screws for breaks or damaged threads. Replace the
cotter pin.
c. Reassembly and Installation.
(1) Position the choke control (5) (fig. 4-27) to the
exhaust pipe (7) and secure with the two machine
screws (6).
(2) Position the control rod (11) on the carburetor
choke control lever (13) and the automatic choke control
lever (9). Secure with the two cotter pins (10) (ser. nos.
L-1475-T through L-1478-T) or two clips (10) (ser. nos.
L-1666-T through L- 1668-T).
(3) Position the control lead (3) on the choke control (5)
and secure with the nut (4).
d. Adjustment.
(1) Loosen the clamp screw (8) slightly so that there
is still enough drag to rotate the choke control shaft.
(2) Lift up on the control lever (9) until the
carburetor choke control lever (13) is in the up, or closed
position.
(3) Tighten the clamp screw (8).
(4) When the lever (9) is released it should go back
to the intermediate position.
4-26 Air Cleaner
a. Removal and Disassembly.
(1) Remove the governor
control
lever.
4-33
TM 5-3655-210-12
Wash all parts in a cleaning solvent. Replace the hose
if damaged. Clean all gasketed surfaces thoroughly,
inspect the air cleaner and bracket for leaks or breaks,
clean the hole in the timing gear breather plug. Replace
all damaged parts. Replace gaskets.
c. Reassembly and Installation.
(1) Position the hose clamps (13) on the hose (14).
(2) Position the hose on the air cleaner bracket (7)
and tighten the hose clamp screw (16) securing the hose
to the bracket.
(3) Position the gasket (12) and the bracket (7) on
the timing gear cover (21, fig. 4-27) and secure with the
two lockwashers (28) and machine bolts (27).
(4) Screw the stud (6, fig. 4-28) into position in the
bracket (7).
(5) On serial nos. L-1475-T through L-1478-T units,
position the gasket (10) on the timing gear breather (11)
and screw into position in the bracket. On serial nos. L1666-T through L-1668-T units, position the gasket (17)
and performed packing (21) on the breather (18) and
secure to air cleaning mounting bracket (7) with four
screws (20) and washers (19).
(6) Place the gasket (5) in position on the bracket
assembly.
(7) Position the gasket (3) in the oil cup (4).
(8) Fill the oil cup (4) with oil to the oil level mark
and position the cup on the bracket assembly (7).
(9) Position the cap and filter assembly (1) over the
stud (6) and secure with the wing nut (2).
4-27. Governor
a. Removal.
(1) Remove the cotter pin securing the governor
control rod to the lever (18, fig. 4-24) and remove the
rod from the lever.
(2) Remove the spring (17) from the governor
lever, marking the hole in the lever so that the spring
may be replaced in its proper position.
(3) Remove the oil tube by unscrewing the two tube
nuts, securing the tube to the governor, and to the street
tee (19, fig. 4-27).
(4) Remove the two capscrews and lockwashers
securing the governor to the gear cover (21, fig. 4-27).
(5) Remove the two machine bolts (26) and the
lockwashers (25) securing the governor through the
timing gear cover (21) and liftoff the housing(l, fig.4-29)
and the gasket (2).
(6) Slide the thrust sleeve and flyweight assembly
(6, fig. 4-29) and the shim washer (5) from
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Cap and filter assembly
Wing nut
Gasket
Oil cup assembly
Gasket
Stud
Air cleaner bracket
Machine bolt
Lockwasher
Gasket
Breather
Figure 4-28. Air cleaner, exploded view.
4-34
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Gasket
Hose clamp
Hose
Nut
Screw
Gasket
Breather
Washer
Screw
Performed packing
TM 5-3655-210-12
the shaft that is pressed into the timing gear cover (21,
fig. 4-27).
WARNING
Dry cleaning solvent, P-D-680 or P-S-661, used to
clean parts is potentially dangerous to personnel
and property. Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid repeated and
prolonged skin contact. Do not use near open
flame or excessive heat. Flash point of solvent is
100F.-138F. (38C.-59C.)
b. Cleaning, Inspection and Repair. Wash all parts
thoroughly in a cleaning solvent. Inspect the capscrews
for damaged threads. Clean the gasket mating surfaces
on the governor housing and the gear cover spacer.
Inspect the housing for cracks and leaks. Inspect the
shim washer for excessive wear. Inspect the flyweight
and thrust sleeve assembly for bearing, gear, and
bushing wear. Replace all damaged parts. Replace the
gasket.
(3) Replace the oil tube.
(4) Replace the spring (17, fig. 4-24) in the
proper hole in the lever (18).
(5) Slide the governor control rod into the lever
(18) and secure with the cotter pin.
d. Adjustment. The rod from the governor to the
carburetor must be adjusted to the proper length. With
the engine stopped, the governor spring (17) will hold
the flyweights "IN" and the rod must be of such length as
to hold the carburetor throttle wide open at that point.
To check the accuracy of this adjustment, remove the
cotter pin securing the rod to the lever (18) and slide the
rod from the lever. Push the rod toward the carburetor
as far as possible. This will fully open the throttle. The
bent end of the throttle rod should now line up exactly
with the hole in the lever (18). If it does not, screw the
rod in or out of the swivel block on the carburetor lever
until it is lined up properly. Position the rod in the
governor lever and secure with the cotter pin.
c. Installation.
(1) Position the shim washer (5, fig. 4-29) and
the flyweight assembly (6) on the shaft in the timing
gear cover (21, fig. 4-27).
(2) Position the gasket(2, fig. 4-29) and housing
(1) and secure, with the four lockwashers (3), the two
machine bolts (4) through the timing gear cover and the
two capscrews (7) through the governor housing.
4-28. Fuel Pump And Fuel Strainer (Serial Nos.L1475-T through L-1478-T.
a. Removal and Disassembly.
(1) Loosen the two tube nuts (10, fig. 4-24)
securing the fuel tube (11) to the carburetor (16) and the
fuel pump and remove the tube.
(2) Unscrew the tube nut securing the main fuel
tube to the fuel strainer and push the fuel tube out of
the way.
TS 024554
1.
2.
3.
4.
Housing
Gasket
Lockwasher
Machine bolt
5.
6.
7.
8.
Shim washer
Flyweight and thrust sleeve assembly
Capscrew
Control arm
Figure 4-29. Governor, partially exploded view.
4-35
TM 5-3655-210-12
(3) Remove the two capscrews and lockwashers
securing the fuel pump to the engine. Lift off the fuel
pump and strainer assembly and gasket.
(4) Using a pair of pliers, remove the priming
lever stop pin (28, fig. 4-30), then remove the
priming lever (27) from the crankcase and lift out
priming lever spring (10, fig. 4-31).
(5) Unscrew the thumb nut '17, fig. 4-31)
freeing the sediment bowl (18).
(6) Swing the bail (16) to the side and remove
the bowl (18), gasket (19) and the screen (20).
(7) Lift the bail (16) from the cover (3) and
remove the thumb nut (17) from the bail.
(8) Remove the shut-off valve and packing nut
(1) from the cover. Lift the packing (2) from the
cover.
(9) Unscrew the cover from the fuel pump (6)
and unscrew the fittings (4 and 5).
(10) Slide the performed packing (11) from the
primer lever (12).
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-138F. (38C.-59C.).
b. Cleaning, Inspection and Repair. Clean all parts
in a cleaning solvent.
Blow dry with com-
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Strainer bleed-off valve
Cylinder filling compressor liquid shut-off valve
Liquid equalizing line valve
Dehydrator by-pass valve
Refrigerator suction valve
Transfer pump bleed-off valve
Liquid fill line valve thru pump
Receiver tank inlet line
Dehydrator
Union nut
Liquid line shutoff valve, conversion
Transfer hose bleed-off valve (thru pump)
Cylinder filling valve
Tube nut
Cylinder fill pressure regulating valve
Safety relief valve cylinder fill
Union nut
Cylinder filling valve
Transfer hose bleed-off valve
Vapor return valve, conversion
Transfer hose bleed-off valve vapor
Liquid line vapor relief valve
Vapor equalizing line valve
High pressure vapor return valve
Fire protection valve
Vapor return valve, storage
Carburetor priming lever
Stop pin
Liquid fill line valve, by-pass pump
Liquid shut-off valve to cylinder filling compressor
Figure 4-30. CO2, manifolds, installed view.
4-36
TM 5-3655-210-12
(3) Hook the spring into position on the priming
lever and secure the lever with the pin (13).
(4) Screw the fittings (4 and 5) into position on the
fuel pump.
(5) Position the gasket (7) and the fuel pump (6) on
the engine crankcase and secure with the two
capscrews (15) and lockwasher (14).
(6) Position the packing (2) and the shut-off valve
and packing nut assembly (1) in the cover (3) and
secure with the packing nut.
(7) Screw the fitting (4) into the cover (3) and screw
the cover into position on the fuel pump (6).
pressed air making sure the passages are clean.
Inspect the cover, bowl, and bail for chips, cracks, or
other defects. Inspect the threads for damage. Inspect
the screen for tears or enlarged opening. Check the fuel
pump. Inspect the fuel line for breaks, thread damage
or other defects. Replace all damaged parts. Install a
new oil seal and gaskets.
c. Reassembly and Installation.
(1) Position the spring (10, fig. 4-31) on the engine
crankcase.
(2) Install the packing (11) in the priming lever (12)
and position the lever in the crankcase
.
1.
2.
3.
4.
5.
Shut-off valve and packing nut
Packing
Cover
Elbow
Pipe nipple
6.
7.
8.
9.
10.
Fuel pump
Gasket
Tube nut
Fuel tube
Spring
11.
12.
13.
14.
15.
Preformea packing
Primer lever
Pin
Lockwashers
Capscrew
Figure 4-31. Fuel filter, exploded view.
4-37
16.
17.
18.
19.
20.
Ball
Thumb nut
Sediment bowl
Gasket
Screen
TM 5-3655-210-12
(4) Observe the pressure reading on the gage. The
proper reading is between 3 and 4 lbs. (1.35 and 1.8
kg).
(5) If this reading is not obtained, check the fuel
tubes and fitting between the fuel pump and the fuel
tank for leaks.
(6) Remove the pressure tester and adapter.
(7) Position the fuel tube (9, fig. 4-31) on the
carburetor and fuel pump and secure with the two tube
nuts (8).
(8) Position the fuel tube (9) on the carburetor and
fuel pump and secure with the two tube nuts (8).
(9) Screw the thumb nut (17) into position on the
bail (16).
(10) Position the bail in the cover (3).
(11) Swing the bail to one side and place the
screen (20), gasket (19) and the sediment bowl (18) into
position. Swing the bail (16) back into position under
the sediment bowl and secure with the thumb nut (17).
(12) Position the main fuel tube on the fuel filter
and secure with the tube nut (8, fig. 4-31).
d. Test.
(1) Remove the fuel tube (11, fig. 4-24) from the
carburetor (16) and fuel pump (6, fig. 4-31).
(2) Install the pressure tester between the fuel
pump and the carburetor.
(3) Start the engine and run at idle speed.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Exhaust manifold
Nut
Lockwasher
Saddle washer
Capscrew
Lockwasher
Adjusting needle screw
Adjusting nut
Governor control rod
10.
11.
12.
13.
14.
15.
16.
17.
18.
4-29. Fuel Pump And Fuel Strainer (Serial Nos. L1666-T through L-1668-T).
a. Removal and Disassembly.
(1) Loosen the two tube nuts (10, fig. 4-32)
securing the fuel tube (11) to the carburetor (16) and the
fuel
pump,
and
remove
the
tube.
Tube nut
Fuel tube
Support pin
Cotter pin
Governor control lever
Screw
Carburetor
Spring
Cross shaft lever
19.
20.
21.
22.
23.
24.
25.
26.
Chain
Setscrew
Stop collar
Air cleaner mounting bracket
Locknut
Governor control
Throttle rod
Cylinder block
Figure 4-32. Governor controls, installed view.
4-38
TM 5-3655-210-12
(2) Unscrew the tube nut securing the main fuel
tube to the fuel pump and push the fuel tube out of the
way.
(3) Remove the two capscrews and lockwashers
securing the fuel pump to the engine. Lift off the fuel
pump and gasket.
(4) Unscrew fittings (4, fig. 4-33) from fuel pump
cover.
WARNING
Dry cleaning solvent, P-D-680 or P-S661,
used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the fumes
are dangerous if inhaled. Avoid repeated
and prolonged skin contact. Do not use
near open flame or excessive heat. Flash
point of solvent is 100F.-138F. (38C.59C.).
TS 024558
1.
2.
3.
4.
5.
Shut-off valve and packing nut
Packing
Cover
Elbow
Pipe nipple
6.
7.
8.
9.
10.
Fuel pump
Gasket
Tube nut
Fuel tube
Spring
11.
12.
13.
14.
15.
Performed packing
Primer lever
Pin
Lockwashers
Capscrews
Figure 4-33. Fuel filter, exploded view.
4-39
16.
17.
18.
19.
20.
Bail
Thumb nut
Sediment bowl
Gasket
Screen
TM 5-3655-210-12
Figure 4-34. Engine, fuel system view.
4-40
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
12.
Oil filter assembly
Oil filter inlet hose
Choke control lead
Nut
Automatic choke control
Machine screw
Exhaust pipe, nipple
Machine screw
Choke control lever
Choke control rod
Hose clamp screw
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Carburetor choke lever
Hose clamp
Hose
Oil filler and gage
Oil filler body
Oil filler nipple
Street tee fitting
Plug (timing)
Timing gear cover
IET lock washer
Nut
Figure 4-34 - Continued.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
TM 5-3655-210-12
Cap screw
Lock washer
Machine bolt
Machine bolt
Lock washer
Breather plug
Air cleaner mounting bracket
Oil filter mounting bracket
Machine bolt
Oil filter outlet hose
Hose nut
(4) Remove the cotter pin (10) (serial nos.
L1475-T through L-1478-T) securing the choke rod (11)
to the carburetor choke, lever (13), and slide the rod
from the choke lever.
(5) Remove the two nuts (2, fig. 4-32), lock
washers (3) and washers (4) securing the intake
manifold and carburetor (16) to the block (26) and
remove the intake manifold and carburetor assembly,
and manifold gasket.
b. Cleaning, Inspection and Repair.
(1)
Clean all parts with a cleaning solvent.
(2)
Blow dry with compressed air; make
sure the passages are clean.
(3)
Inspect the fuel pump cover and body
for chips, cracks, or other defects. Inspect the threads
for damage. Inspect the fuel line for breaks, thread
damage, or other defects.
(4)
Replace all damaged parts. Install a
new gasket.
c. Reassembly and Installation.
(1) Screw the fittings (4, fig. 4-33) into
position on the fuel pump.
(2) Position the gasket (7) and the fuel pump
(6) on the engine crankcase and secure with the two cap
screws (15) and lock washer (14
(3) Position the fuel tube (9) on the carburetor
and fuel pump and secure with the two tube nuts (8).
(4) Position the main fuel tube on the fuel
pump and secure with the tube nut.
d. Test.
(1) Remove the fuel tube (11, fig. 4-32) from
the carburetor (16) and fuel pump (6, fig. 4-33). (2)
Install a pressure tester and adapter between the fuel
pump and the carburetor.
(3) Start the engine and run at idle speed.
(4) Observe the pressure reading on the
gage. The correct reading is between 3 and 4 lbs. (1.
35 and 1. 8 kg).
(5) If the correct reading is not obtained,
check the fuel tubes and fitting between the fuel pump
and fuel tank for leaks. (6) Remove the pressure tester
and adapter.
(7) Position the fuel tube (11, fig. 4-32 on the
carburetor and fuel pump and secure with the two tube
nuts (10).
NOTE
These nuts also retain the exhaust
manifold. Support the exhaust system
before removing the intake manifold.
(6) Remove the two machine bolts (3, fig. 435) and lock washers (4) securing the carburetor (9) and
gasket (12) to the intake manifold (1).
(7) Remove the adapter (8) from the
carburetor and, on serial nos. L-1475-T through L1478T units, the pipe plug (13) from the manifold.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F. -138F.
(38C. -59C. ).
b. Cleaning and Inspection. Wipe the carburetor
with a cloth dampened in cleaning solvent. Wash all the
other parts in cleaning solvent. Replace all damaged
parts and gaskets. Replace the carburetor if it is
defective.
c. Reassembly, Installation and Adjustment.
Reverse the removal and disassembly procedures. Turn
idle adjusting screw (7, fig. 4-32) as needed to get
smoothest idle possible.
4-30. Carburetor And Intake Manifold
a. Removal and Disassembly.
(1) Remove the fuel tube (11, fig. 4-32).
(2) Remove the throttle rod (25) from the
lever and unscrew it from the carburetor throttle lever.
(3) Loosen the hose clamp (14, fig. 4-34).
4-41
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
Intake manifold
Gasket
Machine bolt
Lock washer
Saddle washer
Lock washer
Nut
8.
9.
10.
11.
11.
12.
13.
Adapter
Carburetor
Throttle rod
Cotter pin
Cotter pin
Gasket
Plug
Figure 4-35. Intake manifold and carburetor.
4-42
TM 5-3655-210-12
Section IX. GASOLINE ENGINE LUBRICATION SYSTEM AND VALVE TAPPETS
4-31. Description
A plunger type pump supplies oil through a spray nozzle
to holes in the connecting rods, and to an oil header line
and the timing gear train. A line goes to a restricted flow
type oil filter. The oil returns to the pan from the timing
gear housing through the front main bearing.
4-32. Oil Filter
a. Removal
(1) Remove the inlet (2, fig. 4-34) and the
outlet (33) oil hoses from the oil filter (1) by unscrewing
the two hose nuts (34).
(2) Remove the four nuts, lock washers, and
machine bolts (32) securing the oil filter (1) to the
mounting bracket (31). Lift off the filter assembly.
b. Disassembly
(1) Unscrew the wing nut (1, fig. 4-36)
securing the cover assembly (2) to the body assembly
(11). Lift off the cover assembly.
(2) Remove the gasket (13) from the cover
assembly and lift the element (12), from the body.
Discard the gasket and the element.
(3) Remove the nut (10), the lock washer (17)
and the machine screw (16) securing the strap (9) to the
body. Remove the strap from the body assembly (11).
WARNING
Dry cleaning solvent, P-D-680 or PS661 used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F. -138F. (38C. -59C.).
c. Cleaning, Inspection and Repair. Wash all parts
thoroughly in cleaning solvent, inspect the body, cover
assembly and the strap for cracks or leaks. Replace all
damaged parts.
d. Reassemnbly and Installation. Reverse the
disassembly and removal procedures.
1.
2.
3.
4.
5.
6.
7.
8.
4-33. Oil Lines
a. Removal and Disassembly
(1) Remove the two oil filter lines at the oil
filter.
(2) Unscrew the oil filter inlet hose (2, fig. 434) from the street tee (19), and unscrew the oil filter
outlet hose (33) from the top of the timing gear cover
(21) (serial nos. L-1475-T through L-1478-T) or from TS
024561
Wing nut
Cover assembly
Street tee
Adapter
Hose assembly
Hose assembly
Lock washer
Nut
9.
10.
11.
12.
13.
14.
15.
16.
17.
Strap
Nut
Body assembly
Filter element
Gasket
Oil line
Machine bolt
Machine screw
Lock washer
Figure 4-36. Oil filter, exploded view.
4-43
TM 5-3655-210-12
Dry cleaning solvent, P-D-680 or P-S661, used to clean
parts is potentially dangerous to personnel and property.
Use in a well-ventilated area as the fumes are
dangerous if inhaled. Avoid repeated and prolonged
skin contact. Do not use near open flame or excessive
heat. Flash point of solvent is 100F. -138F. (38C. 59C. ).
b. Cleaning, Inspection and Repair. Clean the
valve cover gasket surface on the engine block. Wash
the covers, washers, and hardware in solvent. Inspect
the threads for damage. Replace all damaged parts and
install new gaskets.
c. Tappet adjustment.
(1) Turn the crankshaft over by hand until the
lifter (6, fig. 4-38) that is to be adjusted is at its lowest
position.
(2) On serial nos. L-1475-T through L-1478-T
units, insert a 0, 012 inch (. 0305cm) feeler gage (5)
between the valve stem (8) and lifter screw (7). On
serial nos. L-1666-T through L-1668-T units, insert a 0.
008 inch (. 0203cm) feeler gage for the two intake
valves and a 0. 016 inch (. 0406cm) feeler gage for the
two exhaust valves.
i. Installation. Reverse the removal procedures.
TS 024562
the engine base (serial nos. L-1666-T through L-1668T).
(3) Remove the oil tube by unscrewing the
two tube nuts securing the tube to the street tee (19) and
the governor. Lift out the tube.
(4) Unscrew the street tee from the engine
crankcase.
(5) Unscrew the adapter (4, fig. 4-36) from
the street tee (3).
WARNING
Dry cleaning solvent, P-D-680 or PS661, used the clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F. -138F. (38C. -59C. ).
b. Cleaning, Inspection and Repair. Clean all the
parts in a cleaning solvent. Inspect the lines for cracks
or evidence of leakage. Check the fittings and tube nuts
for damaged threads. Replace all damaged parts.
c. Reassembly and Installation.
Reverse the
disassembly and removal procedure.
4-34. Tappets
a. Valve cover, removal and disassembly.
(1) Remove the fuel tube (11, fig. 4-32).
(2) Remove the throttle rod (25).
(3) Loosen the hose clamp (14, fig. 4-34).
(4) Remove the cotter pin (10) securing the
choke rod (11) to the carburetor choke lever (13) and
slide the rod from the choke lever.
(5) Remove the two nuts (2, fig. 4-32), lock
washers (3) and washers (4) securing the intake
manifold and carburetor (16) to the block (26) and
remove the intake manifold carburetor assembly, and
manifold gasket.
NOTE
These nuts also retain the exhaust
manifold. Support the exhaust system
before removing the intake manifold.
(6) Remove the two machine bolts (3, fig. 435) and lock washers (4) securing the carburetor (9) and
gasket (12) to the intake manifold (1).
(7) Remove the adapter (8) from the
carburetor and the pipe plug (13) from the manifold.
(8) Remove the cap screw (1, fig. 4-37), the
support pin (6), and the valve covers (3) and gaskets (4)
from the engine block.
1.
2.
3.
4.
Cap screw
Washer
Cover
Gasket
5.
6.
7.
Washer
Support pin
Cotter pin
Figure 4-37. Valve cover and gasket.
WARNING
4-44
TM 5-3655-210-12
1.
2.
3.
4.
5.
Head
Air shroud heat deflector
Valve cover
Gasket
Feeler gage
6.
7.
8.
9.
Valve lifter
Adjusting screw
Valve stem
Block
Figure 4-38. Tappet adjustment.
Section X. EXHAUST SYSTEM
4-35. Description
The exhaust system consists of the exhaust manifold,
the exhaust pipes, muffler, and tail pipe.
4-36. Tail Pipe-and Muffler
a. Removal and Disassembly.
(1) Remove the two nuts (23, fig. 4-39) and
4-45
TM 5-3655-210-12
Figure 4-39. Muffler and exhaust pipes.
4-46
TM 5-3655-210-12
1
2
3
4
*5
6
7
8
9
10
11
12
13
Muffler
Elbow
Pipe nipple
Pipe coupling
Shroud
Flywheel cover
Machine screw
Lock washer
Caps crew
Battery lead
Lock washer
Cap screw
Bracket
14
Tail pipe tube
15
Belt tightener mounting
16
Cap screw
17
Nut, terminal, lower
18
Lock washer
19
Lead
20
Lead
21
Nut, terminal, upper
22
Lead
23
Nut, U-bolt clamp
24
Bracket
25
Clamp (U-bolt)
26
Solenoid
Figure 4-39. - Continued
(2) Unscrew the elbow (2, fig. 4-39) from the
pipe (3) and the pipe (3) from the other elbow (2).
(3) Unscrew the elbow from the exhaust pipe
(4).
(4) Remove the two machine screws (6, fig.
4-34) securing the automatic choke control (5) to the
exhaust pipe (7) and lower the choke control out of the
way.
(5) Remove the two nuts (2, fig. 4-32), lock
washers (3) and clamp washers (4) securing the exhaust
manifold (1) to the block (26).
(6) Lift off the manifold (1) and gaskets and
unscrew the pipe.
b. Inspection and Repair. Inspect for cracks or
breaks. Inspect the threads for damage. If the threads
are not too badly damaged rechase the threads with a
pipe die. Replace all damaged parts. Discard the old
gaskets and replace.
c. Installation. Reverse the removal procedure.
lock washers securing the bracket (24) and clamp (25).
Lift off the clamp and bracket.
(2) Slide the tail pipe (14) downward away
from the muffler (1).
(3) Unscrew the muffler (1) from the elbow
(2) and remove. Lift the tail pipe (14) up through the
mounting bracket (13) and remove.
(4) Remove the cap screw (12) and lock
washers (11) securing the bracket (13) and remove the
bracket.
b. Inspection and Repair. Wash all parts in a
cleaning solvent. Inspect the muffler and pipe for holes,
leaks or cracks. Inspect the mounting bracket for cracks
or breaks. Weld minor cracks in the bracket. Replace
all other damaged parts.
c. Reassembly and Installation.
Reverse the
disassembly and removal procedures.
4-37. Exhaust Manifold and Pipes
a. Removal.
(1) Remove the muffler and tail pipe.
4-47
TM 5-3655-210-12
Section XI. GASOLINE ENGINE IGNITION SYSTEM
c. Installation and Timing. When the magneto has
been removed it must be retimed to the engine.
(1) Remove the four machine screws (7, fig.
4-39) and lift off the screen (6).
4-38. Description
The spark is produced by a magneto. The ignition
current is transmitted into the engine cylinder through an
ignition cable and spark plug. A ground out cable which
connects to the shut-off switch on the engine control
panel is provided to ground out the magneto and shut
off the engine.
(2) Remove the spark plug closest to the
flywheel. Hold the thumb over the spark plug hole and
turn the engine over slowly with the hand crank until a
definite pressure can be felt. When this occurs, the
number one piston is coming up on the compression
stroke. Reinstall the spark plug.
4-39. Spark Plugs and Wiring
a. Removal and Disassembly.
(1) Remove the four coupling nuts (2, fig. 4401) securing the two spark plug cables (3) to the spark
plugs (1) and the magneto (6).
(2) Remove the machine screw (5), securing
the clip (4) and the spark plug cables to the cowling.
Remove the spark plug cables.
(3) Clean the dirt from around the spark
plugs. With a spark plug wrench, remove the plugs and
gaskets.
b. Cleaning, Inspection and Repair. Clean the
spark plugs by sand blasting. If the plugs are pitted or
burned, replace them. Replace damaged parts. Reset
plug gap to 0. 030 in. (. 0762 cm). Replace the spark
plug gaskets, if necessary.
c. Reassembly and Installation.
Reverse the
removal and disassembly procedures.
4-40. Magneto
a. Removal
(1) Remove the spark plug cables and the
ground cable from the magneto.
(2) Hold a wrench on the cap screw (7, fig. 4401) securing the magneto (6) and remove the nut (23,
fig. 4-34) and the lock washer (22).
(3) Remove the cap screw.
(4) Hold the magneto and remove the cap
screw (24, fig. 4-34) and the internal-external lock
washer (22) securing the magneto to the timing gear
cover (21). Lift out the magneto and the gasket.
WARNING
Dry cleaning solvent: P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F. -138F. (38C. -59C. ).
1.
2.
3.
4.
5.
6.
7.
b. Cleaning and Repair. Wipe with a clean cloth
dampened in a cleaning solvent. Inspect the magneto
cover for breaks or cracks. Replace all damaged parts.
Shielded spark plug
Nut
Shielded ignition cable
Clip
Screw
Magneto assembly
Cap screw,
8.
9.
10.
11.
12.
13.
IE toothed lock washer
Nut
Cap screw
Timing gear cover
Cylinder block
Cylinder head
Figure 4-40. Ignition suppression components
(Sheet 1 of 2)
4-48
TM 5-3655-210-12
1.
2.
3.
4.
5.
Nut
Machine screw
Shielded ignition cable
Clip
Combustion head
6.
7.
8.
9.
10.
Shielded spark plug
Nut
Heater base
IE toothed lock washer
Cap screw
11.
12.
13.
14.
Housing
IE toothed lock washer
Ignition unit
Radio interference suppression
Figure 4-40. Ignition suppression components (Sheet 2 of 2)
(3) Continue to turn the engine until the edge
(6, fig. 4-41) of the vane (4) marked X is in line with the
vertical center line mark (5) on the shroud (1). Leave
the' flywheel in this position as the number one piston is
now on top dead center. Note the flywheel (2) is marked
with "DC" (7) near the marked vane.
(4) Remove the plug (20, fig. 4-34).
(5) Turn the magneto gear (3, fig. 4-42)
clockwise until the impulse coupling snaps.
(6) Hold the gear in this position and mount
the gasket and magneto to the engine meshing the
gears so that the "X" marked tooth (4) is centrally
located in the inspection hole.
(7) Replace the attaching hardware, and the
wiring.
(8) Whiten tip of vane (4, fig. 4-41) next to
timing mark (7) on the engine flywheel with chalk or
paint. Connect a timing light to the engine. With engine
operating at governed speed, timing light should cause
vane (4) to appear stationary in alignment with mark (3)
in shroud.
(9) Install the inspection hole plug (20, fig. 434) in the timing gear cover and replace-the screen.
d. Breaker Point and Condenser Removal.
(1) Remove the ground and spark plug
cables.
(2) Remove the magneto cover and gasket
from the magneto.
(3) Remove the terminal screw (3, fig. 4-43).
(4) Remove the breaker arm lock (7) and
washers (5), and take the breaker arm (8) off the pin (6).
(5) Remove the aligning washer (11, fig. 444) from the pin.
WARNING
Dry cleaning solvent, P-D-680 or PS661, used to clean parts is
potentially dangerous to personnel
and property.
Use in a wellventilated area as the fumes are
dangerous if inhaled.
Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat.
Flash point of
solvent is 100F. -138F. (38C. -59C.
).
4-49
TM 5-3655-210-12
e. Cleaning and Inspection. Wipe all parts with a
clean rag dampened in a solvent. Inspect contact points
for burning or pitting. Replace damaged parts, except
lightly pitted points may be filed to a smooth mating
surface.
f. Breaker Point and Condenser Installation.
Reverse the removal procedures in d. above.
g. Breaker Point Gap Adjustment.
(1) Loosen the screws (4, fig. 4-43).
(2) Turn the rotor (12) so the points are fully
open.
(3) Insert a 0. 015 in. feeler gage (11)
between the points.
(4) Use a screwdriver in the adjusting slot
(10) to move the stationary point as needed to get
clearance producing just slight drag with gage between
points, and retighten screws (4) to hold adjustment.
1
2
3
4
5
Shroud
6
Flywheel
7
Running spark advance mark 8
Timing vane
9
Top dead center mark
10
Edging vane
Flywheel timing mark
Lock washer
Flywheel nut
Pin
Figure 4-41. Flywheel timing marks.
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
Timing gear cover
Magneto
Magneto drive gear
Magneto drive gear timing mark
Magneto
Condenser lead
Terminal screw
Screw
Washer
Pivot pin
7.
8.
9.
10.
11.
12.
Lock
Breaker arm
Fixed contact
Adjusting slot
Feeler gage
Rotor
Figure 4-43. Breaker point, removal and adjustment
Figure 4-42. Magneto gear timing marks.
4-50
TM 5-3655-210-12
1.
2.
3.
4.
Magneto cover
Gasket
Condenser
Screw
5.
6.
7.
8.
Lock
Washer
Washer
Breaker arm
9.
10.
11.
12.
Screw
Fixed contact
Aliening washer
Screw
Figure 4-44. Condenser and breaker points, exploded view.
Section XII. 24 VOLT ELECTRICAL SYS. TEMS ENGINE AND VEHICULAR
suction pressure. The high pressure switch opens to
stop the engine when the discharge pressure reaches
240 psi (16. 872 kg per sq. cm). The low pressure
switch will close again when the suction pressure rises
to 12 psi (. 8436 kg per sq. cm), and the high pressure
switch will close when the pressure drops to 240 psi (16.
872 kg per sq. cm). The tank pressure control switch
(10) closes the circuit to the gasoline engine at 305 psi
(21. 4415 kg per sq. cm) and opens the circuit when the
pressure drops to 295 psi (20. 7385 kg per sq. cm). An
alarm pressure switch (14) is provided for each pressure
vessel, which closes the circuit to the alarm bell (15)
when tank pressures exceed 325 psi (22. 8475 kg per
sq. cm) or are below 250 psi (17. 575 kg per sq. cm).
e. When the unit is set for automatic operation,
using the gasoline engine for power, the automatic
engine control (17) will crank the engine for a
predetermined time interval. If the engine fails to start
after the cranking cycle, the control will cease to
function and a failure, light will light on the control panel.
Power is supplied to the control when the tank pressure
control switches close.
4-41. Description
a. The 24 volt electrical system is comprised of
three circuits. (fig. 4-45).
b. The running light circuit is operated from the
towing vehicle batteries and comprises the front trailer
receptacle, the rear receptacle, the trailer tail lights, the
service clearance lights, and the blackout service lights.
c. The dome light circuit is powered by either the
tractor (1, fig. 4-46) or trailer (2) batteries through the
TRACTOR-TRAILER control switch (6). The other
components are the three dome light switches (3), the
storage compartment dome lights (5) and power
compartment dome lights (4).
d. The DC control circuit is controlled through the
trailer batteries and consists of the toggle switches (13,
9, 8, 7, 6, 11, and 12, fig. 4-47) heater failure lights (10,
14), the gage line heater lights (5), ammeter (1) circuit
breaker (3), and the fuel gage (4), all mounted on the
DC control panel (fig. 4-47).
Two refrigeration
compressor pressure switches (22, 23, fig. 4-48) are
connected to the ignition system of the engine. The low
pressure switch (22) opens to ground out the magneto
to stop the engine at zero pounds per square inch
4-51
TM 5-3655-210-12
Figure 4-45. Trailer running light wiring schematic.
4-52
TM 5-3655-210-12
(2) Remove the four nuts (7) and lock
washers (6) securing the hold-down bars (5) and remove
the bars.
(3) Lift the batteries from the battery retainer
(13)
b. Installation. Reverse procedure in a. above.
c. Testing. Refer to TM 96140-200-15.
4-43. Starter and Solenoid
a. Removal.
(1) Remove the battery ground lead (2, fig. 449) from the battery.
(2) Remove the nut (17, fig. 4-39) from the
solenoid (26) releasing the battery lead (10). Remove
the regulator lead (20) wire.
(3) Remove the nut (21), releasing the switch
lead (20) and the automatic choke lead (22).
(4) Remove the nut (10, fig. 4-50) and lock
washer securing the starter lead (16) to the solenoid (11)
and remove the lead.
(5) Remove the nut (18) and lock washer
securing the lead (16) to the starter (17).
(6) Remove the two machine screws (12) and
lock washers securing the solenoid (11) to the shroud
(9). Lift off the solenoid.
(7) Remove the two caps crews (20) and lock
washers (21) securing the starter bracket(19)to the
crankcase (22). Remove the bracket from the starter.
(8) Remove the three cap screws (15) and
lock washers (14) securing the starter (17) to the timing
gear plate (13). Remove the starter from the plate.
TS 024572
1. Tractor batteries
4. Power compartment dome
lights
2. Trailer batteries
5. Storage compartment dome
lights
3. Dome light switches 6. "Tractor-trailer" control
switch
b. Installation. Reverse the procedure in a above.
4-44. Generator Regulator
a. Removal.
(1) Remove the screw (25, fig. 4-51)
releasing the lead (24) from the regulator (20).
(2) Remove the two wiring harnesses (15 and
19) from the regulator.
(3) Remove the four cap screws (21) nut, and
lock washers securing the regulator (20) to the mounting
plate (22). Remove the regulator.
(4) Remove the two cap screws (23), nuts,
and lock washers (26) securing the mounting plate (22)
to the frame (27). Remove the plate.
b. Installation. Reverse the removal procedure in a
above.
Figure 4-46. Dome light schematic.
f. The generator regulator (3, fig. 4-48) contains a
cut-out to prevent reverse current flow from the battery
to the generator when the generator is not operating. It
also contains a voltage limiter set at 28 ½ ± 1 volt. A
current limiter, incorporated as protection for the
generator, is set for maximum output of 18 amperes.
g. The generator (4) supplies all the current
required by the equipment and maintains the batteries
(21) in a fully charged condition for cranking the
gasoline engine.
h. Two 12-volt batteries connected in series supply
power to the 24-volt DC system. The negative terminal
of the battery is the ground.
4-42. Batteries
a. Removal.
(1) Loosen the nuts (4, fig. 4-49) securing the
leads (2, 8 and 9) to the batteries (12) and lift the lead
free of the battery.
4-45. Generator
a. Generator Removal.
(1) Loosen the coupling nut securing the
wiring harness (15, fig. 4-51) to the generator (31) and
disconnect the harness.
(2) Remove the cap screw (13) securing the
generator (31) to the adjusting bracket (14).
4-53
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
Ammeter
Electrical control switch (tractor or trailer)
Circuit breaker
Fuel indicator gage
Gage lines operating lights
Storage vessel gage line switch
Conversion vessel gage line switch
Compartment heater control switch
9.
10.
11.
12.
13.
.
14.
15.
Conversion heater control switch
Conversion heater failure light
Gasoline engine manual stop switch
Gasoline engine manual starter switch
Gasoline engine control switch for automatic or manual
control
Gasoline engine failure light
Engine control panel
Figure 4-47. Engine Control Panel
(3) Raise the generator and slip off the
generator drive belt (1).
(4) Remove the two nuts (29), lock washers
(30), and cap screws (28) securing the generator (31) to
the frame (27). Lift out the generator.
(5) Remove the nut (3, fig. 4-52), lock washer
(4) and cap screw (6) securing the adjusting bracket (9)
to the frame, releasing the strap.
b. Brush Replacement.
(1) Loosen the screw (1, fig. 4-52) securing
the strap (2) on the generator (5) and slide the strap
from the generator.
(2) Remove the screw (13) securing the
brush (-12) to the brush holder' (15).
(3) Lift the brush arm with a stiff wire and
remove the brush.
(4) Reverse steps (1) to (3) to install brushes.
c. Generator Installation. Reverse the removal
procedure to install the generator, and tighten drive belt
to 1-% in. (3. 81 cm) deflection at midspan.
4-46. Pressure Switches
a. Refrigeration Compressor Pressure Switch
Adjustment. The compressor pressure switches are set
with the adjusting screws on top of the switches (1 and
2, fig. 4-53). Set the suction pressure switch (2) to open
at zero psi to shut off the engine or electric motor. The
low pressure suction switches reset to
4-54
TM 5-3655-210-12
1. Gasoline engine start and stop switches
2. Ammeter
3. Voltage regulator
4. Generator
5. Heater switch
6. Coolant circulating pump
7. Warning light
8. Heater control plug
9. Heater
10. Tank pressure control switch
11. Limit switch
12. Heating element
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Space heater
Pressure alarm switch
Alarm bell
Starting motor
Automatic engine control
Pressure control switch
Automatic-manual engine control switch
Magneto
Batteries
Low pressure control switch
High pressure control switch
Figure 4-48. DC control wiring schematic
allow operations to resume when the suction pressure
rises to 12 psi (. 8436 kg per sq. cm). Set the discharge
switches (high pressure) (1) to open at 240 psi (16. 872
kg per sq. cm) to stop the electric motor or gasoline
engine. The high pressure switches close to resume
operation when the pressure drops to 210 psi (14. 763
kg per sq. cm). Adjust the switches to the correct
settings as indicated on the dial by using a screw driver
on the adjusting screw.
b. Tank Pressure Switch Adjustment. Adjust the
tank pressure switches (4) by turning the adjusting
knobs (5 and 6) to the desired setting on the scale. The
correct setting is 305 on the high side (knob 5) and 295
on the low side (knob 6). The pressure switch (8),
connected to the conversion heater, is set at 275 on the
high side and 260 on the low side.
(2) Remove the two nuts (3, fig. 4-55)
securing the wires to the fuel gage (2) or ammeter (8).
Remove the wires from the ammeter.
(3) Remove the two nuts (3) securing the
clamp (7) and the unit to the control panel (19) and
remove the clamp (7) and ammeter (8).
b. Installation. Reverse removal procedure.
4-48. Automatic Starter Control
a. Removal.
(1) Refer to the wiring diagram (fig. 4-56) and
tag the wire leads connected to the starter control (9,
fig. 4-55).
(2) Remove the nuts securing the leads to the
control terminals and remove the leads.
(3) Remove the two nuts (21) and lock
washers (22) securing the control and shock mounts
(20) to the mounting bracket (18) and lift out the control
and mounts.
4-47. Ammeter and Fuel Gage
a. Removal.
(1) Disconnect battery ground lead (2, fig. 454).
4-55
TM 5-3655-210-12
1
2
3
4
5
6
Cap screw
Ground lead
Battery cable bolt
Nut
Hold-down bar
Lock washer
7
8
9
10
11
12
Nut
Battery connector lead
Battery to solenoid lead
Cap screw
Terminal lug
Battery
Figure 4-49. Batteries and box, exploded view.
4-56
13
14
15
16
17
18
Battery retainer
Nut
Lock washer
Hold-down rod
Support
Machine screw
TM 5-3655-210-12
1. Shroud cover
2. Spark plug cable
3. Cable nut
4. Lockwasher
5. Machine screw
6. Oil filter bracket
clamp
7. Lockwasher
8.
9.
10.
11.
12.
13.
Nut
Shroud
Nut
Solenoid
Machine screw
Timing gear plate
15.
16.
17.
18.
19.
20.
Capscrew
Lead
Starter
Nut
Bracket
Capscrew
14. Lockwasher
Figure 4-50. Starter and solenoid removal
4-57
21.
22.
23.
24.
25.
26.
Lockwasher
Crankcase
Machine screw
Cylinder shroud
Heat deflector
Spark plug cable
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Generator drive belt
Jack shaft drive pulley
Hose
Cylinder filling unit drive belt
Clutch
Valve cap
Cylinder head plug adapter
Cylinder head
Nipple
Packing retainer nut
Adapter
Pipe
Capscrew
Adjusting bracket
Wiring harness
Belt tightener stud
17.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Nut
Nut
Mounting bracket
Wiring harness
Regulator
Capscrew
Mounting plate
Capscrew
Lead
Machine screw
Lockwasher
Frame
Capscrew
Nut
Lockwasher
Generator
Figure 4-51. Generator and regulator removal.
4-58
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
Screw
Strap
Nut
IE washer
Generator
Capscrew
Lockwasher
Capscrew
9.
10.
11.
12.
13.
14.
15.
(2) Remove the screws (6, fig. 4-55)
securing the wires to the switch to be removed and lift
the wires from switch.
(3) Remove the two screws (12) securing
the switch to the engine control panel and remove the
switch.
(4) Reverse steps (l)to (3) to install new
switch.
4-50. Gage Panel Switches
The power compartment dome light switch (18,
fig. 4-57) and the two vessel alarm bell cut-out switches
(16 and 17) are removed, inspected, cleaned, and
installed in the same manner as all other switches.
4-51. Alarm Bell
a. Removal and Disassembly.
(1) Disconnect the three identification
lights on the bell cover at the connector (fig. 4-56).
(2) Remove the nine machine screws (2,
fig. 4-58) and lockwashers securing the bell cover (3) to
the rear housing (1) and remove the cover.
(3) Refer to figure 4-59 1 or figure 4-59 2
and disassemble the alarm bell.
b. Assembly and Installation.
Reverse a.
above to assemble and install the alarm bell.
4-52. Blackout and Service Stop and Taillights
a. Removal
(1) To remove either blackout or service
stop and taillights (11) and 15, fig. 4-60) uncouple wire
connectors (14) and tag leads for identification, then
remove capscrews (12) and lockwashers (13) to free
blackout units, or screws and nuts attaching service
units. Reverse this procedure to install.
(2) To replace lamps, loosen screws,
remove door (1, fig. 4-61) and remove defective lamp
by pressing in while turning lamp to left, to disengage
lamp base from socket, then remove lamp. Install new
lamp by reversing removal procedure above.
NOTE
Procedure above is typical for both service and
blackout taillights.
b. Disassembly. Refer to figures 4-61 and 462 and disassemble the light.
c. Repair. Replace all damaged parts.
d. Reassembly.
Reverse disassembly
procedures.
Adjusting bracket
Nut
Wiring harness
Brush
Screw
Lead
Holder
Figure 4-52. Generator brush installation
b.
Installation.
(1) Position the two shock mounts (20)
and starter control (9) on the bracket (18) and secure
with the two nuts (21) and lockwashers (22).
(2) Connect the wires to the terminals,
refer to figure 4-56.
4-49.
Control Panel Switches
a. General. The gage line heater switches(16
and 17, fig. 4-55), the conversion heater switch (14),
the space heater switch (15), the gasoline engine start
and stop switches (11 and 13), the automatic manual
control switch (10), the circuit breaker (4), and the
tractor-trailer switch (5) are all removed, cleaned,
inspected and installed in the same manner. Disconnect
the battery ground lead (2, fig. 4-54) before working on
any of these switches.
b. Replacement.
(1) Tag the wire leads on the switch to be
removed, refer to the wiring diagram, figure 4-56.
4-53.
Clearance Lights
a. To replace lamp, (3, fig. 4-63), remove
screws (11), door (1), lens (2) and press and turn lamp
left to release. Reverse these steps to complete
operation. To replace entire light assembly proceed as
follows:
b. Remove door and lens as given above.
Inside trailer body, at light to be replaced, disconnect
electrical connector by pressing two halves together
while twisting them.
4-59
TM 5-3655-210-12
TS 024579
1.
2.
3.
4.
5.
Compressor pressure switch (discharge)
Compressor pressure switch (suction)
Connector
Tank pressure switch
Adjusting knob, high side
6.
7.
8.
9.
10.
Figure 4-53. Pressure switch adjustment.
4-60
Adjusting knob, low side
Alarm bell pressure switch
Tank pressure switch low pressure
Receiver shut-off (inlet)
Receiver outlet line
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
Negative terminal
Ground lead
Battery filler cap
Connector lead
Positive terminal
Nut
7.
8.
9.
10.
11.
12.
c. Remove screws (7) and take off clearance
light and gasket (9). Reverse this procedure to install
light.
Battery to solenoid lead cable
Battery
Battery hold-down bar
Bracket hold-down rod
Washer, flat
Nut
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid
repeated
and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
4-54.
Dome Lights
a. To remove dome lights, disconnect wire
connector (10, fig. 4-64), remove three screws (2)
holding base (4) to roof of compartment. Reverse
procedure to install.
b. To replace lamp, loosen two screws (3)
holding lens (5) to base (4), turn lens to remove it, and
replace lamp. Reposition lens and tighten screws.
b. Cleaning, Inspection and Repair. Clean
with a cloth dampened in a cleaning solvent. Inspect for
damaged threads, cracked or broken glass, or any other
damage. Replace damaged parts. Reverse removal
procedure to reinstall.
c. Replacing. To replace a burned out lamp,
unscrew the lens from the front of the light, replace the
lamp and screw the lens back in place.
4-55.
Failure and Gage Line Lights
a. Removal. Tag the wires of the light to be
removed.
Then remove the nut and lockwasher
securing the light to the panel and slide the assembly
out the front of the panel.
4-61
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Clamp
Fuel indicator gage
Nut
Circuit breaker
Tractor-trailer switch
Screw
Clamp
Ammeter
Automatic engine control
Manual-automatic control switch
Gasoline engine start switch
Screw
Gasoline engine stop switch
Conversion heater switch
Heater switch
Conversion vessel gage line heater switch
Storage vessel gage line heater switch
Bracket
Engine control panel
Shock mount
Nut
Lockwasher
Figure 4-55. Control panel unit removal
4-62
TM 5-3655-210-12
Figure 4-56. Wiring diagram
4-63
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
Gage panel
Level gage
Hose
Hose nut
Elbow
Nut
Tee
8.
9.
10.
11.
12.
13.
14.
Pressure gage
Adapter
Tube nut
Tube
Screw
Nipple
Bushing
15.
16.
17.
18.
19.
20.
21.
Elbow
Alarm bell cut-out switch, storage vessel
Alarm bell cut-out switch conversion vessel
Dome light switch
Nut
Elbow
Tube
Figure 4-57. Gage panel, rear view.
4-64
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
Rear housing
Machine screw
Bell cover
Right rear door
Storage tank pressure gage
Conversion tank level gage
Adjusting screw
Conversion tank pressure gage
9.
10.
11.
12.
13.
14.
15.
Toggle switch
Storage tank level gage
Door handle
Screw
Left rear door
Machine screw
Shutter
Figure 4-58. Liquid level gages, pressure vessels.
4-65
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
Machine screw
Machine screw
Lockwasher, No. 10
Capscrew
Washer
Gong
Gong post
8.
9.
10.
11.
12.
13.
Shakeproof washer
Gong adjusting plate
Carriage bolt
Frame and pad assembly
Cover
Gasket
Figure 4-59. Alarm bell, partially exploded view (ser. nos.
L-1475-T through L-1478-T) (Sheet 1 of 2).
4-66
TM 5-3655-210-12
1. Screw machine (2)
2. Gong
3. Bell mechanism
4. Mounting box
Figure 4-59. Alarm bell, partially exploded view (ser. nos.
L-1666-T through L-1668-T) (Sheet 2 of 2).
1.
2.
3.
4.
Frame
Bumper assembly
Nut
Bracket
5.
6.
7.
8.
Lockwasher
Capscrew
Machine bolt
Nut
9.
10.
11.
12.
Bracket
Bracket
Service stop and taillight
Capscrew
Figure 4-60. Taillight removal,
4-67
13.
14.
15.
16.
Lockwasher
Connector
Blackout stop and taillight
Nut
TM 5-3655-210-12
1.Door assembly
2. Machine screw
3. Retaining ring
4. Gasket
5. Lamp
6. Lamp
7. Socket and wiring assembly
8. Machine screw
9. Eyelet
10. Grommet
11. Connector
12. Body
Figure 4-61. Blackout stop and taillight, exploded view.
1. Door
2. Lens
3. Gasket
4. Gasket
5. Lamp
6. Socket
Figure 4-62. Service taillight, exploded view.
4-68
7. Wiring
8. Body
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
Door
Lens
Lamp
Screw
Washer
Wiring assembly
7.
8.
9.
10.
11.
Figure 4-63. Clearance light, exploded view.
4-69
Screw
Base
Gasket
Spring nut
Screw
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Coolant line
Machine screw
Machine screw,
Dome light base
Dome light lens
Housing
Coolant line
Tube nut
Bracket
Connector
Coolant line
Pipe plug
Nipple
Tee
Nipple
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Pipe union
Saddle stand
Capscrew
Coolant pump
Coolant pump lead
Wiring harness
U-bolt
Bracket
Nut
Machine screw
Limit switch
Limit switch cover
Lockwasher
Coolant line
Figure 4-64. Heater compartment and dome lights, installed view.
4-70
TM 5-3655-210-12
Section XIII. 220 VOLT AC ELECTRICAL SYSTEM
(high pressure) (1) to open at 240 psi (16.872 kg per sq
Description
cm) to stop the electric motor or gasoline engine. The
The conversion and storage unit is equipped
high pressure switches close to resume operation when
with a 20-volt electrical system, shown schematically in
the pressure drops to 210 psi (14.763 kg per sq cm).
Figure 4-65. This system consists of the electrical
Adjust the switches to the correct settings as indicated
motor, motor starter, reversing switch, high pressure
on the dial by using a screw driver on the adjusting
switch, low pressure switch, refrigeration control
screw.
switches, tank pressure control switch, power
b. Tank Pressure Switch Adjustment. Adjust
receptacle, and electrical motor interlock control.
the tank pressure switches (4) by turning the adjusting
knobs (5 and 6) to the desired setting on the scale. The
4-57. Pressure Switches
correct setting is 305 on the high side (knob 5) and 295
The refrigeration pressure control switches (4
on the low side (knob 6). The pressure switch (8),
and 8, fig. 4-53) and the tank pressure switch are
connected to the conversion heater, is set at 275 on the
identical to the gasoline engine pressure switches and
high side and 260 on the low side.
are adjusted in the same manner, as follows:
a. Regrigeration Compressor Pressure Switch
4-58. Electric Motor Removal
Adjustment. The compressor pressure switches are set
a. Disconnect the 220-volt power cable from
with the adjusting screws on top of the switches (1 and
the power receptacle.
2, fig. 4-53). '.Set the suction pressure switch (2) to
b. Remove the screws (26, fig.
4-66)
open at zero psi to shut off the engine or electric motor.
securing the correction box cover (27) to the motor (1),
The low pressure suction switches reset to allow
and remove the cover.
operations to resume when the suction pressure rises to
12 psi (.8436 kg per sq cm). Set the discharge switches
4-56.
1. Power receptacle
2. Reversing switch
3. Control box
4. Electric motor
5. D.C. control panel
.6. Gasoline engine-electric motor interlock
Figure 4-65. 220-volt wiring schematic.
4-71
7. Low pressure switch refrigeration
8. High pressure switch refrigeration
9. Tank pressure switch
TM 5-3655-210-12
f.
Remove the four nuts (22), lockwashers
(23), and capscrews (28) securing the motor (1) to the
frame (19).
g. Slide the motor (1) to the left until the
shaft(21) clears the sleeve (3) and lift the motor from
the compartment.
c.
Tag the wires and remove the three
terminal screws which connect the wiring to the motor.
d. Remove the nut (25) securing the cable
assembly (24) to the motor.
e. Remove the three screws (2) securing the
clutch cover (20) to the clutch sleeve (3).
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Motor, alternating current
Screw, internal wrenching head
Clutch sleeve
Pillow block bearing
Plain washer
Capscrew
Hose assembly, rubber
Elbow, pipe
Pipe union
Nut, pipe union
11.
12.
13.
14.
15.
16.
17.
18.
19.
Belts, transfer pump
Countershaft assembly
Transfer pump
Drive belts
Flywheel compressor
Flywheel, cylinder filling unit
Drive belts
Belt, generator drive
Frame
20.
21.
22.
23.
24.
25.
26.
27.
28.
Figure 4-66. Electric motor, installed view
4-72
Clutch housing cover
Motor shaft
Nut, plain
Lockwasher
Cable assembly
Conduit nut
Machine screw
Cover
Capscrew
TM 5-3655-210-12
Section XIV. ENGINE AND POWER COMPARTMENT COOLING SYSTEM
the other one up or down as necessary.
tightening the nut.
4-59. Description
a. The gasoline engine is air-cooled. The air is
sucked in by the vanes on the engine flywheel and
blown through the air shroud to cool the engine.
b. The power compartment has three shutters to
control the temperature. One shutter controls the air
flow to the gasoline engine and with the shutter in the
rear door is operated by preset thermostatic controls.
The third shutter, located in front of the refrigeration
condenser, is manually operated.
Secure by
4-60. Rear Door Shutter and Control Rod
a. Control Removal and Disassembly.
(1) Remove the cotter pin (3, fig. 4-67) and
washer (4) securing the control rod (6) to the shutter arm
(5) and slide the control rod from the arm.
(2) Remove the nut (7) from the top of the
control rod (6) and slide the rod from the control arm (8).
Remove the nut (7) from the rod.
(3) Remove the two capscrews (11) and
lockwashers (10) securing the bracket (9) to the door
(1). Remove the bracket and control.
(4) Remove the bracket from the control by
removing the two capscrews and lockwashers.
b. Shutter Removal. Remove the 14 machine
screws (14, fig. 4-58) and lockwashers securing the
shutter (15) to the door (13) and lift out the shutter
assembly.
WARNING
Dry cleaning solvent, P-D-680 or P-S-661,
used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact. Do
not use near open flame or excessive
heat. Flash point of solvent is 1OOF.138F. (38C.-59C.).
c. Control and Shutter Cleaning, Inspection and
Repair. Clean all parts in a cleaning solvent. Inspect
the threads for damage. Inspect the control mounting
bracket and shutter for bends, cracks, or distortion.
Straighten any bends, if possible. Replace all damaged
parts.
d. Shutter Installation.
Reverse the removal
procedures in b above.
e. Control Reassembly and Installation. Reverse
the procedure in a above.
f. Adjustment. If the shutter fails to open or close
properly loosen one of the nuts (7, fig. 4-67) and turn
1.
2.
3.
4.
5.
6.
Door
Control
Cotter pin
Washer
Shutter arm
Control rod
7.
8.
9.
10.
11.
Nut
Control arm
Bracket
Lockwasher
Capscrew
Figure 4-67. Rear door shutter control removal.
4-73
TM 5-3655-210-12
(1) Disconnect the control cable from behind the
shutter control (9, fig. 4-68) by loosening the setscrew
securing the cable in position.
(2) Remove the three nuts, lockwashers, and
machine screws (8) securing the control assembly (9) to
the bracket (7). Remove the control.
4-61. Engine Shutter and Control Rod
Repair and replacement procedures are similar to
those given in the instructions above for the rear door
shutter and control rod.
4-62. Refrigeration Shutter Control
a. Control Removal.
TS 024595
1. Expansion valve adjusting screw
2. Expansion valve
3. Low pressure gage line valve, conversion
4. Low pressure gage line valve, storage
5. Bleeder valve for carbon dioxide, conversion
6. Bleeder valve for carbon dioxide, storage
7. Shutter control mounting bracket
8. Machine screw
9. Shutter control
10. Capscrew
11.
12.
13.
14.
15.
16.
17.
18.
19.
Relief valve for carbon dioxide, storage
Relief valve for carbon dioxide, storage
Safety vent switching valve, storage
Safety relief valve, transfer pump
High pressure gage line valve, conversion
High pressure gage line valve, storage '
Relief valve for carbon dioxide, conversion
Safety vent switching valve, conversion
Relief valve for carbon dioxide, conversion
Figure 4-68. Power compartment valves and controls.
4-74
TM 5-3655-210-12
(3) Remove the four capscrews (10)
lockwashers securing the bracket to the wall.
Remove the bracket.
WARNING
Dry cleaning solvent, P-D-680 or P-S-661,
used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact. Do
not use near open flame or excessive
heat. Flash point of solvent is 100F.138F. (38C.-59C.).
(8) Take a firm grip on the flywheel (2), pull
outward and at the same time strike the end of the
flywheel nut (9) with a babbitt hammer, loosening the
flywheel from the tapered crankshaft.
(9) Remove the nut (9) and lockwasher (8) and
slide the flywheel from the crankshaft.
(10) Remove the woodruff key from the
crankshaft.
(11) Remove the battery ground lead (2, fig.449) from the battery.
(12) Remove the nut (17, fig. 4-39) from the
solenoid (26) releasing the battery lead (10). Remove
the regulator lead wire (20).
(13) Remove the nut (21), releasing the switch
lead (20) and the automatic choke lead (22).
(14) Remove the nut (10, fig. 4-50) and
lockwasher securing the starter lead (16) to the solenoid
(11) and remove the lead.
(15) Remove the nut (18) and lockwasher
securing the lead (16) to the starter (17).
(16) Remove the two machine screws (12) and
lockwashers securing the solenoid (11) to the shroud (9).
Lift off the solenoid.
(17) Remove the two capscrews (20) and
lockwashers (21) securing the starter bracket (19) to the
crankcase (22). Remove the bracket from the starter.
(18) Remove the three capscrews (15) and
lockwashers (14) securing the starter (17) to the timing
gear plate (13). Remove the starter from the plate.
(19) Remove
the three capscrews and
lockwashers (7), and capscrews securing the bracket (6)
to the air shroud (9) and remove the bracket.
WARNING
Dry cleaning solvent, P-D-680 or P-S-661,
used to clean parts is potentially
dangerous to personnel and property.
Use in a well ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or excessive
heat. Flash point of solvent is 100F.138F. (38C.-59C.).
and
b. Cleaning, Inspection and Repair. Clean all parts
in a cleaning solvent. Inspect the mounting bracket for
breaks, bends, or cracks.
Repair or replace as
necessary. Inspect for damaged threads, bent, broken,
or distorted cable casing and cable.
Replace all
damaged parts.
c. Installation. Reverse the removal procedure.
4-63. Flywheel
a. Removal
(1) Remove the four machine screws (7, fig. 439) and lockwashers (8). Remove the cover (6).
(2) Loosen the flywheel nut (9, fig. 4-41) two or
three threads.
(3) Take a firm grip on the flywheel (2), pull
outward and at the same time strike the end of the
flywheel nut (9) with a babbitt hammer, loosening the
flywheel from the tapered crankshaft.
(4) Remove the nut (9) and lockwasher (8) and
slide the flywheel from the crankshaft.
(5) Remove the woodruff key from the
crankshaft.
b. Installation. Reverse the removal procedure.
4-64. Engine Shrouding
a. Removal and Disassembly.
(1) Remove the four coupling nuts (2, fig. 4-40
1) securing the two spark plug cables (3) to the spark
plugs (1) and the magneto (6).
(2) Remove the machine screw (5), securing
the clip (4) and the spark plug cables to the cowling.
Remove the spark plug cables.
(3) Remove the nine machine screws (5, fig.450) and lockwashers (4), and lift off the cover (1).
(4) Remove the two machine screws (23).
(5) Remove the two machine screws (5) and
lockwasher (4), and lift off the heat deflector and
cylinder shroud.
(6) Remove the four machine screws (7, fig.
4-39) and lockwashers (8). Remove the cover (6).
(7) Loosen the flywheel nut (9, fig. 4-41) two or
three threads.
b. Cleaning, Inspection and Repair. Clean all parts
in a cleaning solvent. Inspect all sheet metal parts for
damage. Bent parts may be straightened and minor
damage repaired.
Replace all badly damaged or
missing parts. Inspect hardware for damaged threads or
any other damage. Replace all damaged parts.
c. Reassembly and Installation.
Reverse the
removal and disassembly procedures.
4-75
TM 5-3655-210-12
Section XV. WHEELS, TIRES, TUBES AND BEARINGS
WARNING
Inflate the tire with the locking-ring down.
4-65. Description
The wheels are demountable, steel, open ventilated
type, complete with rim. The tires are tube-type with
flap.
(7) Install the wheel (fig. 4-70).
4-68. Wheel Bearings and Hubs a. Removal.
a. Removal
(1) Jack up the wheel to be removed.
(2) Remove the ten outer cap nuts (3, fig. 469), and lift off the outer wheel.
(3) Remove the ten inner wheel nuts (4) and
lift off the inner wheel.
4-66. Wheels
a. Removal
(1) Jack up the wheel to be removed.
(2) Remove the ten outer cap nuts (3, fig. 469), and lift off the outer wheel.
(3) Remove the ten inner wheel nuts (4) and
lift off the inner wheel.
b. Installation. Refer to Figure 4-70 and install
wheels.
4-67. Tires and Tubes a. Removal.
a. Removal.
(1) Jack up the wheel to be removed.
(2) Remove the ten outer cap nuts (3, fig. 469), and lift off the outer wheel.
(3) Remove the ten inner wheel nuts (4) and
lift off the inner wheel.
(4) Deflate the tire completely (remove valve
core).
(5) Tap the side ring lightly with a hammer.
(6) Insert a tire tool into the recess of the
locking ring and pry the locking ring out of the groove of
the side ring. Remove the side ring.
(7) Remove the tire and tube from the wheel
rim.
(8) Remove the flap and inner tube from the
tire.
b. Inspection and Repair. Inspect the tire and tube
for breaks and cuts. Remove any foreign matter
imbedded in the tire. Repair tube. Replace tire if
damaged.
c. Installation.
(1) Position the tube in the casing with the
valve stem to the outside.
(2) Position the casing flap in the tire with the
opening over the valve stem. Inspect the tube and flap
to make sure they lap smoothly in the tire.
(3) Place the casing on the wheel making sure
the valve stem is centered in the valve stem opening in
the wheel.
(4) Place the side ring on the wheel and pry it
down so that the split locking ring may be entered.
(5) Wedge the split locking ring into place for
seating.
(6) Inflate the tires to 70 psi (4.921 kg per sq
cm).
1.
2.
3.
4.
5.
6.
7.
Tire
Wheel
Outer cap nut
Inner cap nut
Hub
Bearing cone
Inner retaining nut
8. Retaining ring
9. Outer retaining nut
10. Axle
11. Gasket
12. Hubcap
13. Lockwasher
14. Capscrew
Figure 4-69. Wheel and hub removal.
4-76
TM 5-3655-210-12
Figure 4-70. Wheel mounting details.
(4) Remove the six capscrews(14, fig. 4-69)
and lockwashers (13) securing the hub cap (12) and
gasket (11) to the hub (5) and remove the hub cap and
gasket.
(5) Remove the outer retaining nut (9),
retaining ring (8) and inner retaining nut (7) from the
axle (10).
(6) Pull the hub (5) outwards until the outer
bearing cone (6) rests on the end of the axle. Then
push the hub back and remove the cone.
(7) Remove the hub assembly (5) from the
axle.
(8) Remove the wiper (8, fig. 4-71) from the
axle.
b. Disassembly.
(1) Remove the ten nuts (13, fig. 4-71), and
lockwashers (12) securing the adapter flange (5) to the
brake drum (2) and remove the drum and hub (4) from
the flange (5).
(2) Press the seal (7), bearing (6) and the two
cups (3) from the hub.
WARNING
Dry cleaning solvent, P-D-680 or P-S-661,
used to clean parts is potentially
dangerous to personnel and property. Use
in a well-ventilated area as the fumes are
dangerous if inhaled. Avoid repeated and
prolonged skin contact. Do not use near
open flame or excessive heat. Flash point
of solvent is 100F.-138F. (38C.-59C.)
c. Cleaning, Inspection and Repair. Wash all parts
in a cleaning solvent. Inspect the bolts for damaged
threads. Inspect the bearings, cups, and seal for
excessive wear; replace if damaged. Inspect the drum
and flange for wear or breaks. If grooved or damaged
report to the proper authorities.
d. Reassembly.
Reverse
the
disassembly
procedure.
4-77
TM 5-3655-210-12
1.
2.
3.
4.
5.
Bearing cone
Brake drum
Bearing cup
Hub
Adapter flange
6.
7.
8.
9.
Bearing cone
Seal
Wiper
Shoulder bolt
10.
11.
12.
13.
Shoulder bolt
Clamp,
Lockwasher
Nut
Figure 4-71. Hub and drum assembly, exploded view.
(6) Position the outer bearing cone (6) on the
e. Installation
(1) Make sure all the old grease has been
removed.
(2) Pack the bearings with lubricants; kneading
the lubricant between the inner race and the cage by
hand. Coat the inside of the hub and the axle with
grease to prevent rusting.
(3) Position the rear bearing cone (6, fig. 4-69)
and the grease seal in the hub.
(4) Slide the wiper (8, fig. 4-71) into position
on the axle.
(5) Position the hub (5, fig. 4-69) on the axle,
being careful not to damage the axle threads.
axle.
(7) Install the inner retaining nut (7) and
tighten while turning the wheel until the bearing just
seats. Back off the nut one-third turn so that the wheel
and bearings turn freely.
(8) Position the retaining ring (8) on the axle
(10) and the dowel on the nut(7), and secure with the
outer nut (9).
(9) Position the gasket (11) and hub cap (12)
on the axle and secure with the six lockwashers (13) and
capscrews (14).
Section XVI. BRAKE SYSTEM
apply the brakes. The system includes connections at
the front so the air brake system can be connected to
and operated by the air brake system of the truck or
tractor towing the trailer. Connections are provided also
at the rear of the trailer to permit connecting to a second
trailer. Following are the devices composing the trailer
air brake system with a brief description of the function
of each device.
4-69. Description (See Fig, 4-72)
a. General.
Air brake equipment on trailers
operates the trailer brakes through compressed air in
conjunction with the air brake system on the truck or
tractor towing the trailer. As shown in figure 4-72, trailer
air brake system consists of the air devices necessary to
direct and control the flow of the compressed air and
those necessary to transform the energy of compressed
air into the mechanical force and motion necessary to
4-78
TM 5-3655-210-12
Figure 4-72. Air brake system layout.
4-79
TM 5-3655-210-12
trailer reservoir from escaping through the broken or
disconnected line, and at the same time permits air
pressure in the trailer reservoir to flow to the trailer
brake chambers, applying the brakes.
c. Parking. Disconnecting the trailer from the
tractor will automatically apply the brakes on the trailer.
Do not, however, leave the trailer parked depending on
the air brakes to hold it if there is any danger of it
moving should the air pressure leak off and, the ,brakes
release. In such cases, the wheels must be blocked to
prevent the trailer moving. If the brakes on a trailer
have been applied automatically and it is necessary to
release them without reconnecting the trailer to the truck
or tractor, open the trailer reservoir drain cock. This will
release the air pressure in the trailer brake system and
the brakes will release.
b. Relay-Emergency
Valve.
The
relay
emergency valve relays the braking action from the
truck or tractor and provides an automatic application of
the trailer brakes in the event the trailer breaks away
from the truck or tractor.
c. Actuator. Actuators transform the energy of
compressed air into the mechanical force necessary to
apply the brakes. One actuator is used to operate the
brakes on each wheel.
d. Slack Adjusters. Slack adjusters, on the brake
camshaft, provide a quick and easy method of adjusting
the brakes to compensate for lining wear. One slack
adjuster is used for the brakes on each wheel.
e. Reservoir. The reservoir stores the compressed
air until it is needed for brake operation.
f. Drain Cock. A drain cock at the bottom of the
reservoir permits the draining of condensation, which
normally collects there.
g. Hose Couplings. Hose couplings mounted at
the ends of the service line and the emergency line
provide a means of attaching hose connections from the
truck or tractor air brake system.
h Tubing and Tubing Fittings. Tubing and tubing
fittings connect the air brake devices in the air brake
system.
i. Hose Assemblies. Hose assemblies are used
where it is necessary to' have a flexible air line between
two points of the trailer which change their position in
relation to each other.
4-71. Brake Adjustment
Refer to figure 4-73 and adjust each slack adjuster
so the wheel brake just drags slightly, and the angle
between the push rod and slack adjuster arm is greater
than 90° when brakes are applied, as shown in figure 474.
4-72. Wheel Brake Replacement
a. Jack up trailer and remove wheel and brake
drum.
b. Refer to figure 4-75 and remove items in the
following order:
(1) Brake spring.
(2) Anchor pin retaining rings and spring pins.
(3) Anchor pins and brake shoes.
(4) Cam roller retaining rings and the rollers.
c. Reverse steps a and b above to complete
replacement and adjust brakes as follows: -Refer to
figure 4-73 and adjust each slack-adjuster so the wheel
brake just drags slightly, and the angle between the
push rod and slack adjuster arm is greater than 90°
when brakes are applied, as shown in figure 4-74.
4-70. Operation
a. Normal. The trailer reservoir is kept charged by
compressed air flowing from the tractor reservoir
through the emergency line and through the relayemergency valve to the reservoir on the trailer. When
the brakes are applied compressed air flows from the
brake valve on the tractor through the service line to the
relay-emergency valve. The relay-emergency' valve
then operates to permit air pressure to flow from the
trailer reservoir to the trailer brake chambers, applying
the brakes. If the brakes on the tractor are released the
relay emergency valve permits air pressure in the trailer
brake chambers to escape to atmosphere. The relay
emergency valve always reacts to keep the same air
pressure in the trailer brake chambers as the brake
valve is delivering through the service line. Thus the air
pressure in the trailer brake chambers and the
effectiveness of the trailer brakes are controlled by the
driver operating the brake valve on the towing vehicle.
b. Emergency. In the event the trailer breaks away
from the towing vehicle breaking the emergency line, or
if the emergency line is disconnected, the relayemergency valve operates to prevent air pressure in the
4-73. Slack Adjuster Replacement
a. Refer to figure 4-73 and disconnect push rod
clevis from slack adjuster.
b. Remove retaining ring from camshaft., splined
end and take off slack adjuster.
c. Reverse a and b above to install replacement
slack adjuster, then adjust brakes as follows: Refer to
figure 4-73 and adjust each slack adjuster so the wheel
brake just drags slightly, and the angle between the
push rod and slack adjuster arm is greater than 900
when brakes are applied as shown in figure 4-74.
4-80
TM 5-3655-210-12
Figure 4-73. Axle with brake system parts, removed.
mounting nuts, and washers, and actuator from
mounting flange.
(b) Let the actuator hang free by its hoses and
actuate the tractor protection valve, then drain tractor
reservoir. Vehicle will be held by wheel chocks.
(c) Disconnect hoses from actuator and
remove.
b. Installation.
4-74. Actuator
a. Removal. Block and hold the vehicle by chock
blocks.
(1) To remove the actuator in a locked condition
when the trailer is disconnected.
(a) Completely drain trailer reservoir.
(b) Remove delivery and lock port lines from
actuator (fig. 4-79).
(c) Back off slack adjuster or actuator
mounting nuts until sufficient force has been displaced
to permit removal of the yoke pin from the clevis (fig.
4-78).
(d) Completely remove actuator mounting nuts
and remove actuators.
(2) To remove the safety actuator in an unlocked or
unapplied condition.
(a) With the actuator in the released position
and the tractor and trailer connected, remove yoke pin,
NOTE
Safety actuator must be installed with the
drain slot pointing down.
(1) With shaft in fully released position, mount
actuator to mounting bracket and tighten securely.
(2) Fasten actuator push rod yoke to slack adjuster
with yoke pin. Lock yoke pin with cotter pin.
4-81
TM 5-3655-210-12
d. Leakage Test.
(1) With system pressure up and actuators in
the released position, check drain slot and around push
rod boot with soap solution to detect possible leakage by
the locking piston grommet.
(2) Make and hold a service brake application,
and again check the actuator drain slot for diaphragm
leakage. Continue to hold the service application and
coat around the clamping ring with soap solution to
detect seal leakage. Should leakage be detected at the
clamping ring, tighten the clamping ring nuts evenly but
only enough to stop leakage.
4-75. Trailer Release Valve Replacement
a. Refer to figure 4-72 and disconnect, cap and tag
the lines to the trailer release valve.
b. Unscrew the valve and pipe nipple from the
relay-emergency valve.
c. Reverse steps a. and b. above to install valve.
4-76. Check Valve Replacement
a. Refer to figure 4-72. Disconnect, tag and cap
lines and fittings to check valve.
b. Unscrew and remove check valve from relay
emergency valve.
c. Reverse steps a. and b. above to install.
4-77. Relay Emergency Valve
a. Removal
(1) Block trailer wheels and drain air from
reservoir.
(2) Remove trailer release valve.
(a) Refer to figure 4-72 and disconnect,
cap and tag the lines to the trailer release valve.
(b) Unscrew the valve and pipe nipple
from the relay-emergency valve.
(c) Reverse steps (a) and (b) above to
install valve.
(3) Refer to figure 4-72. Disconnect, cap and
tag lines to valve.
(4) Remove mounting bolts and take valve
from reservoir.
b. Installation. Reverse procedure in a. above
and test as given below.
c. Operating and Leakage Test. Check tractor
dash air gage against' a test gage known to be accurate
prior to performing these tests. 'Connect tractor air lines
to the trailer on which valve is to be tested. Block
wheels or otherwise hold both vehicles by a means other
than air brakes during these tests.
(1) Start these tests with no air pressure in
tractor or trailer air brake system. During the initial
charge of the tractor-trailer air brake system, note that
the trailer brakes are applied as the trailer emergency
Figure 4-74. Slack adjuster, correct travel
(3) Connect air lines to actuators. Take care
that the correct lines are installed in correct port.
(4) Adjust brakes to correct shoe to drum
clearance as follows: Refer to figure 4-73 and adjust
each slack adjuster so the wheel brake just drags
slightly, and the angle between the push rod and slack
adjuster arm is greater than 90° when brakes are
applied, as shown in figure 4-74.
c. Operating Test.
(1) With actuator in the released position,
make several service brake applications and note that
actuator applies and releases properly.
(2) Disconnect trailer emergency line or throw
trailer into emergency by use of tractor protection valve
and observe that the actuator applies. Drain trailer
reservoir and observe that actuator remains applied.
(3) Close trailer reservoir drain and fully
charge trailer air supply. Make and hold a heavy
service application (about 5 seconds). Actuator should
release as service application is released.
4-82
TM 5-3655-210-12
Figure 4-75. Wheel brake assembly
be applied to coverplate, coverplate vent, and exhaust
port of valve to detect possible inlet valve, inlet valve
guide grommet and emergency piston grommet
leakage. A combined leakage as indicated by a oneinch (2.54 cm) soap bubble in not less than 5 seconds is
permissible. No leakage is permissible at pipe plugs or
fittings.
(3) Make and hold a full service brake
application with system reservoir pressure stabilized at
90100 psi (6.327-7.03 kg per sq cm) with engine
stopped. A two minute check should result in no more
than an eight pound pressure drop for the combination
vehicle system.
If this check indicates possible
excessive leakage of valve, soap suds should be
applied to cover plate, cover plate vent, and exhaust
port to detect exhaust valve, valve guide grommet,
line is charged. However, remember that under these
conditions, the trailer emergency line will not be charged
until the tractor pressure increases to the point, of
opening the emergency valve in the tractor protection
valve if installed. Note further that this brake application
is completely released as trailer emergency line
pressure reaches approximately 60-65 psi (4.2184.5695
kg per sq cm).
(2) Fully charge tractor and trailer air brake
systems. Make several service brake applications and
check for prompt braking response at all trailer wheels.
With brakes released and system reservoir pressure
stabilized at 90-100 psi (6.327-7.03 kg per sq cm), with
engine stopped, a two minute check should result in no
more than a six pound pressure drop for the
combination vehicle system. If this check indicates
possible excessive leakage of valve, soap suds should
4-83
TM 5-3655-210-12
b. Disconnect, cap and tag lines and fittings to
item to be replaced, until item is free.
c. Reverse steps a. and b. above to install item
being replaced.
emergency piston grommet, and relay piston grommet
leakage. A combined leakage as indicated by a oneinch (2.54 cm) soap bubble in not less than two seconds
is permissible. Release the service brake application.
(4) With tractor and trailer air brake system
fully charged, move the tractor protection control valve
to "emergency" position or close the emergency line cutout cock on the tractor and uncouple the trailer
emergency line coupling. Note that trailer brakes apply
promptly. Check at valve, and at the emergency line
coupling at the front of the trailer for leakage. No
leakage is permissible at emergency line coupling.
Reconnect and recharge tractor and trailer air brake
system, noting that trailer brakes release at a maximum
of 65 psi (4.5695 kg per sq cm) trailer emergency line
pressure as the trailer air brake system is recharged to
full normal operating pressure.
(5) With tractor and trailer air brake systems
fully charged, stop engine. Reduce pressure by making
a series of at least five brake applications and note that
trailer brakes apply automatically at approximately 45
psi. (3.1635 kg per sq cm) tractor reservoir pressure or
at the automatic emergency setting of the tractor
protection equipment, if installed.
4-79. Reservoir a. Removal.
a. Removal
(1) Block trailer wheels and drain air from
reservoir.
(2) Remove trailer release valve.
(a) Refer to figure 4-72 and disconnect,
cap and tag the lines to the trailer release valve.
(b) Unscrew the valve and pipe nipple
from the relay-emergency valve.
(c) Reverse steps (a) and (b) above to
install valve.
(3) Refer to figure 4-72. Disconnect, cap
and tag lines to valve.
(4) Remove mounting bolts and take
valve from reservoir.
(5) Refer to figure 4-72. Disconnect lines
and remove fittings connected to reservoir.
(6) Remove attaching parts at mounting
brackets and lift off reservoir.
b. Installation. Reverse procedures in a. Above
c. Inspection. Inspect exterior of reservoir for
unpainted areas, and corrosion.
d. Test. Pressure test for leaks, using water
pressure only, at not more than 150 pounds per square
inch (10.545 kg per sq cm).
4-78.
Hose Couplings, Cutout Cocks, Air
Strainers, Replacement
a. Refer to figure 4-72. Open drain cock to drain
air pressure from system.
Section XVII. FRAME
c. Cleaning, Inspection and Repair. Wash all parts
in a cleaning solvent. Inspect the grease fittings and
spring for breaks or damage. Replace if broken or
damaged. Inspect the threads for damage. Replace if
broken or damaged. Inspect the threads for damage,
and repair or replace nuts and capscrews. Inspect the
latch, lock, and pintle hook for breaks or cracks. Weld
minor cracks. Replace parts, if badly damaged. Inspect
the pins for wear or other damage; replace if worn or
damaged excessively.
d. Reassembly. Refer to figure 4-77 and assemble
the pintle hook.
e. Installation. Reverse step a. above.
4-80. Pintle Hook
a. Removal. Remove the nuts, lockwashers and
capscrews (8, fig. 4-76), securing the pintle hook (7) to
the frame, and remove the pintle hook.
b. Disassembly.
Refer to figure 4-77 and
disassemble the pintle hook.
WARNING
Dry cleaning solvent, P-D-680 or P-S-661,
used to clean parts is potentially dangerous
to personnel and property. Use in a wellventilated area as the fumes are dangerous if
inhaled. Avoid repeated and prolonged skin
contact. Do not use near open flame or
excessive heat. Flash point of solvent is
100F.-138F. (38C.-59C.).
4-81. Landing Gear and Braces
a. Removal and Disassembly.
4-84
TM 5-3655-210-12
TS 024603
1 208 v, ac power receptacle
2 Vapor equalizing line
3. Liquid fill line(pump by-pass)
4. 24 v., dc receptacle
5. Liquid fill line
6 Blackout stop and taillight
7. Pintle hook
8 Capscrew
9 Stop and taillight, service
Figure 4-76. Power receptacles, installed view.
(8) Remove the four nuts (4) and lockwashers
(3) securing the mounting bracket to the frame, and
remove the bracket.
(1) Remove the nut (2, fig. 4-78) or (2, fig. 479), lockwasher and capscrew (4), securing the diagonal
brace (3) to the mounting bracket (1).
(2) Remove the nut, lockwasher, and
capscrew (16, fig. 4-80) securing the brace (17) to the
landing jack (21), and slide the brace out through the
power compartment.
(3) Remove the four screws (20), securing the
plate (18) and gasket(19) to the housing, and remove
the plate and gasket.
(4) Remove the nuts, lockwashers, and
capscrews, securing the cross brace (11) to the landing
jacks (21), and remove the brace.
(5) Remove the nut (14), machine bolt (12),
and the two washers (15), securing the foot (13) to the
landing jack, and remove the foot and slide the spacer
from the jack.
(6) Remove the nuts, lockwashers, and
capscrews, securing the crank handle (9) and bracket
(23) to the jack and remove the handle.
(7) Remove the nine nuts (5), lockwashers (6),
and capscrews (22), securing the landing jack to the
mounting bracket (23), and remove the jack.
WARNING
Dry cleaning solvent, P-D-680 or P-S-661,
used to clean parts is potentially dangerous
to personnel and property. Use in a wellventilated area as the fumes are dangerous if
inhaled. Avoid repeated and prolonged skin
contact. Do not use near open flame or
excessive heat. Flash point of solvent is
100F.-138F. (38C.-59C.).
b. Cleaning, Inspection and Repair. Wash all parts
with a cleaning solvent. Inspect the threads for damage,
and replace damaged nuts. and capscrews. Inspect for
cracks, breaks, bends and distortion. Repair minor
breaks by welding, and straighten any bends. Replace
all badly damaged parts.
c. Reassembly and Installation.
Reverse the
procedure in a. above.
4-85
TM 5-3655-210-12
Figure 4-77. Pintle hook, exploded view.
4-86
TM 5-3655-210-12
1.
2.
3.
4.
Bracket
Nut
Brace
Capscrew
5.
6.
7.
8.
Transfer hose (vapor)
Freon tank
Fire extinguisher
Quick release clamp
9.
10.
11.
12.
Figure 4-78. Storage compartment, face view.
4-87
Holder
Transfer hose (liquid)
Cylinder filling hoses
Scales
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
Bracket
Nut
Brace
Capscrew
Transfer hose (vapor)
Freon tank
7.
8.
9.
10.
11.
12.
Fire extinguisher
Quick release clamp
Holder
Transfer hose (liquid)
Cylinder filling hoses
Scale
Figure 4-79. Storage compartment, face view (ser. nos. L-1666-T through L-1688-T).
4-88
TM 5-3655-210-12
1. Shaft support
2. Crankshaft
3. Lockwasher
4. Nut
5. Nut
6. Lockwasher
7. Gear box
8. Fitting
9. Crank assembly
10. Crank holder
11. Cross brace
12. Machine bolt
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Foot
Nut
Washer
Capscrew
Diagonal brace
Plate
Gasket
Screw, 10-32
Landing jack leg
Capscrew
Bracket
Figure 4-80. Landing gear, installed view.
4-89
TM 5-3655-210-12
Section XVIII. SPRINGS
4-82.
are installed, take care to maintain axle alinement
dimensions presented on figure 4-81.
c. Adjustment. Refer to figure 4-81 and adjust
axle spacing as indicated to within 1/16 in. (.1588 cm)
of values given.
Torque Arms
a. Removal. Refer to figure 4-81 and remove the
torque arms.
b. Installation. Refer to figure 4-81 and install the
torque arms. If replacement adjustable arms
Figure 4-81. Torque arm adjustment and removal.
Section XIX. BODY
b. Installation. Position the reflector on the trailer
and secure with the two machine screws.
4-83. Description
The pressure vessel power compartment and
storage compartment are completely inclosed by
aluminum panels. Two access doors are provided in
both the power and storage compartments and the rear
pressure vessel. Access plates are provided to the gas
tank, over each of the four lifting eyes, the front
pressure vessel, and one at the front of the trailer for the
wiring connections. Reflectors are provided at each
corner of the trailer and at the front and rear of the
trailer fenders.
4-85. Power Compartment Door
a. Door Removal. Remove the rivets securing the
door to the housing and lift off the door.
b. Disassembly.
(1) Remove the two cotter pins (20, fig. 4-82)
and washers (19) securing the two rods (1 and 14) to the
lock (15).
(2) Lift the rods from the lock and remove
them through the holes in the door brackets.
(3) Lift the spring (18) from the lock.
(4) Remove the four machine screws (26) and
lockwashers (27) securing the lock to the door (4), and
remove the lock.
4-84. Reflectors
a. Removal. Remove the two machine screws
securing the reflector to the trailer, and remove the
reflector.
4-90
TM 5-3655-210-12
Figure 4-82. Power compartment door, exploded view
1. Rod
2. Lock strip
3. Glass
4. Door
5. Molding
6. Gasket
7. Bracket
8. Retaining ring
9. Pin
10. Handle
11. Shaft
12. Screw, F.H. (4)
13. Screw, F.H. (20) (ser. Nos. L-1475-T through L-1478-T)
13. Screw, F.H. 12) (ser. nos. (L-1666-T through L-1668-T)
4-91
14.
15.
16.
16.
17.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Rod
Lock
Lockwasher, #10
Lockwasher, #10
Machine screw, #10-32
Machine screw, #10-32
Spring
Washer
Cotter pin,
Rod
Bracket
Spring
Cotter pin
Flatwasher
Machine screw
lockwasher,
TM 5-3655-210-12
and cotter pins (20). Assemble and install door holder
assembly.
d. Installation. Position the door on the housing
and secure with the twelve flathead screws (13).
(5) Remove the four flathead screws (12)
securing the handle assembly and gasket (6) to the
door, and lift off the gasket and handle assembly.
(6) Remove the snap ring (8) securing the
shaft (11) in the bracket (7), and remove the shaft and
handle from the bracket.
(7) Using a punch and hammer, remove the
pin (9) securing the handle (10) to the shaft, and slide
the handle from the shaft.
(8) Pull the locking strip (2) securing the glass
(3) from the molding (5).
(9) Remove the glass and molding from the
door.
(10) Remove screws (26) and lockwashers (27),
and remove door holder assembly.
(11) Remove cotter pin (24) and disassemble
door assembly.
4-86. Storage Compartment Door
a. Removal. Remove the ten flathead securing the
door to the housing, and remove the door.
b. Disassembly.
(1) Remove the two nuts (15, fig. 4-88),
lockwashers (12), and machine screws (9) securing the
plate (14) and catch (10) to the door (1), and remove the
plate and catch.
(2) Remove the six machine screws (13) and
lockwashers (12) securing the lock (11) to the door, and
remove the lock.
(3) Remove the three machine screws
(4)securing the handle guide (5) and gasket (3) to the
door, and remove the, guide and gasket.
(4) Remove and disassemble the handle
assembly.
c. Installation. Place the door on the housing and
attach with the ten screws.
d. Reassembly.
(1) Reassemble the handle assembly (6, fig.
4-83) and secure to the door (1).
(2) Position the gasket (3) and guide (5) on the
door and secure with the three machine screws (4).
(3) Position the lock (11) on the door and
secure with the six lockwashers (12) and screws (18).
(4) Position the catch (10) and plate (14) on
the door and secure with the two screws (9),
lockwashers (12) arid nuts (15).
c. Reassembly.
(1) Position the molding (5, fig. 4-82) and
glass (3) in the door (4) and -secure with locking strip,
using a glass installing tool.
(2) Position the handle (10) on the shaft (11)
and secure with the pin (9).
(3) Position the shaft in the bracket (7) and
secure in place with the snap ring (8).
(4) Position the gasket (6) and the bracket on
the door and secure with the four flathead screws (12).
(5) Position the lock (15) on the door and
secure with the four lockwashers (16) and machine
screws (17).
(6) Position the spring (18) and the two rods
(1, 14) on the door and secure with the two washers (19)
4-92
TM 5-3655-210-12
1. Door
2. Flathead screw, 10-32
3 Gasket
4. Machine screw, 10-32
5. Guide
6. Handle assembly
7. Screw, flathead, 10-32
8. Gasket
9. Machine screw, 10-32
10. Catch
11. Lock
12. Lockwasher, No. 10
13. Machine screw, 10-32
14. Plate
15. Nut, 10-32
Figure 4-83. Storage compartment door, exploded view.
4-93
TM 5-3655-210-12
Section XX. REFRIGERATION SYSTEM
driving unit, when the tank pressure exceed the limit of
2953056 psi (20.7385-21.44156 kg per sq. cm). The
driving unit, through a clutch, turns the counter shaft
which, through another clutch, turns the compressor. As
the compressor operates, it draws refrigerant in at the
suction port and discharges it out of discharge port.
b. The flow of refrigerant and the pressure in the
evaporator coil is controlled by the expansion valve.
This valve is a pressure-regulating device which acts to
maintain a constant pressure of approximately 5 psi
(.3515 cm) in the evaporator coil.
When the
compressor reduces the suction pressure
4-87. General
a. A conventional commercial refrigeration unit, in
the power compartment, limits pressure of stored carbon
dioxide to 305 psi (21.4416 kg per sq. cm) in response
to pressure sensitive automatic controls. The system is
shown schematically in figure 4-84. During normal
operation, the driving unit is energized by the associated
tank pressure control switch. When the tank pressure
rises to 305 psi, (21.4415 kg per sq. cm) this switch
closes the circuit to the driving unit. If the unit is
operated manually by either driving unit, the tank
pressure switches are bypassed and do not control
operation of the
1.
2.
3.
4.
5.
6.
7.
Discharge service valve
Condenser
Evaporator coil
Expansion valve
Suction pressure switch (gas and electric)
Receiver
Refrigerant
8. Sight glass
9. Receiver inlet valve
10. Dehydrator
11. Receiver liquid outlet valve
12. Discharge pressure switch (gas and electric)
13. Compressor
14. Suction service valve
Figure 4-84. Refrigeration flow diagram
4-94
TM 5-3655-210-12
The low pressure switches will close again when the
suction pressure rises to 12 psi (.8436 kg per sq. cm).
The high pressure switches will close when the
discharge pressure drops to 210 psi (14.763 kg per sq.
cm). The four compressor pressure switches operate
only when the unit is operated manually by either driving
unit, take care to prevent the suction and discharge
pressures from exceeding the normal limits. Two
pressure gages shall be installed on the compressor,
one on the suction side and one on the discharge side
so that the suction and discharge pressures may be
checked.
4-88. Compressor
Inspect the general condition of the compressor
(fig. 4-85) for cleanliness, freedom from oil leaks and
unusual noises during operation. Keep compressor and
condenser cooling surfaces particularly clean to
maintain full operating efficiency.
4-89. Receiver
Inspect receiver (7, fig. 4-85) for security of
attachment, and general freedom from visible damage
or surface corrosion. Check sight glass (1) for adequate
charge in receiver. To add refrigerant, proceed as
follows:
a. Install a discharge pressure gage in the
discharge service valve.
b. Connect a full freon cylinder to the gage port(3,
fig. 4-85), using a charging hose with dehydrator, and a
vacuum-pressure gage.
c. Before tightening the charging hose connector
at the compressor crack the cylinder valve slightly to
purge air from the hose.
d. Close the suction service valve (2) one turn.
e. Start the compressor, and slowly admit freon
from the supply cylinder until the sight glass appears full
of refrigerant.
CAUTION
If the compressor pounds, or frost forms
on the cylinder head, throttle down the
rate of flow of refrigerant with the freon
cylinder valve.
4-90. Pumping Down the System
NOTE
The refrigerant must be pumped down
into the receiver when the unit is put in
storage, shipped, adding or changing
oil.
a. Remove the valve cap (fig. 4-86) and close the
receiver liquid outlet valve tightly.
b. Remove the plug from the compressor suction
valve (1, fig. 4-87) and install an adapter (2) and
pressure gage, with a range of 30 inches of mercury
(vacuum) -0 to 100 psi (7.03 kg per sq. cm).
to 5 psi (.3515 cm), the expansion valve opens,
admitting liquid refrigerant from the receiver into the
evaporator coil. At this pressure, the liquid refrigerant
will boil at approximately -23.3C. (-010F). Since the
refrigerant is considerably warmer than this when it first
enters the evaporator it begins to absorb heat from its
surroundings, until it and the evaporator coil are cooled
at approximately -23.3 C. (-10F). From this point on
the heat for boiling the refrigerant comes from the
carbon dioxide outside of the evaporator.
The
refrigerant continues to absorb heat until it is entirely
vaporized and at a temperature approximately the same
as that of the carbon dioxide in the tank.
c. While the refrigerant has been boiling and
absorbing heat, it has been moving through the
evaporator coil.
The final condition, when the
refrigerant is entirely boiled away into vapor at the
temperature of the carbon dioxide, is obtained just as
the refrigerant reaches the end of the evaporator coil.
From the evaporator, the refrigerant enters the
compressor where the pressure is raised, to cause
condensation of the vapor and liberation of the absorbed
heat in the condenser. Air removes the heat, and the
refrigerant is liquefied. Thus, the heat removed from
the carbon dioxide is transferred by the refrigerant to the
outside air.
From the condenser, the liquefied
refrigerant flows to the receiver to complete the cycle.
d. When the carbon dioxide has been refrigerated
to the extent that the tank pressure is reduced to 295 psi
(20.7385 kg per sq. cm), the tank pressure switch opens,
breaking the circuit to the driving unit, and the
compressor stops. While the compressor is idle, the
refrigerant in the evaporator coil will warm up to the
temperature of the carbon dioxide in the tank. This
increases the suction pressure of the refrigeration
system to 11 psi (.7733 kg per sq. cm), which holds the
expansion valve entirely closed, until the compressor
starts again.
e. The service values shut off the flow of
refrigerant when service is required on the system. The
sight glass permits operation of the refrigerant flow. The
dehydrator is used to remove moisture from the
refrigerant.
f. Four compressor pressure switches act as a
safety device for the compressor.
Two of these
switches, one for low pressure and one for high
pressure, are connected with the electric motor circuit
and the other two, one for low pressure and one for high
pressure, are connected to the gasoline engine circuit.
The low pressure switches open to stop the electric
motor or the gasoline engine at 0O psi suction pressure.
The high pressure switches open to stop the electric
motor or the gasoline engine at 240 psi (16.872 kg per
sq. cm) discharge pressure.
4-95
TM 5-3655-210-12
c. Operate the refrigeration compressor so that the
refrigerant is pumped from the suction side of the
compressor into the receiver until the suction pressure
drops to 0 psi.
d. Allow the unit to stand for a few minutes; then if
the pressure gage shows a rise above zero, restart the
compressor to get rid of the refrigerant which has come
out of the oil.
e. If removing or opening the condenser, shut off
the receiver inlet valve at the front end of the inlet line
(4). A small amount of refrigerant will probably be lost
unavoidably, whenever the system is opened. This is
not serious as long as the foregoing steps to prevent
major loss of refrigerant are observed.
1.
2.
3.
4.
Refrigerant sight glass
Suction valve
Freon charging port
Suction valve shut-off
5.
6.
7.
8.
Oil level sight glass
Receiver tank inlet line
Receiver
Oil filler plug
Figure 4-85. Refrigeration compressor, installed view.
4-96
TM 5-3655-210-12
1. Strainer bleed-off valve
2. Cylinder filling compressor liquid shut-off valve
3. Liquid equalizing line valve
4. Dehydrator by-pass valve
6. Refrigerator suction valve
6. Transfer pump bleed-off valve
7. Liquid fill line valve thru pump
.8. Receiver tank inlet line
9. Dehydrator
10. Union nut
11. Liquid line shut-off valve, conversion
12. Transfer hose bleed-off valve (thru pump)
13, Cylinder filling valve
14. Tube nut
15. Cylinder fill pressure regulating valve
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Safety relief valve cylinder fill
Union nut
Cylinder filling valve
Transfer hose bleed-off valve
Vapor return valve, conversion
Transfer hose bleed-off valve vapor
Liquid line vapor relief valve
Vapor equalizing line valve
High pressure vapor return valve
Fire protection valve
Vapor return valve, storage
Carburetor priming lever
Stop pin
Liquid fill line valve, by-pass pump
Liquid shut-off valve to cylinder filling compressor
Figure 4-86. CO2, manifolds, installed view.
4-97
TM 5-3655-210-12
1. Suction valve
2. Adapter,
3. Receiver liquid outlet valve
4. Receiver inlet line
5. Lubricating oil sight glass
6 Suction valve shut-off
Figure 4-87. Refrigeration receiver and suction value.
4-98
TM 5-3655-210-12
Section XXI. CLUTCHES AND DRIVE BELTS
NOTE
If the clutch shows a tendency to slip
when load is applied, tighten adjusting
nut as above until there is no slippage.
4-92. Drive Belts
a. General. Power is transmitted from the electric
motor and gasoline engine by V-belts to line shafting,
then from the shaft to the driven unit. Driven units are:
C02, transfer pump; refrigeration compressor; cylinder
filling compressor; generator.
4-91. Clutch Adjustment
a. Loosen the setscrew (11, fig. 4-88) in the
adjustment nut (12).
b. Release the clutch as far as possible.
c. Unscrew the adjusting nut(12) until the clutch
can easily be engaged.
d. Turn the adjusting nut (12) clockwise as far as
possible by hand.
e. Release the clutch and tighten the adjusting nut
1/8 turn.
f. Secure the adjusting screw in this position with
the setscrew (11).
1.
2.
3.
4.
5.
6.
7.
Transfer pump
Adapter
Tube nut
Tube
Union nut
1/3 union
Clutch arm
8. Capscrew
9. Clutch arm
10. Clutch drive ring
11. Setscrew
12.. Adjusting nut
13. Drive belt
14. Frame
Figure 4-88. Clutch adjusting points.
4-99
15.
16.
17.
18.
19.
Capscrew
Line assembly
Safety relief valve
Elbow
Pipe plug
TM 5-3655-210-12
b. Adjustment. All belts are adjusted to a tension
permitting 1-/2 inch (3.81 cm) deflection under firm
thumb pressure midway between pulleys, except the
transfer pump belt, for which 1 inch (2.54 cm)
deflection is specified. All belts are tensioned by
loosening the connected unit on its base, moving it as
required, and tightening the base fasteners to hold the
tension.
Section XXII. CARBON DIOXIDE TRANSFER
AND CYLINDER FILLING SYSTEM
Replace a damaged pump or report to the proper
authority. Inspect the pipes and capscrews for damaged
threads or any other damage. Replace badly damaged
pipe fittings.
c. Installation.
(1) Screw the two elbows (18, fig. 4-88), pipe
plug (19), and adapter (2) into position in the pump (1).
(2) Screw the line (16) and the close nipple
into position in the two elbows.
(3) Screw the two 1/3 unions into position on
the line (16) and nipple.
(4) Screw the safety relief valve (17) into
position on the line (16).
(5) Position the pump assembly (1) on the
frame (14) with the drive belts (13) in position on the
pulley and secure with the four nuts, washers,
lockwashers, and capscrews (15).
(6) Secure the pipes with the two union nuts.
(7) Position the tube (4) on the adapter (2) and
secure with the tube nut (3).
(8) Open valves (4, 11 and 30, fig. 4-86) and
close valve (6).
4-93. Description
The carbon dioxide system (fig. 4-89) through the
use of the transfer pump (30), cylinder filling unit (37),
valving, and clutches is used to perform the various
conversion and storage functions of the unit. This
system consists of the transfer pump, cylinder filling
unit, a liquid level and pressure gage for each tank,
dehydrator, cylinder filling manifold, vapor manifold, and
carbon dioxide manifold.
4-94. Transfer Pump
a. Removal.
(1) Close valves (4, 11 and 30, fig. 4-86)
(2) Open pump bleed-off valve (6).
(3) Unscrew the tube nut (3, fig.
4-88)
securing the tube (4) to the adapter (2).
(4) Unscrew the two union nuts (5).
(5) Slide the drive belt (13) off the pump.
(6) Remove the four capscrews (15), nuts,
washers, and lockwashers, securing the transfer pump
to the frame, and lift out the pump assembly.
(7) Remove the line (16) and the close nipple
from the two elbows (18).
(8) Remove the two elbows, adapter (2), and
pipe plug (19) from the pump assembly.
(9) Remove the two 1/3 unions from the two
pipes.
(10) Remove the safety relief valve (17) from
the line (16).
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-138F. (38C.-59C.).
b. Cleaning, Inspection and Repair. Clean the
pump with a clean cloth dampened in a cleaning
solvent. Wash all other parts in a cleaning solvent.
Inspect the pump for loose bearings, bushings, pulley,
cracks, and leaks. Tighten a loose pulley.
4-95. Dehydrator
a. Removal.
(1) Close valves (4, 7 and 11, fig. 4-86).
(2) Unscrew the two union nuts (10), securing
the-dehydrator assembly (9), and lift the assembly from
the unit.
b. Installation. Reverse procedure in a. above.
4-96. C02 Liquid Manifold
a: Removal.
(1) Remove the carbon 'dioxide from both
vessels.
(2) Remove the two unions (18, fig. 4-90) and
nipples (17) from the manifold, at 3 and 5, figure 4-91.
(3) Loosen the hose nut (6, fig. 4-92) and
remove the hose (5) from the valve (30).
(4) Remove the two nuts (27) and U-bolt (29)
securing the pipe and valve (30) to the bracket (28).
(5) Loosen the tube nut securing the tube (22)
to the valve assembly (25).
4-100
TM 5-3655-210-12
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
1. Tank pressure-control switch (conversion heater)
2. Alarm pressure switch conversion
3. Pressure gage (conversion)
4. Pressure gage (storage)
5. Tank pressure control switch (gasoline engine)
6. Tank pressure control switch (electric motor)
7. Alarm pressure switch (storage)
8. Liquid level gage (storage)
9. Low pressure gage line valve (storage)
10. High pressure gage line valve (storage)
11. Fire valve
12. Conversion pressure vessel
13. Storage pressure vessel
14. Bleeder valve for C02 (storage)
15. Relief valve for C02 (storage
16. Relief valve for C02 (storage
17. Safety vent switching valve (storage)
18. Liquid line shut-off valve (conversion)
19. Bleeder valve for CO2 (conversion)
20. Relief valve for CO2 (conversion)
21. Relief valve for CO2 (conversion)
22. Safety vent switching valve (conversion)
23. Dehydrator
24. Liquid equalizing line valve
25. Vapor relief valve(liquid line)
26. Transfer hose bleed off valve (thru pump)
27. Liquid fill line valve (thru pump)
Dehydrator by-pass valve
Transfer pump bleed-off valve
Transfer pump
Transfer hosebleed-off valve (by-pass pump)
Safety relief valve (transfer pump discharge)
Liquid fill line valve (by-pass pump)
Liquid shut-off valve (storage)
Liquid shut-off valve to cylinder fill compressor
Strainer bleed-off valve
Cylinder filling unit
Cylinder filling hose bleed-off valve
Cylinder filling hose bleed-off valve
Transfer hose bleed-off valve (vapor)
Vapor equalizing line valve
Cylinder filling hose
Cylinder filling valve
Cylinder filling valve
Cylinder filling pressure gage
Pressure regulating valve (cylinder fill)
Vapor return valve (conversion)
Vapor return valve (storage)
High pressure vapor return valve
Safety relief valve cylinder fill
Strainer
High pressure gage line valve (conversion)
Low pressure gage line valve (conversion)
Liquid level gage conversion
Figure 4-89. Schematic piping diagram.
4-101
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
Valve
Tee assembly
2/3 union
Valve
Nipple
Cross assembly
Nut
Handle
9. Lockwasher
10. Flatwasher
11. Bracket
12. Valve (3) (includes items (7) and (8)
13. Adapter
14. Cross assembly
15. U-bolt
16. Elbow assembly adapter
17. Nipple
18: 1/3 union
19. Cap (2)
20. Nipple
21. Elbow assembly
22. Elbow assembly adapter
Figure 4-90. CO2, liquid manifold, exploded view.
c. Cleaning, Inspection and Repair. Wash all parts
in a cleaning solvent. Inspect the valves for loose nuts,
damaged threads, or any other damage. Tighten loose
nuts and replace damaged valves. Inspect for broken
pipes and fittings or damaged threads. Replace broken
pipes and fittings.
d. Reassembly.
Refer to figure 4-90 and
reassemble the manifold.
e. Installation.
Reverse the procedures in a.
above.
4-97. Carbon Dioxide Vapor Manifold
a. Removal.
(1) Empty the pressure vessels.
(2) Remove the liquid manifold.
(3) Remove the 1/3 union (13, fig. 4-94) and
nipple (12) from the vapor manifold connection at 2,
figure 4-91.
(4) Remove the tube nut (14, fig.
4-86)
securing the copper tube to the valve (15).
(6) Remove the four nuts (20) bevel washers
(21) and the two U-bolts (18) securing the cylinder filling
manifold to the liquid manifold.
(7) Loosen the five union nuts (10, fig. 4-93)
securing the manifold to the piping and lift out the
manifold assembly.
b. Disassembly.
Refer to figure 4-90 and
disassemble the manifold.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-138F. (38C.-59C).
4-102
TM 5-3655-210-12
1.
2.
3.
4.
5.
208 v, ac power receptacle
Vapor equalizing line
Liquid fill line (pump by-pass)
24 v, dc receptacle
Liquid fill line
6.
7.
8.
9.
Blackout stop and taillight
Pintle hook
Capscrew
Stop and taillight, service
Figure 4-91. Power receptacles, installed view.
(5) Unscrew the two union nuts (17), securing
the vapor manifold, and lift out the assembly.
b. Disassembly.
Refer to figure 4-94 and
disassemble the manifold.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-138F. (38C.-59C.).
c. Cleaning, Inspection and Repair. Wash all parts
in a cleaning solvent. Inspect the valves for loose nuts,
damaged threads, or any other damage. Tighten loose
nuts and replace damaged valves. Inspect for broken
pipes and fittings or damaged threads. Replace broken
pipes and fittings.
d. Reassembly.
Refer to figure 4-94 and
reassemble the manifold.
e. Installation. Reverse the procedure in a above.
4-98. Cylinder Filling Manifold
a. Removal.
(1) Empty the pressure vessels.
(2) Remove the two unions (18, fig. 4-90) and
nipples (17) from the manifold, at 3 and 5, figure 4-91.
(3) Loosen the hose nut(6, fig. 4-92) and
remove the hose (5) from the valve (30).
(4) Remove the two nuts (27) and U-bolt (29)
securing the pipe and valve (30) to the bracket (28).
(5) Loosen the tube nut securing the tube (22)
to the valve assembly (25).
(6) Remove the four nuts (20) bevel washers
(21) and the two U-bolts (18) securing the cylinder filling
manifold to the liquid manifold.
(7) Loosen the five unions nuts (10, fig. 4-93),
securing the manifold to the piping and lift out the
manifold assembly.
(8) Remove the 1/3 union (13, fig. 4-94) and
nipple (12) from the vapor manifold connection at 2,
figure 4-91.
(9) Remove the tube nut (14, fig.
4-93)
securing the copper tube to the valve (15).
(10) Unscrew the two union nuts (17), securing
the vapor manifold, and lift out the assembly.
(11) Remove the hose(3, fig. 4-95) from the
pipe (12) by unscrewing the hose nut (10).
4-103
TM 5-3655-210-12
Figure 4-92. Clutch controls, installed view.
4-104
TM 5-3655-210-12
1. Strainer
2. Street elbow
3. Pipe nipple
4. Union nut
5. Hose
6. Hose nut
7. Transfer pump clutch shifter
8. Cylinder filling compressor clutch shifter
9. Refrigeration compressor clutch shifter
10. Strainer bleed off valve
11. Tube nut
12. Bleed off tube strainer
13. Refrigeration compressor
14. Capscrew
15. Nut
16. Lockwasher
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Bevel washer
U-bolt
Frame
Nut
Bevel washer
Transfer pump bleed off tube
Bracket
Lockwasher
Transfer pump bleed off valve
Cylinder filling compressor
Nut
Bracket
U-bolt
Liquid shut-off valve cylinder fill compressor
Coupling
Cylinder filling pressure gage.
1. Strainer bleed-off valve
2. Cylinder filling compressor liquid shut-off valve
3. Liquid.
4. Dehydrator by-pass valve
5. Refrigerator suction valve
6. Transfer pump bleed-off valve
7. Liquid fill line valve thru pump
8. Receiver tank inlet line
9. Dehydrator
10. Union nut
11. Liquid line shut-off valve, conversion
12. Transfer hose bleed-off valve (thru pump)
13. Cylinder filling valve
14. Tube nut
15. Cylinder fill pressure regulating valve
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Safety relief valve cylinder fill
Union nut
Cylinder filling valve
Transfer hose vapor return valve
Vapor return valve, conversion
Transfer hose bleed-off valve vapor
Liquid line vapor relief valve
Vapor equalizing line valve
High pressure vapor return valve
Fire protection valve
Vapor return valve, storage
Carburetor priming lever
Stop pin
Liquid fill line valve, by-pass pump
Liquid shut-off valve to cylinder filling compressor
Figure 4-93. CO2 manifolds, installed view.
4-105
TM 5-3655-210-12
1.
2.
3.
4.
5.
Valve
Valve (3)
Nipple
Elbow, and tee assembly
2/3 union
6. Relief valve
7. Nipple
8. Tee assembly
9. Valve
10. Nipple
11.
12.
13.
14.
15.
Elbow assembly adapter
Nipple
1/3 union
Cap
Adapter
Figure 4-94. CO2 vapor manifold, exploded view.
(12) Unscrew the pipe (12) from the cylinder
filling manifold and lift the manifold from the assembly.
b. Disassembly.
Refer to figure 4-96' and
disassemble the manifold.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
c. Cleaning, Inspection and Repair. Wash all parts
in a cleaning solvent. Inspect the valves, frangible disc
gage, and washer for any type of damage and replace if
necessary. Inspect the welds for breaks or cracks and
repair if necessary. Replace all fittings which have
damaged threads.
d. Reassembly.
Refer to figure 4-96, and
reassemble the manifold.
4-99. CO2 Liquid Level Gases
a. Removal.
(1) Close the valves (3, 4, 15, 16, fig. 4-97).
(2) Loosen the hose nut (4, fig. 4-98) slightly
to relieve the pressure, then loosen entirely, and remove
the hose (3).
(3) Unscrew the tube nut (10) securing the
tube (11 or 21) depending on which gage is being
removed.
(4) Remove the adapter (9), elbow (15),
bushing (14), and nipple (13) from the gage.
(5) Remove the four machine screws(12)
securing the gage to the panel, and remove the gage.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
4-106
TM 5-3655-210-12
1. Generator drive belt
2. Jack shaft drive pulley
3. Hose
4. Cylinder filling unit drive belt
5. Clutch
6. Valve cap
7. Cylinder head plug adapter
8. Cylinder head
9. Nipple
10. Packing retainer nut
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Adapter
Pipe
Capscrew
Adjusting bracket
Wiring harness
Belt tightener stud
Nut
Mounting bracket
Wiring harness
Regulator
Figure 4-95. Generator and regulator removal.
4-107
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
Gage
Street elbow
Dampener
Adapter bushing
Pipe
Manifold assembly
Elbow
8. Tube nut
9. Tube
10. Cylinder filling valve
11. Nut
12. Lockwasher
13. U-bolt
14. Chain
15.
16.
17.
18.
19.
20.
21.
Cotter pin
Cap
Valve, pressure regulating
Adapter
Washer
Frangible disc
Cap
22.
23.
24.
25.
26.
27.
28.
U-bolt
Bracket
Lockwasher
Nut
Coupling
Screw
Handle
Figure 4-96. Cylinder filling manifold, exploded view.
(2) Loosen the tube nut (10, fig. 4-98) on the
gage to be adjusted, to relieve the pressure.
(3) After waiting for several minutes for the
indicator to stabilize, tap the face of the gage slightly to
be sure the indicator is not sticking.
(4) Turn the adjusting screw until the "zero"
mark is directly under the indicator.
(5) Tighten the tube nut.
(6) Turn on the valves.
Note
The trailer must be level for the gages
to read correctly.
b. Cleaning, Inspection and Repair. Clean the
gage with a cloth dampened in a cleaning solvent.
Wash all other parts in a cleaning solvent. Inspect for a
broken or damaged gage.
Replace if broken or
damaged. Inspect for damaged or cracked fittings and
damaged threads and replace all damaged parts.
c. Installation. Reverse the procedure in a. above.
d. Adjustment.
(1) Shutoff the valves (3,4,15 and 16, fig. 497).
4-108
TM 5-3655-210-12
1. Expansion valve adjusting screw
2. Expansion valve
3. Low pressure gage line valve, conversion
4. Low pressure gage line valve, storage
5. Bleeder valve for carbon dioxide, conversion
6. Bleeder valve for carbon dioxide, storage
7. Shutter control mounting bracket
8. Machine screw
9. Shutter control
10. Capscrew
11.
12.
13.
14.
15.
16.
17.
18.
19.
Relief valve for carbon dioxide, storage
Relief valve for carbon dioxide, storage
Safety vent switching valve, storage
Safety relief valve, transfer pump
High pressure gage line, valve, conversion
High pressure gage line valve, storage
Relief valve for carbon dioxide, conversion
Safety vent switching valve, conversion
Relief valve for carbon dioxide, conversion
Figure 4-97. Power compartment valves and controls.
4-100. C02 Tank Pressure Gages
a. Removal.
(1) Shut off the four valves (3, 4, 15 and 16,
fig. 4-97).
(2) Remove the hose nut (4, fig. 4-98) and
tube nut (10) securing the hose (3) and tube (11) to that
gage.
(3) Remove the elbow (5) and adapter (9) from
the tee.
(4) Remove the tee from the gage.
(5) Remove the machine screws securing the
gage to the panel and remove the gage.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F
(38C.-59C.).
4-109
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
Gage panel
Level gage
Hose
Hose nut
Elbow
Nut, 8-32
Tee
8. Pressure gage
9. Adapter
10. Tube nut
11. Tube
12. Screw
13. Nipple
14. Bushing
15.
16.
17.
18.
19.
20.
21.
Elbow
Alarm bell cut-out switch, storage vessel
Alarm bell cut-out switch, conversion vessel
Dome light switch
Nut, 8-32
Elbow
Tube
Figure 4-98. Gage panel, rear view.
4-110
TM 5-3655-210-12
b. Cleaning, Inspection and Repair. Clean the
gage with a cloth dampened in a cleaning solvent.
Wash all other parts in a cleaning solvent. Inspect for a
broken or damaged gage.
Replace if broken or
damaged. Inspect for damaged or cracked fittings and
damaged threads and replace all damaged parts.
c. Installation.
Remove the procedure in a.
above.
4-101. Cylinder Filling Compressor
The cylinder filling unit draws the carbon dioxide in from
the storage tank at 300 psi (21.09 kg per sq cm) and
raises the pressure to approximately 600 to 1,000 psi
(42.18-70.3 kg per sq cm) for charging the cylinders,
800 psi (56.24 kg per sq cm) is normal. The unit is
operated through a clutch engagement on the
countershaft.
4-102. Lines And Fittings
a. Removal.
(1) Make sure valves(2, 24, fig. 4-93) are
closed.
(2) Unscrew the hose nut (6, fig.
4-92)
securing the hose (5) to the elbow (2) and remove the
hose from the valve (30).
(3) Remove the rear hose (5) from the cylinder
filling manifold pipe.
(4) Unscrew the nipple (3) from the elbow (2).
(5) Remove the elbow (2) from the strainer (1).
(6) On serial nos. L-1475-T through L-1478-T
units, unscrew the union nut (4) releasing the 1/3 union
and the elbow, and remove the 1/3 union from the
elbow.
(7) On serial nos. L-1475-T through L-1478-T
units, unscrew the elbow and 2/3 union from the
compressor, and remove the union and nipple from the
elbow.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
b. Cleaning, Inspection and Repair. Wash all the
parts in a cleaning solvent. Inspect the hoses and
fittings for cracks, breaks, or damaged threads.
Replace all damaged parts.
c. Installation.
Reverse the procedure in a.
above.
4-103. Strainer
a. Removal.
(1) Make sure valves(2, 24, fig. 4-93) are
closed.
(2) Remove the strainer intake line and
fittings.
(3) Unscrew the tube nut (11, fig.
4-92)
securing the tube (12) to the valve (10) and remove the
tube.
(4) Remove the strainer (1) and nipple from
the compressor.
b. Disassembly.
Refer to figure 4-99 and
disassemble strainer.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged ski' contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
c. Cleaning and Inspection. Wash all parts in a
cleaning solvent. Clean the gasket mating surfaces
thoroughly. Inspect for cracks, leaks, or damaged
threads. Inspect the screen for tears, holes, or other
damage and replace strainer if necessary.
d. Reassembly. Reverse procedure in b. above.
e. Installation. Reverse procedures in a. above.
4-104. Suction And Discharge Valves
a. Suction Valve Removal.
(1) Make sure valves (2,24, fig.4-93) are
closed.
(2) Unscrew the hose nut (6, fig.
4-92)
securing the hose (5) to the elbow (2) and remove the
hose from the valve (30).
(3) Remove the rear hose (5) from the cylinder
filling manifold pipe.
(4) Unscrew the nipple (3) from the elbow (2).
(5) Remove the elbow (2) from the strainer (1).
(6) Unscrew the union nut (4) releasing the 1/3
union and the elbow, and remove the 1/3 union from the
elbow.
(7) Unscrew the tube nut (11) securing the
tube (12) to the valve (10) and remove the tube.
(8) Remove the strainer (1) and nipple from
the compressor.
(9) Remove the valve cap (6, fig. 4-95).
(10) Pull the outer gasket, valve, and the inner
gasket from the cylinder head (8) and discard the
gaskets. Replace the new gaskets.
b. Discharge Valve Removal.
(1) Make sure valves (2, 24, fig. 4-93) are
closed.
4-111
TM 5-3655-210-12
(4) Unscrew the nipple (3) from the elbow (2).,
(5) Remove the elbow (2) from the strainer (1).
(6) Unscrew the union nut (4) releasing the 1/3
union and the elbow, and remove the 1/3 union from the
elbow.
(7) Unscrew the elbow and 2/3 union from the
compressor, and remove the union and nipple from the
elbow.
(8) Remove the valve cap (6, fig. 4-95) from
the adapter (7).
(9) Lift the outer gasket, valve, and the inner
gasket from the adapter (7) and discard the gaskets.
Replace the new gaskets.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid
repeated
and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
c. Cleaning, Inspection and Repair. Wash all the
parts in a cleaning solvent and dry thoroughly with,
compressed air. Inspect the valves to see if they have
been seated properly; if not, replace the valves.
NOTE
Loss of capacity in the cylinder filling
unit is usually due to faulty valve
operation.
d. Suction Valve Installation. Reverse procedures
in a. above.
e Discharge Valve Installation.
Reverse
procedures in b. above.
4-105. Packing Nut Adjustment
Leakage past the packing retainer nut (10. fig. 495) is usually shown by excessive spurts of snow past
the packing nut. This can be corrected by tightening the
packing nut. It is important that the packing is not too
tight, as this will cause undue wear. If adjusting the
packing nut does not stop the leak, report the deficiency
to the proper authority.
Figure 4-99. Strainer, exploded view.
(2) Unscrew the hose nut (6, fig.
4-92)
securing the hose (5) to the elbow (2) and remove the
hose from the valve (30).
(3) Remove the rear hose (5) from the cylinder
filling manifold pipe.
4-112
TM 5-3655-210-12
Section XXIII. CONVERSION HEATER
pressure gage, solenoid valve, and a fuel manifold. The
heater is operated on 24-volt DC from' the electrical
system of the vehicle. It is hooked to the heater control
panel (8, fig. 4-102) by disconnect plug (10). Power is
transmitted through the control panel to the water pump
(9), ignition unit (6), water temperature thermostat (1),
water temperature limit switch (2), stack temperature
switch (3), and the fuel pump and blower motor (5). The
current to the spark plug (7) in turn comes from the
ignition unit. An expansion tank (4, fig. 4-100) is the
reservoir for the heater fluid.
4-106. Description
The conversion heater speeds the process of
converting solid carbon dioxide into liquid carbon
dioxide in the conversion pressure vessel. The heater is
mounted in the storage compartment (fig. 4-100) and
can be operated manually by a toggle switch (9, fig. 4101) on the DC control panel. The heater is normally
operated automatically, except when used in
conjunction with the space heater in the power
compartment. Heat is produced by burning gasoline
supplied by a motor driven fuel pump. The fuel system
also contains a fuel filter
1. Filler cap
2. Union nut
8. Sight glass
4. Expansion tank
5. Saddle stand clamp
6. Capscrew
7. Nut
8. Anti-freeze bleed-off petcock
9. Compartment heater diversion valve
10. Tube nut
11.
12.
14.
15.
16.
17.
18.
19.
20.
Conversion heater diversion valve
Anti-freeze bleed-off petcock,
Gasket
Capscrew
Spark plug
Coupling nut
Tube nut
Fuel pressure gage
Vibrator switch
Figure 4-100. Conversion heater, installed view.
4-113
21.
22.
23.
24.
25.
26.
27.
28.
Heater fluid line
Saddle stand
Drain cock
1-3 union
1/3 union
Nipple
Elbow
Nipple
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
Ammeter
Electrical control switch (tractor or trailer)
Circuit breaker
Fuel indicator
Gage lines operating lights
Storage vessel gage line switch
Con version vessel gage line switch
Compartment heater control switch
9. Conversion heater control switch
10. Conversion heater failure light
11. Gasoline engine manual stop switch
12. Gasoline engine manual starter switch
13. Gasoline engine control switch for
automatic or manual
14. Gasoline engine failure light
15. Engine control panel
Figure 4-101. Engine control panel.
the sight glass (3).
(4) Remove the two 1/3 unions (24) and the
drain cock (23).
(5) Remove the two 2/3 unions (25).
(6) Remove the two nipples (26), elbows (27),
and nipples (28) from the tank (4).
(7) Remove the four nuts (7), lockwashers,
and capscrews (6), two clamps (5).
4-107. Expansion Tank And Fluid Lines
a. Removal.
(1) Drain the coolant into a container by
removing the cap from the drain nipple (15, fig. 4-103)
under the unit. Remove the nipple.
(2) Unscrew the two tube nuts (10, fig. 4-100)
securing the line (21) and remove the line.
(3) Unscrew the two union nuts (2) and
remove
4-114
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7. Spark plug
8. Control panel
9. Water pump
10. Disconnect plug
11. Disconnect plug
Water temperature thermostat
Water temperature limit switch
Stack temperature switch
Solenoid valve
Pump and blower motor
Ignition unit
Figure 4-102. Heater wiring diagram.
damaged threads. Replace cracked or badly damaged
pipes and fittings. Inspect the sight glass for broken
glass or any other damage. Replace a damaged sight
glass assembly. Test the tank for breaks by filling with
water. Repair leaks by brazing.
c. Reassembly.
Reverse the procedure in a.
above.
4-108. Water Manifold
a. Removal.
(1) Drain the system.
(2) Remove the limit switch cover (27, fig. 4103).
(3) Tag and remove the leads.
(4) Uncouple the lead (20 to the pump motor
(19).
(5) Remove the two lines ( and 29).
(8) Remove the tee (14, fig. 4-103), and
nipple (13).
WARNING
Dry cleaning solvent, P-D-680 or P-D661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
b. Cleaning and Inspection. Clean the tank with a
cloth dampened in a cleaning solvent. Wash all other
parts in a cleaning solvent and dry thoroughly. Inspect
the pipes and fittings for cracks, leaks, or
4-115
TM 5-3655-210-12
1. Coolant line
2. Machine screw
3. Machine screw
4. Dome light base
5. Dome light lens
6. Housing
7. Coolant line
8. Tube nut
9. Bracket
10. Connector
11. Coolant line
12. Pipe plug
13. Nipple
14. Tee
15. Nipple
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Pipe union
Saddle stand
Capscrew
Coolant pump
Coolant pump lead
Wiring harness
U-bolt
Bracket
Nut
Machine screw
Limit switch
Limit switch cover
Lockwasher
Coolant line
Figure 4-103. Heater compartment and dome lights, installed view.
(6) Unscrew the two tube nuts (10, fig. 4-100)
securing the line (21) and remove the line.
(7) Remove the two capscrews (15) securing
the
front end of the manifold to the heater and the two
capscrews (15) securing the rear end and lift out the
manifold and the two gaskets (14). Discard the gaskets.
4-116
TM 5-3655-210-12
and solder cracks. Replace the gasket if worn or
damaged. Inspect for damaged threads and replace
damaged parts.
c. Installation. Reverse procedures in a. above.
4-110. Fuel Pump
a. Removal.
(1) Pull the disconnect plug (31, fig. 4-106).
(2) Remove the four capscrews (11) that
secure the plate (13) to the combustion head.
(3) Remove the four machine screws and
washers securing the blower (15) to the pump (10) and
slide the blower (15), plate (13), and gasket (14) out and
away from the heater.
(4) Remove the two fuel tubes (6 and 7).
(5) Disconnect and tag the taped leads (19).
(6) Remove the four capscrews (24) securing
the pump (10). Remove the fuel pump from the heater.
b. Disassembly.
Refer to figure 4-107 and
disassemble the fuel pump.
c. Installation. Reverse procedures in a. above.
4-111. Fuel Manifold And Filter Assembly
a. Fuel Manifold Removal.
(1) Disconnect the plug (31, fig. 4-106).
(2) Remove the wire to the solenoid valve (23)
(3) Loosen the two tube nuts (18, fig. 4-100)
and remove the tubes.
(4) Remove the three fuel tubes (6,7, and 22,
fig. 4-106) by unscrewing the six tube nuts (9) and
lifting out.
(5) Remove the fuel tube (17, fig. 4-108).
(6) Remove the two screws (8, fig. 4-106),
nuts, and washers securing the fuel filter bracket.
(7) Remove the four nuts, washers, and
capscrews (24) securing the manifold to the pump
assembly (10).
(8) Remove
the
two
capscrews
and
lockwashers securing the manifold to the base.
Remove the manifold.
b. Fuel Filter Disassembly. Refer to figure 4-109
and disassemble the fuel filter.
c. Manifold and Solenoid Disassembly. Refer to
figure 4-110 and disassemble the manifold and
solenoid.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
b. Disassembly. Refer to figure 4-104 or 4-105
and disassemble the manifold.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
c. Cleaning, Inspection and Repair. Wipe off the
motor and limit switch with a cloth dampened in a
cleaning solvent. Wash all other parts in a solvent.
Inspect the brushes for wear and replace if worn
excessively. Inspect the pump, motor, and switch for
cracks, breaks, or any other damage. Replace if
damaged. Inspect the pipes and fittings for breaks,
leaks and damaged thread. Replace all excessively
damaged parts.
d. Refer to figure 4-104 and 4-105 and reassemble
the manifold, installing new gaskets at all points where
they are needed.
e. Installation.
Reverse the procedures in a.
above, installing new gaskets (14, fig. 4-100).
4-109. Blower
a. Removal.
(1) Pull the disconnect plug (30, fig. 4-106).
(2) Remove the four capscrews (11) that
secure the plate (13) to the combustion head.
(3) Remove the four machine screws and
washers securing the blower (15) to the pump (10) and
slide the blower (15), plate (13), and gasket (14) out and
away from the heater.
(4) Remove the two fuel tubes (6 and 7, fig. 4106).
(5) Disconnect and tag the taped leads (19).
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous
to
personnel
and
property. Use in a well-ventilated
area as the fumes are dangerous if
inhaled.
Avoid repeated and
prolonged skin contact. Do not use
near open flame or excessive heat.
Flash point of solvent is 100F.-138F.
(38C.-59C.).
b. Cleaning, Inspection and Repair. Wash all parts
in a cleaning solvent, inspect for bent, cracked, or
broken housing or fan. Straighten bent fins
4-117
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
Valve handle
Setscrew
Nipple
Tube
Elbow, adapter
Nipple
Valve
Plate
10.
11.
12.
13.
14.
15.
16.
17.
Screw, flat head
Nut,
Washer
Washer
Nipple
Drain cock
Elbow
Street elbow
18.
19.
20.
21.
22.
23.
24.
25.
Nipple
Nut
Lockwasher
Flanged coupling
Gasket
U-Bolt
Nut
Nipple
26.
27.
28.
29.
30.
31.
32.
33.
Tee
Adapter
Tube
Bushing
Elbow, adapter
Tube
Pump assembly
Adapter plate
34.
35.
36.
37.
38.
39.
40.
41.
Capscrew
Machine screw
Lockwasher
Guard
Cap
Brush
Nipple
Lead
Figure 4-104. water manifold, exploded view. (ser. nos. L1475-T through L-1478-T).
4-118
TM 5-3655-210-12
1. Valve handle
2. Setscrew
3. Nipple
4. Tee
5. Adapter
6. Tube
7. Nipple
8. Union
9. Tube
10. Elbow, adapter
11. Nipple
12. Valve
13. Plate
14. Limit switch
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Screw, flathead
Nut
Lockwasher
Nipple cock
Drain cock
Elbow
Elbow, street
Nipple
Nut
Lockwasher
Flanged coupling
Gasket
U-bolt
Nut
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Bushing
Elbow adapter
Nipple
Tube
Pump assembly
Adapter plate
Screw, cap
Screw, machine
Lockwasher, No. 8
Guard
Cap
Brush
Nipple
Lead
Figure 4-105. Water manifold, exploded view (serial nos. L-1666-Tthrough L1668-T).
4-119
TM 5-3655-210-12
1. Wiring harness
2. Capscrew
3. Ignition unit
4. APk plug cable
5. Machine screw
6. Fuel tube
7. Fuel tube
8. Machine screw
9. Tube nut
10. Fuel pump
11. Capscrew
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Lockwasher
Plate
Gasket
Blower
Self-tapping screw
Plate
Blower wheel
Taped lead
Screw
Screw
Fuel tube
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Solenoid valve
Capscrew
Fuel manifold
Fuel g
Thumb screw
Vibrator
Control box
Disconnect plug
Disconnect plug
Switch
Lockwire
Figure 4-106. Blower and fuel pump removal
d. Cleaning, Inspection and Repair. Clean the
upper (magnetic) part of the solenoid valve with a cloth
dampened in a cleaning solvent. Wash all other parts in
a solvent. Replace any part with damaged threads.
Replace a damaged valve or spring. Inspect the
solenoid valve and the pressure gage for any damage
and replace if damaged.
e. Manifold Fuel Filter, Solenoid, Reassembly and
Installation. Reverse the procedure in a. b. and c.
above.
f. Adjustment and Testing.
(1) Check the fuel pressure gage with the
heater in operation. It should read 30 + 3 psi (2.109 +
.2109 kg per sq cm). If the pressure is outside these
limits, remove the adjusting screw (4, fig. 4-110) and
the pressure relief stud (6). Reinstall .the adjusting
screw without the stud so that it plugs the opening and
then operate the pump to flush the valve seat. Clean
and reinstall the stud and adjusting screw in the correct
position.
(2) Adjust the fuel pressure to 30 psi (2.109 kg.
per sq cm) by loosening the locknut (3) and turning the
screw (4).
(3) Check the bypass flow by removing the
fuel line nearest the solenoid valve.
(4) If the pressure cannot be raised to 30 psi
(2.109 kg per sq cm), and there is a good bypass flow,
replace pressure relief stud.
4-120
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Plate
Blower wheel
Machine screw
Housing
Lock washer
Nut
Nut
Cap
Brush
Adapter
11.
12.
13.
14.
15.
16.
17.
18.
19.
Figure 4-107. Blower and fuel pump, exploded view.
4-121
Fuel pump
Machine screw
Washer
Motor
Machine screw
Bracket
Set screw
Washer, No6
Self-tapping screw
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
Water temperature limit switch
Hex nut
Hex nut
Machine screw
Machine screw
Combustion head
Cap screw
8.
9.
10.
11.
12.
13.
14.
Bail
Nozzle assembly
Self-tapping screw
Cover
Cap screw
Nut, No 10
Tube nut
15.
16.
17.
18.
19.
20.
21.
Adapter
Thumb nut
Fuel tube
Gasket
Spark plug
Nut
Cable
Figure 4-108. Fuel line removal.
(5) If the pressure cannot be raised to 30 psi
(2.109 kg per sq. cm) by adjusting the relief stud, and
the bypass flow is unsteady or there is no flow, the fuel
pump is worn and should be replaced.
a. Removal.
(1) Pull the disconnect plug (31, fig. 4-106).
(2) Remove the spark plug cable (21, fig. 4108) by loosening the nut (20).
(3) Unscrew the two tube nuts(14) securing
the fuel tube (17) and remove the tube.
(4) Remove the three cap screws (7) and lock
washers securing the combustion head (6) and gasket to
the heater assembly and lift off the head and gasket.
b. Disassembly.
(1) Remove the spark plug (13, fig. 4-111)
and packing (14) from the head (3).
(2) Loosen the thumbnut (8) and lift the bail
(9) and thumbnut from the head.
NOTE
An air leak can result from the "0" ring
gasket in the filter cover not sealing
properly against the filter body. Check
the fittings with soapy water to detect
leaks.
4-112. Combustion Head
4-122
TM 5-3655-210-12
(5) Remove the nozzle assembly (11) and
adapter (7) from the holder.
(6) Remove the electrode (6) and lock
washer (4) from the head.
(7) Remove the three screws (16) and washer
(15) securing the chamber (1) and gasket (2) to the
head. Remove the gasket and chamber.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-138F. (38C.-59C.).
c. Cleaning, Inspection and Repair. Clean all parts
in a cleaning solvent. Inspect the spark plug and
electrodes. Inspect the plug for cracked or broken
porcelain. Replace the plug if damaged. Inspect for
worn electrodes. Replace ground electrode if worn.
Inspect the spray nozzle for cracks, burrs, broken
screen, or any other damage and replace if damaged.
Inspect for damaged threads and gaskets. Replace all
damaged hardware and gaskets.
1.
2.
3.
4.
5.
6.
7.
8.
Adapter elbow
Bushing
10.
Machine bolt11.
Washer
12.
Filter head 13.
Gasket
14.
Gasket
15.
Element
16.
NOTE
When the spark plug and the ground electrode are
installed, the gap between the two should be 3/16
(0.188) to 1/8 (0.125) inch (.4775 -.3175 cm).
d. Reassembly.
Reverse the disassembly
procedures in b. above to reassemble the combustion
head.
e. Installation. Reverse the removal procedures in
a. to install the combustion head.
f. Spark and Plug Gap Testing
(1) Disconnect the solenoid wire by removing
the machine screw (20, fig. 4-106) and lifting the wire
out of position to shut off the fuel supply.
(2) Remove the fuel tube (17, fig. 4-108).
(3) Remove the head assembly with plug wire
installed.
(4) Start the unit and check the spark for
intensity (it should be a vivid blue in color). Check the
spark plug gap (3/16 (0.188) to 1/8 (0.126) inch (.4775.3175 cm).
(5) Secure the combustion head to the
heater.
(6) Install the fuel tube and solenoid lead.
g. Spray Nozzle Test. Remove the nozzle holder
from the head and with the fuel pump working check the
angle of fuel spray. It should be 600 to 1200 with a
uniform cone. If the spray angle is not
9. Washer
Flat washer
Spring
Body
Machine screw
Clamp
Lock washer
Nut
Figure 4-109. Fuel filter, exploded view.
(3) Remove the nut from the bail.
(4) Lift the nozzle holder (10) and packing
(12) from the head.
4-123
TM 5-3655-210-12
1
2
3
4
5
Cap nut
6
Washer
7
Lock nut
8
Adjusting screw 9
Spring
10
Pressure relief stud
Preformed packing
Manifold
Spacer
Solenoid valve, upper section
11
12
13
14
15
Elbow
Machine screw
Lock washer, No. 10
Solenoid valve, lower section
Elbow
16
17
18
19
20
Adapters
Cap screw
Fuel pressure g
Nipple
Elbow
Figure 4-110. Fuel manifold, exploded view.
correct, clean off the tip and strainer assembly, or
replace the tip and strainer assembly if necessary.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated are as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-138F. (38C.-59C.).
4-113. Water Limit Switch And Thermostat
a. Removal and Disassembly.
(1) Drain the coolant system.
(2) Pull out the disconnect plug (31, fig. 4106).
(3) Tag the leads and remove the two screws
(4, fig. 4-108) securing the leads to the switch to be
removed.
(4) Unscrew the switch (1) from the heater
using two wrenches, with one on the hex part of the
switch and the other on the hex part of the heater pipe.
(5) Remove six screws (5) securing the cover
to the switch and lift off the cover.
b. Cleaning, Inspection and.. Repair. Wipe off the
switch with a cloth dampened in a cleaning solvent.
Inspect the contact points in the switch. Clean the
points if they are dirty, pitted, or burned, using only soft
tissue or fine cloth. Open the points, with the
4-124
TM 5-3655-210-12
1
2
3
4
6
6
Combustion chamber
Gasket
Combustion head
Lock washer
Cap screw
Electrode, ground
7
8
9
10
11
Adapter
Thumbnut
Bail
Nozzle holder
Spray nozzle
12
13
14
15
16
Packing
Spark plug
Packing
Washer, No
10
Machine screw, flat head
(10) Remove the two cap screws (15) securing
the front end of the manifold to the heater and the two
cap screws (15) securing the rear end and lift out the
manifold and the two gaskets (14). Discard the gaskets.
(11) Pull the disconnect plug (31, fig. 4-106).
(12) Remove the four cap screws (11) that
secure the plate (13) to the combustion head.
(13) Remove the four machine screws and
washers securing the blower (15) to the pump (10) and
slide the blower (15), plate (13), and gasket (14) out and
away from the heater.
(14) Remove the two fuel tubes (6 and 7).
(15) Disconnect and tag the taped leads (19).
(16) Remove the four cap screws (24) securing
the pump (10). Remove the fuel pump from the heater.
(17) Remove the wire to the solenoid valve
(23).
(18) Loosen the two tube nuts (18, fig. 4-100)
and remove the tubes.
(19) Remove the three fuel tubes (6, 7, and
22, fig. 4-106) by unscrewing the six tube nuts (9) and
lifting out.
(20) Remove the fuel tube (17, fig. 4-108).
(21) Remove the two screws (8, fig. 4-106),
nuts, and washers securing the fuel filter bracket.
(22) Remove the four nuts, washers, and cap
screws (24) securing the manifold to the pump assembly
(10).
(23) Remove the two cap screws and lock
washers securing the manifold to the base. Remove the
manifold.
(24) Remove the two screws (10, fig. 4-108)
securing the stack switch cover (11) to the stack and
remove the cover.
fingers and insert the tissue or cloth between them.
Permit the points to close and pull the tissue gently from
between the points. Replace the switch if the points are
badly pitted or burnt. Replace the switch if any other
damage is noticed.
NOTE
Do not use point file or emery cloth in
cleaning points.
c. Reassembly and Installation.
Reverse the
removal and disassembly given in a. above.
4-114. Wiring And Ignition Unit
a. Removal
(1) Remove the disconnect plug (31, fig.
4-106).
(2) Tag the leads and remove the two screws
(4, fig. 4-108) securing the leads to the switch to be
removed.
(3) Unscrew the switch (1) from the heater
using two wrenches, with one on the hex part of the
switch and the other on the hex part of the heater pipe.
(4) Remove six screws (5) securing the cover
to the switch and lift off the cover.
(5) Remove the limit switch cover (27, fig.4112).
(6) Tag and remove the leads.
(7) Uncouple the lead (20) to the pump motor
(19).
(8) Remove the two lines (7 and 29).
(9) Unscrew the two tube nuts (10, fig. 4100) ;securing the line (21) and remove the line.
4-125
TM 5-3655-210-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Coolant line
Machine screw
Machine screw
Dome light base
Dome light lens
Housing
Coolant line
Tube nut
Bracket
Connector
Coolant line
Pipe plug
Nipple
Tee
Nipple
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Pipe union
Saddle stand
Cap screw
Coolant pump
Coolant pump lead
Wiring harness
U-bolt
Bracket
Nut
Machine screw
Limit switch
Limit switch cover
Lock washer
Coolant line
Figure 4-112. Heater compartment and dome lights, installed view.
4-126
TM 5-3655-210-12
(25) Tag the leads and remove the two screws
securing the two wires to the stack switch.
(26) Remove the nut (13) securing the ground
lead to the frame.
(27) Remove the two cap screws (12), nuts,
and washers securing the harness to the heater.
(28) Remove the screw securing the wire to
the ignition unit (3, fig. 4-106).
(29) Remove the cap screw (2), nut, and
washer and the two screws (5), nuts, and washers
securing the wiring harness to the heater. Remove the
harness.
(30) Remove the four screws (8), nuts, and
washers securing the ignition unit to the frame. Remove
the ignition unit.
4-115. Power Compartment Heater (Ser. Nos. L1475-T through L-1478-T)
a. Removal
(1) Disconnect the lead connector (5, fig. 4113). Close coolant line shutoff valve. Prepare to drain
residual fluid from heater and connective lines (about 3
quarts) 2.85 liters) into a container. If clean, save
coolant for use.
(2) Loosen the four hose clamps (11)
securing the two hoses (13) to the heater (6) and the
coolant lines (14).
(3) Remove the four cap screws (9) and lock
washers (10) securing the heater (6) and the four
mounts (8) to the floor (7).
(4) Slide the two hoses (13) off the heater
and lift out the heater (6) and the four mounts (8).
(5) Remove the two hoses (13) off the lines
(14) and slide the four clamps (11) from the hoses.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-138F. (38C.-59C.).
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-138F. (38C.-59C.).
b. Cleaning, Inspection and Repair. Wipe all parts
with a cloth dampened in a cleaning solvent. Inspect for
broken or cracked wires and connections. Repair minor
damage. If the wiring harness is badly damaged,
replace the harness. Inspect the damaged threads and
replace any damaged hardware. Inspect 'the ignition
unit for damage. Replace a damaged unit or report the
damage to the proper authority.
c. Installation. Reverse the removal procedures in
a above.
d. Vibrator Replacement. The vibrator (28, fig. 4106) has two sets of contact points. The switch (32) is
safety wired at the factory. If the vibrator is inoperative
and the switch is still wired, cut the wire and pull the
switch out. If the lock wire(33) has been cut, the switch
pulled out and the vibrator is inoperative install a new
vibrator as follows.
(1) Unplug the disconnect plug (31).
(2) Loosen the thumb screw (27) and push
the bail downward.
(3) Pull the vibrator (28) from the ignition unit
·(3).
(4) Push the switch (32) in, and secure with
the lock wire (33).
(5) Position the new vibrator (28) in the
ignition unit (3) and secure with the bail and thumb
screw (27).
(6) Plug in the disconnect plug (31).
b. Cleaning, Inspection and Repair. Clean the
heater sheet metal with a cloth dampened in a cleaning
solvent. Wash all other metal parts in a solvent.
Inspect the heater for cracked or frayed wire. Repair a
damaged wire or connector. Report any other damage
to the heater to the proper authority. Inspect for cracked
or damaged hoses and clamps, damaged threads, or
any other damage. Replace all damaged parts.
c. Installation.
(1) Position the four clamps (11, fig. 4-113)
on the two hoses (13) and slide the hoses far enough on
the two lines (14) to allow the heater (6) to be installed.
(2) Position the heater (6) and the four
mounts (8) on the floor (7) and secure with the four lock
washers (10) and cap screws (9).
(3) Couple the connector (5).
4-116. Power Compartment Heater (Serial Nos. L1666-T through L-1668-T
a. Removal.
(1) Disconnect the lead connector(3, fig. 4114). Close coolant line shutoff valve. Open drain cock
(6)
4-127
TM 5-3655-210-12
1.
2.
8.
4.
5.
6.
7.
8.
C02 pump
Frame
Pump drive belts
Lead
Connector
Heater
Floor
Resilient mount
9.
10.
11.
12.
18.
14.
15.
16.
Cap screw
Lock washer
Clamp
Screw
Hose
Coolant lines ·
Nut
Washer
Figure 4-113. Heater removal points (ser. no. L-1475-Tthrouh L-1478-T).
4-128
TM 5-3655-210-12
1.
2.
3.
4.
5.
Coolant lines
Clamp
Connector
Lead
Heater
6.
7.
8.
9.
10.
Drain cock
Hose
Cap screw
Lock washer
Spacer
Figure 4-114. Heater removal points (ser. nos. L-1 666-T through L1668-T).
and drain residual fluid from heater and connective lines
(about 8 quarts) into a container. If clean, save coolant
for reuse.
(2) Loosen the four hose clamps (2) securing
the two hoses (7) to the heater fittings and the coolant
lines (1).
(3) Remove the four cap screws (8) and
lock washers (9) securing the heater (5) and the four
spacers (10) to the floor.
(4) Slide the two hoses (7) off the heater
fittings and lift out the heater (5) and the four spacers
(10).
(5) Remove the two hoses (7) from the lines
(1) and slide the four clamps (2) off the hoses.
WARNING
Dry cleaning solvent, P-D-680 or P-S661, used to clean parts is potentially
dangerous to personnel and property.
Use in a well-ventilated area as the
fumes are dangerous if inhaled. Avoid
repeated and prolonged skin contact.
Do not use near open flame or
excessive heat. Flash point of solvent
is 100F.-188F. (88C.-59C.).
b. Cleaning, Inspection and Repair.
4-129
TM 5-3655-210-12
(4) Replace all damaged parts.
c. Installation.
(1) Position the four clamps (2, fig. 4-114) on
the two hoses (7) and slide the hoses far enough o0 the
two lines (1) to allow the heater (5) to be installed.
(2) Position the heater (5) and the four
spacer, (10) on the floor and secure with the four: lock
washers (9) and cap screws (8).
(3) Couple the connector.
(1) Clean the heater sheet metal with a cloth dampened
in a cleaning solvent. Wash all other metals in a
solvent.
(2) Inspect the heater lead for cracked or frayed wire.
Inspect for cracked or damaged hoses and clamps,
damaged threads, or any other damage.
(3) Repair a damaged wire or connector.
Report any other heater damage to direct support
maintenance.
4-130
TM 5-3655-210-12
APPENDIX A
REFERENCES
A-1. Fire Protection
TB 5-4200-200-10
A-2. Lubrication
LO 5-365210-12
A-3. Painting
TM 43-0139
A-4. Radio Suppression
TM 11-483
A-5. Maintenance
MIL-A-11755C
TM 38-750
TM 5-351
TM 5-3656-210-35
TM 750-244-3
TM 9-1870-1
TM 9-6140-200-15
A-6.Shipment and Storage
TB 740-93-2
TM 740-90-1
Hand Portable Fire Extinguishers Approved for Army Users.
Lubrication Order.
Painting Instructions for Field Use.
Radio Interference Suppression.
Compound, Anti-Freeze, Artic.
Army Equipment Record Procedure.
Gas Generating.
Direct Support, General Support and Depot Maintenance Manual.
Procedure for Destruction of Equipment to Prevent Enemy
Use (Mobility Equipment Command)
Care and Maintenance of Pneumatic Tires.
Operator and Organizational Field and Depot Maintenance
Storage Batteries, Lead Acid Type.
Preservation of USAMECOM Mechanical Equipment for Shipment and Storage.
Administrative Storage of USAMECOM Mechanical Equipment.
A-1
TM 5-3655-210-12
APPENDIX B
MAINTENANCE ALLOCATION CHART
(5) Align. To adjust specified variable
elements of an item to bring about optimum or desired
performance.
(6) 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. Consists 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.
(7) Install. The act of emplacing, seating, or
fixing into position an item, part or module (component
or assembly) in a manner to allow the proper functioning
of an equipment or system.
(8) Replace.
The act of substituting a
serviceable like type part, sub-assembly, or module
(component or assembly) for an unserviceable
counterpart.
(9) Repair. The application of maintenance
services (inspect, test, service, adjust, align, calibrate,
or replace) or other maintenance Actions (welding,
grinding, riveting, straightening, facing, remachining or
resurfacing) to restore serviceability to an item by
correcting specific damage, fault, malfunction, or failure
in a part, sub-assembly, module (component or
assembly), end item, or system.
(10) Overhaul.
That maintenance effort
(service/action) necessary to restore an item to a
completely serviceable/operational
condition as
prescribed by maintenance standards (i.e., DMWR) in
appropriate technical publications. Overhaul is normally
the highest degree of maintenance performed by the
Army. Overhaul does not normally return an item to like
new condition.
(11) Rebuild.
Consists
of
those
services/actions necessary for the restoration of
unserviceable equipment to a like new condition in
accordance with original manufacturing standards.
Rebuild is the highest degree of materiel maintenance
applied to Army equipment. The rebuild operation
includes the act of returning to zero those age
measurements (hours/miles, etc.) considered in
classifying Army equipment/components.
d. Column (4), Maintenance Category.
This
column is made up on sub-columns for each category of
maintenance. Work time figures are listed in these subcolumns for the lowest level of maintenance authorized
to perform the function
B-1.
General
a. This section provides a general explanation of
all maintenance and repair functions authorized at
various maintenance levels.
b. Section II designates overall responsibility for
the performance of maintenance functions on the
identified end item or component and the work
measurement time required to perform the functions by
the designated maintenance level. The implementation
of the maintenance functions upon the end item or
component will be consistent with the assigned
maintenance functions.
c. Section III lists the tools and test equipment
required for each maintenance function as referenced
from Section II.
B-2.
Explanation Of Columns In Section II
a. Column (1), Group Number. Column (1) lists
group numbers to identify related components,
assemblies, sub-assemblies, and modules with their
next higher assembly. The applicable groups are listed
in the MAC in disassembly sequence beginning with the
first group removed.
b. Column
(2), Component/Assembly.
This
column contains the noun names of components,
assemblies, sub-assemblies and modules for which
maintenance is authorized.
c. Column (3), Maintenance Functions.
This
column lists the functions to be performed on the item
listed in Column (2). The maintenance functions are
defined as follows:
(1) Inspect. To determine serviceability of an
item by comparing its physical, mechanical, and/or
electrical characteristics with established standards
through examination.
(2) Test. To verify serviceability and detect
incipient failure by measuring the mechanical or
electrical characteristics of an item and comparing those
characteristics with prescribed standards.
(3) Service. Operations required periodically
to keep an item in proper operating condition, i.e., to
clean (decontaminated), to preserve, to drain, to paint,
or to replenish fuel, lubricants, hydraulic fluids, or
compressed air supplies.
(4) Adjust. To maintain within prescribed
limits, by bringing into proper or exact position, or by
setting the operating characteristics to specified
parameters.
B-1
TM 5-3655-210-12
c. Column (S), Nomenclature. This column lists
the name or identification of the common tool sets,
special tools or test equipment.
d. Column (4), National/Nato Stock No. (NSN).
This column is provided for the NSN of common tool
sets, special tools and test equipment listed in the
nomenclature column.
e. Column (5), Tool Number. This column lists the
manufacturer code and part number of tools and test
equipment.
listed in Column 3. These figures indicate the average
active time required to perform the maintenance
function at the indicated category of maintenance under
typical field operating conditions.
e. Column (5), Tools and Equipment. This
column is provided for referencing by code, the common
tool sets (not individual tools) special tools, test and
support equipment required to perform the designated
function.
B-3.
Explanation Of Columns In Section III
a. Column (1), Reference Code. This column
consists of an arabic number listed in sequence from
Column 5 of Section II. The number references the
common tool sets, special tools and test equipment
requirements.
b. Column (2), Maintenance Category.
This
column shows the lowest category of maintenance
authorized to use the special tools or test equipment.
B-4.
Explanation Of Columns In Section IV
a. Reference Code. This column consists of the
maintenance functions as described in paragraph B-2,
step c.
b. Remarks.
This column lists information
pertinent to the maintenance function to be performed.
B-2
TM5-3655-210-12
(1)
Group
number
01
02
03
04
05
Section II. MAINTENANCE ALLOCATION CHART - Continued
(2)
(3)
(4)
Component/assembly
FILL MANIFOLD
STORAGE BATTERIES
ENGINE CONTROL PANEL
GASOLINE ENGINE
ACCESSORIES
ENGINE ASSEMBLY
Crankcase; Block,
Cylinder Head;
Flywheel
Crankshaft; Bearing;
Pistons; Rods;
Valves
06
CYLINDER FILLING UNIT
Strainer; Valve
07
08
DRIVE SHAFTS, CLUTCHES
AND BELT TIGHTENER
REFRIGERATION SYSTEM
*SUBCOLUMNS ARE AS FOLLOWS:
F-DIRECT SUPPORT
**INDICATES WT/MH REQUIRED
Maint.
function
C
Inspect
Test
Replace
Repair
Inspect
Test
Service
Install
Replace
Repair
Inspect
Replace
Repair
0.3
Inspect
Replace
Repair
Overhaul
Inspect
Service
Replace
Repair
Overhaul
0.4
Maint. category
O
F
H
(5)
D
Tool/
equipment
0.5
0.5
1.7
0.1
1- (2)
0.2
0.2
0.3
0.3
0.4
0.3
1.5
1.6
10.0
12.0
12.0
0.5
1.0
2.0
8.0
16.0
Inspect
Replace
Repair
10.8
4.7
3.5
Inspect
Replace
Repair
Inspect
Service
Replace
Repair
Overhaul
Inspect
Service
Replace
1.0
2 - (4)
6.0
5.0
0.4
0.5
1.5
5.0
5.8
0.2
0.8
1.0
Inspect
Test
Service
Adjust
Align
Replace
Repair
Inspect
Test
Service
Replace
Repair
Overhaul
0.3
0.5
0.2
0.5
0.5
3.0
5.0
0.3
3- (3)
0.8
0.5
6.0
8.0
9.0
C-OPERATOR/CREW,
H-GENERAL SUPPORT,
B-3
O-ORGANIZATIONAL,
D-DEPOT
TM5-3655-210-12
Section II. MAINTENANCE ALLOCATION CHART - Continued
(1)
(2)
(3)
Group
number
Component/assembly
Maint.
function
09
LIQUID QUANTITY AND
PRESSURE CONTROL
Pressure Control
10
11
TRANSFER PUMP, SUCTION
AND DISCHARGE LINE
ELECTRIC MOTOR AND
CONTROL PANEL
Bearing
12
13
14
15
16
17
18
19
POWER COMPARTMENT
HEATER
PRESSURE VESSEL VALVES
LINES AND FITTINGS
INTERIOR LIGHTING
STORAGE COMPARTMENT
COMPONENTS
STOPLIGHTS, TAILLIGHT,
CLEARANCE LIGHTS AND
REFLECTORS
LANDING JACK ASSEMBLY
FENDERS, CHOCK BLOCK
AND LADDER
HOUSING COMPONENTS
CHASSIS ASSEMBLY
Air Brake Chamber;
Valves
Brake Lining
Tandem Assembly
'SUBCOLUMNS ARE AS FOLLOWS:
P-DIRECT SUPPORT.
*INDICATES WT/MH REQUIRED
(4)
C
Inspect
Test
Adjust
Replace
Repair
Inspect
Replace
0.5
Inspect
Replace
Repair
0.3
Inspect
Replace
Repair
Inspect
Replace
0.3
Inspect
Replace
Repair
0.3
Inspect
Replace
Repair
Inspect
Replace
Repair
0.5
Inspect
Replace
Repair
0.8
Inspect
Replace
Repair
0.3
Inspect
Replace
Repair
Inspect
Replace
Repair
Inspect
Replace
Repair
0.5
Inspect
Replace
Repair
Inspect
Replace
Inspect
Replace
0.5
(5)
Maint. category
O
F
H
D
Tool/
equipment
1.1
0.5
3.0
4.0
0.3
1.0
1.0
2.5
0.8
3.0
1.0
3.0
1.0
2.0
1.0
2.0
0.3
0.8
0.5
2.5
6.0
1.5
2.0
2.0
3.0
0.5
2.0
2.5
0.5
3.0
5.0
1.5
2.0
0.5
1.5
0.5
3.0
C-OPERATOR/CREW.
H-GENERAL SUPPORT,
B-4
O-ORGANIATIONAL,
D-DEPOT
TM 5-3655-210-12
(1)
REFERENCE
CODE
SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS FOR AN/GRC-240
(2)
(3)
(4)
MAINTENANCE
LEVEL
NOMENCLATURE
1-(2)
0
Tester, battery
2-(4)
0
Gage, thickness
3-(3)
F
Gage, pressure
B-5
NATIONAL/NATO
STOCK NUMBER
(5)
TOOL*
NUMBER
P/N515TB
(30327)
P/N 166
(74855)
P/N CR1790
(61349)
TM 5-3655-210-12
Section IV. REMARKS
Reference
(2)
(4)
(3)
Remarks
Test batteries for specific gravity.
Adjust valves.
Determine if refrigerant system requires charge.
B-6
TM 5-3655-210-12
APPENDIX C
BASIC ISSUE ITEMS LIST AND ITEMS TROOP INSTALLED OR AUTHORIZED
Section I. INTRODUCTION
Code
Explanation
C-1. Scope
C
Crew/Operator (3) Recoverability code
This appendix lists items required by the
indicates whether unserviceable items should be
operator for operation of the conversion, storage and
returned for recovery or salvage. Items not coded are
charging unit.
non-recoverable.
Recoverability codes are:
C-2. General
This list is divided into the following sections:
Code
Explanation
a. Basic Issue Items List Section II. Not
R
Applied to repair parts (assemblies and
applicable.
components), special tools and test
b. Items Troop Installed or Authorized List
equipment
which
are
considered
Section III. A list of items in alphabetical sequence,
economically reparable at direct and
which at the discretion of the unit commander may
general support maintenance levels.
accompany the conversion, storage and charging unit.
These items are NOT subject to turn-in with the
S
Repair parts, special tools, test
conversion, storage and charging unit.
equipment and assemblies which are
economically reparable at DSU and GSU
C-3. Explanation Of Columns
activities and which normally are
furnished by supply on an exchange
The following provides an explanation of
basis.
columns in the tabular list of Basic Issue Items List,
Section II, and Items Troop Installed or Authorized,
b. National Stock Number.
This column
Section III.
indicates the National stock number assigned to the
a. Source, Maintenance, and Recoverability
item and will be used for requisitioning purposes.
Code(s) (SMR):
c. Description- This column indicates the
(1) Source code indicates the source for the
Federal
item name and any additional description of the
listed item. Source codes are:
item required.
d. Unit of Measure (U/M). A two character
Code
Explanation
alphabetic abbreviation indicating the amount or
P
Repair parts, special tools and test
quantity of the item upon which the allowances are
equipment supplied from GSA/DSA or
based, e.g., ft, ea, pr, etc.
Army supply system and authorized for
e. Quantity Furnished with Equipment (BIIL
use at indicated maintenance levels.
Only). This column indicates the quantity of an item
furnished with the equipment.
Code
Explanation
f.
Quantity Authorized (Items Troop Installed
P2
Repair parts, special tools and test
or Authorized Only). This column indicates the quantity
equipment which are procured and
of the item authorized to be used with the equipment.
stocked for insurance purposes because
g. Illustration (BIIL ONLY). This column is
the combat or military essentially of the
divided as follows:
end item dictates that a minimum
(1) Figure number. Indicates the figure
quantity be available in the supply
system.
number of the illustration in which the item is shown.
(2) Item number.
Indicates the callout
(2) Maintenance code indicates the lowest level
number used to reference the item in the illustration.
of maintenance authorized to install the listed item.
The
maintenance
level
code
is:
C-1
TM 5-3655-210-12
Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST
(1)
SMR
CODE
(2)
(3)
NATIONAL
STOCK NUMBER
DESCRIPTION
REF. NUMBER
& MFR. CODE
PC
4210-00-655-1283
PC
7520-00-5569-9618
PC
4210-00-202-78568
(4)
USABLE
ON CODE
BRACKET, FIRE
EXTINGUICHER
CASE, MAINTENANCE AND
OPERATIONAL MANUAL
EXTINGUISHER, FIRE
C-2
Unit
of
Meas
(5)
QTY
Auth
EA
1
EA
1
EA
1
TM 5-3655-210-12
ALPHABETICAL INDEX
Paragraph
Page
A
Actuator:
Installation ..............................................................................................................................................................................4-74b
Leakage Test .........................................................................................................................................................................4-74d
Operating Test .......................................................................................................................................................................4-74c
Removal .................................................................................................................................................................................4-74a
Administrative Storage....................................................................................................................................................................1-5
Air Cleaner:
Cleaning, Inspection and Repair ............................................................................................................................................4-26b
Inspection and Service...........................................................................................................................................................3-10b
Reassembly and Installation...................................................................................................................................................4-26c
Removal and Disassembly.....................................................................................................................................................3-10a
...............................................................................................................................................................................................4-26a
Alarm Bell:
Assembly and Installation.......................................................................................................................................................4-51b
Removal and Disassembly.....................................................................................................................................................4-51a
Ammeter and Fuel Gage:
Removal .................................................................................................................................................................................4-47a
Automatic Starter Control:
Installation ..............................................................................................................................................................................4-48b
Removal .........................................................................................................................................................................................4-48a
B
Batteries:
Installation ..............................................................................................................................................................................3-16
Removal .................................................................................................................................................................................3-16a
...............................................................................................................................................................................................4-42a
Blackout and Service Stop and Taillight:
Removal .................................................................................................................................................................................4-52a
Blower:
Cleaning, Inspection and Repair ............................................................................................................................................4-109b
Installation ..............................................................................................................................................................................4-109c
Removal .................................................................................................................................................................................4-109a
Body:
Description.............................................................................................................................................................................4-83
Brake System:
Actuator..................................................................................................................................................................................4-69c
Drain Cock .............................................................................................................................................................................4-69f
General ..................................................................................................................................................................................4-69a
Hose Assemblies ...................................................................................................................................................................4-69i
Hose Couplings......................................................................................................................................................................4-69g
Relay-Emergency Valve .........................................................................................................................................................4-69b
Reservoir................................................................................................................................................................................4-69e
Slack Adjuster........................................................................................................................................................................4-69d
Tubing and Tubing Fittings ....................................................................................................................................................4-69h
Brake System Detailed Lubrication Information......................................................................................................................4-13
C
Carbon Dioxide Transfer and Cylinder System:
Description.............................................................................................................................................................................,4-93
Carbon Dioxide Vapor Manifold:
Cleaning, Inspection and Repair ............................................................................................................................................4-97c
Removal .................................................................................................................................................................................4-97a
I-1
4-81
4-82
4-82
4-81
1-1
4-32
3-5
4-34
3-5
4-32
4-59
4-59
4-55
4-59
4-55
3-10
3-10
4-53
4-59
4-117
4-117
4-117
4-90
4-80
4-80
4-78
4-80
4-80
4-80
4-80
4-80
4-80
4-9
4-100
4-103
4-102
TM 5-3655-210-12
Paragraph
Carburetor and Intake Manifold:
Cleaning and Inspection.........................................................................................................................................................4-30d
Reassembly, Installation and Adjustment...............................................................................................................................4-30c
Removal and Disassembly.....................................................................................................................................................4-30a
Check Valve Replacement .............................................................................................................................................................4-76
Checking for Overfilling ..................................................................................................................................................................2-16
Cleaning .........................................................................................................................................................................................3-2
Clearance Lights ............................................................................................................................................................................4-53
Clutch Adjustment..........................................................................................................................................................................4-91
Combustion Head:
Cleaning Inspection and Repair .............................................................................................................................................4-112c
Disassembly...........................................................................................................................................................................4-112b
Installation ..............................................................................................................................................................................4-112e
Reassembly ...........................................................................................................................................................................4-112d
Removal .................................................................................................................................................................................4-112a
Spark and Plug Gap Testing..................................................................................................................................................4-112d
Spray Nozzle Test..................................................................................................................................................................4-112g
Compressor....................................................................................................................................................................................4-88
Control Panel Switches:
General ..................................................................................................................................................................................4-49a
Replacement ..........................................................................................................................................................................4-49b
Controls and Instruments:
Alarm Bell Cutout Switch .......................................................................................................................................................2-2n
Ammeter ................................................................................................................................................................................2-2g
Battery Circuit Breaker ...........................................................................................................................................................2-2y
Battery Selector Switch ..........................................................................................................................................................2-2s
Carburetor Priming Lever .......................................................................................................................................................2-2u
Clutch Shifters .......................................................................................................................................................................2-2z
Compressor Oil Level Sight Glass .........................................................................................................................................2-2k
Conversion Heater Switch......................................................................................................................................................2-2q
Conversion Heater Vibrator Switch ........................................................................................................................................2-2x
Cylinder Filling Pressure Gage ..............................................................................................................................................2-2d
Electric Motor Reversing Switch ............................................................................................................................................2-2w
Electric Motor Starting Switch ................................................................................................................................................2-2v
Fuel Indicator .........................................................................................................................................................................2-2c
Gage Line Heater Switch .......................................................................................................................................................2-2o
Gasoline Engine Control Switch.............................................................................................................................................2-2t
General ..................................................................................................................................................................................2-2a
Governor Controls..................................................................................................................................................................2-2aa
Heater Fuel Pressure Gage ...................................................................................................................................................2-2h
Light Switches........................................................................................................................................................................2-2m
Liquid Level Gage ..................................................................................................................................................................2-2e
Manual Control Valves ...........................................................................................................................................................2-2l
Refrigerant Sight Glass..........................................................................................................................................................2-2j
Shutter Control.......................................................................................................................................................................2-2b
Sight Glass, Expansion Tank.................................................................................................................................................2-2i
Space Heater Switch..............................................................................................................................................................2-2p
Toggle Switches (Momentary)................................................................................................................................................2-2r
Vessel Pressure Gages .........................................................................................................................................................2-2f
Conversion Heater..........................................................................................................................................................................3-25
Conversion Heater Description.......................................................................................................................................................4-106
Cooling System Inspection .............................................................................................................................................................3-13
CO2 Liquid Level Gages:
Adjustment.............................................................................................................................................................................4-99d
Cleaning, Inspection and Repair ............................................................................................................................................4-99b
Removal .................................................................................................................................................................................4-99a
CO' Liquid Manifold:
Cleaning, Inspection and Repair ............................................................................................................................................4-96c
Disassembly...........................................................................................................................................................................4-96b
Removal .........................................................................................................................................................................................4-96a
CO' Tank Pressure Gages:
Cleaning, Inspection and Repair ............................................................................................................................................4-100b
Removal .................................................................................................................................................................................4-l00a
Cylinder Filling Compressor ...........................................................................................................................................................3-26
4-101
I-2
Page
4-39
4-39
4-38
4-82
2-25
3-1
4-59
4-99
4--123
4-122
4-123
4-123
4-122
4-123
4-123
4-95
4-59
4-59
2-1
2-1
2-4
2-3
2-3
2-4
2-1
2-2
2-4
2-1
2-3
2-3
2-1
2-1
2-3
2-1
2-4
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-2
2-1
3-13
4-113
3-6
4-108
4-108
4-106
4-102
4-102
4-100
4-111
4-109
3-13
4-111
TM 5-3655-210-12
Paragraph
Cylinder Filling Manifold:
Cleaning, Inspection and Repair ............................................................................................................................................4-98c
Disassembly...........................................................................................................................................................................4-98b
Removal .................................................................................................................................................................................4-98a
Cylinder Filling Operation (liquid in both
pressure vessels)...................................................................................................................................................................2-14
D
Daily Preventive Maintenance Services ..........................................................................................................................................3-5
Data Plates and Instruction Holders ...............................................................................................................................................3-22
Definitions ......................................................................................................................................................................................4-18
Dehydrator:
Removal .................................................................................................................................................................................4-95a
Description .....................................................................................................................................................................................1-6
Destruction of Army Material to Prevent Enemy
Use ........................................................................................................................................................................................1-4
Detailed Lubrication Information .....................................................................................................................................................4-12
Determining Liquid Level While Pumping.......................................................................................................................................2-15
Difference in Models.......................................................................................................................................................................1-8
Dismantling for Movement..............................................................................................................................................................4-6
Dome Lights ...................................................................................................................................................................................4-54
Drive Belts:
Adjustment.............................................................................................................................................................................4-92b
General ..................................................................................................................................................................................4-92
E
Electric Motor Operation.................................................................................................................................................................2-4
Electric Motor Removal...................................................................................................................................................................4-58
Engine and Power Compartment Cooling System:
Description.............................................................................................................................................................................4-59
Engine Assembly............................................................................................................................................................................3-9
Engine Control Panel Inspection ....................................................................................................................................................3-14
Engine Shrouding:
Cleaning, Inspection and Repair ............................................................................................................................................4-64b
Removal and Disassembly.....................................................................................................................................................4-64a
Engine Shutter and Control Rod.....................................................................................................................................................4-61
Equipment Serviceability Criteria ....................................................................................................................................................1-3
Exhaust Manifold and Pipes:
Inspection and Repair ............................................................................................................................................................4-37b
Removal .................................................................................................................................................................................4-37a
Exhaust System:
Description.............................................................................................................................................................................4-35
Expansion Tank and Fluid Lines:
Cleaning and Inspection.........................................................................................................................................................4-107b
Reassembly ...........................................................................................................................................................................4-107c
Removal .................................................................................................................................................................................4-107a
F
Failure and Gage Line Lights:
Cleaning, Inspection and Repair ............................................................................................................................................4-55b
Removal .................................................................................................................................................................................4-55a
Filling Both Pressure Vessels with Liquid
Carbon Dioxide.......................................................................................................................................................................2-9
Filling the Storage Pressure Vessel with
Liquid Carbon Dioxide (both pressure vessels
empty) ....................................................................................................................................................................................2 -10
I-3
Page
4-106
4-106
4-103
2-23
3-4
3-13
4-27
4-100
1-1
1-1
4-8
2-24
1-6
4-8
4-62
4-100
4-99
2-8
4-71
4-73
3-5
3-6
4-75
4-75
4-74
1-1
4-46
4-46
4-46
4-115
4-115
4-114
4-61
4-61
2-16
2-2
TM 5-3655-210-12
Paragraph
Fire Extinguisher:
Description.............................................................................................................................................................................2-17a
General ..................................................................................................................................................................................3-27
Operation ...............................................................................................................................................................................2-17b
Flywheel:
Removal .................................................................................................................................................................................4-63a
Fuel Filter Service (ser. Nos. L-1475-T through
L-1478-T)...............................................................................................................................................................................3-11
Fuel Manifold and Filter Assembly:
Adjustment and Testing .........................................................................................................................................................4-11f
Cleaning, Inspection and Repair.....................................................................................................................................................4-11d
Fuel Filter Disassembly..........................................................................................................................................................4-11 b
Fuel Manifold Removal...........................................................................................................................................................4-11 a
Manifold and Solenoid Disassembly.......................................................................................................................................4-11c
Manifold Fuel Filter, Solenoid, Reassembly
and Installation .......................................................................................................................................................................4-11e
Fuel Pump:
Disassembly...........................................................................................................................................................................4-110b
Installation ..............................................................................................................................................................................4-110c
Removal .................................................................................................................................................................................4-110a
Fuel Pump and Fuel Strainer (Serial Nos.
L-1475-T through L-1478-T):
Cleaning, Inspection and Repair ............................................................................................................................................4-28b
Reassembly and Installation...................................................................................................................................................4-28c
Removal and Disassembly.....................................................................................................................................................4-28a
Test........................................................................................................................................................................................4-28d
Fuel Pump and Fuel Strainer (Serial Nos.
L-1666T through L-1668T):
Cleaning, Inspection and Repair ............................................................................................................................................4-29b
Reassembly and Installation...................................................................................................................................................4-29c
Removal and Disassembly.....................................................................................................................................................4-29a
Test........................................................................................................................................................................................4-29d
G
Gage Panel Switches .....................................................................................................................................................................4-50
Gages, Lines and Fittings...............................................................................................................................................................3-24
Gasoline Engine Ignition System:
Description.............................................................................................................................................................................4-38
Gasoline Engine Lubrication System and Valve
Tappets:
Description.............................................................................................................................................................................4-31
Gasoline Engine Operation.............................................................................................................................................................2-5
General Lubrication Information .....................................................................................................................................................4-11
General Methods Used to Attain Proper
Suppression...........................................................................................................................................................................4-19
Generator:
Brush Replacement ...............................................................................................................................................................4-45b
Generator Installation .............................................................................................................................................................4-45c
Generator Removal ................................................................................................................................................................4-45a
Generator Regulator:
Removal .................................................................................................................................................................................4-44a
Governor:
Adjustment.............................................................................................................................................................................4-27i
Cleaning, Inspection and Repair ............................................................................................................................................4-27b
Installation ..............................................................................................................................................................................4-27c
Removal .................................................................................................................................................................................4-27a
Governor Controls:
Cleaning, Inspection and Repair ............................................................................................................................................4-24b
Reassembly and Installation...................................................................................................................................................4-24c
Removal and Disassembly.....................................................................................................................................................4-24a
I-4
Page
2-25
3-15
2-25
4-75
3-5
4-120
4-120
4-117
4-117
4-117
4-120
4-117
4-117
4-117
4-36
4-37
4-35
4-38
4-.38
4-38
4-38
4-38
4-59
3-13
4-48
4-43
2-9
4-8
4-27
4-54
4-54
4-53
4-53
4-35
4-35
4-35
4-34
4-30
4-30
4-29
TM 5-3655-210-12
Paragraph
Page
H
Hose Couplings, Cutout Cocks, Air Strainers,
Replacement ..........................................................................................................................................................................4-78
I
Inspecting and Servicing the Equipment ........................................................................................................................................4-3
Installation ......................................................................................................................................................................................4-4
Interference Suppression Components:
Conversion Heater .................................................................................................................................................................4-20e
Gasoline Engine Spark Plugs and Ignition
Cables ...........................................................................................................................................................................4-20a
Heater Spark Plug and Igniter Cable......................................................................................................................................4-20c
Ignition Unit ............................................................................................................................................................................4-20d
Magneto .................................................................................................................................................................................4-20b
L
Landing Gear..................................................................................................................................................................................3-20
Landing Gear and Braces:
Cleaning, Inspection and Repair ............................................................................................................................................4-81b
Removal and Disassembly.....................................................................................................................................................4-81a
Lights:
Clearance Lights ....................................................................................................................................................................3-15b
Dome Lights...........................................................................................................................................................................3-15c
Failure and Gage Line Lights .................................................................................................................................................3-15d
Stop and Taillights .................................................................................................................................................................3-15a
Lines and Fittings:
Cleaning, Inspection and Repair ............................................................................................................................................4-102b
Removal .................................................................................................................................................................................4-102a
Lubrication Instructions:
General ..................................................................................................................................................................................3-1
M
Magneto:
Breaker Point and Condenser Removal .................................................................................................................................4-40d
Breaker Point Gap Adjustment...............................................................................................................................................4-40g
Cleaning and Inspection.........................................................................................................................................................4-40e
Cleaning and Repair...............................................................................................................................................................4-40b
Installation and Timing ...........................................................................................................................................................4-40c
Removal .................................................................................................................................................................................4-40a
Maintenance and Operating Supplies.............................................................................................................................................4-5
Maintenance Forms and Records ..................................................................................................................................................1-2
Maintenance of the Gasoline Engine Fuel System:
Description.............................................................................................................................................................................4-23
Maintenance Procedures, General .................................................................................................................................................3-8
Maintenance Repair Parts ..............................................................................................................................................................4-10
Motor Starter and Protective Devices .............................................................................................................................................3-23
Muffler and Exhaust Pipe Inspection..............................................................................................................................................3-12
N
Normal Conversion Operation ........................................................................................................................................................2-6
O
Oil Filter:
Disassembly...........................................................................................................................................................................4-32b
Removal .................................................................................................................................................................................4-32a
l-5
4-84
4-4
4-4
4-27
4-27
4-27
4-27
4-27
3-13
4-85
4-84
3-6
3-6
3-9
3-6
4-111
4-111
3-1
4-49
4-50
4-50
4-48
4-48
4-48
4-5
1-1
4-29
3-5
4-8
3-13
3-6
2-11
4-43
4-43
TM 5-3655-210-12
Paragraph
Oil Lines:
Cleaning, Inspection and Repair........................................................................................................... 4-33b
Removal and Disassembly ................................................................................................................... 4-33a
Operating Procedures, General ................................................................................................................... 2-1
Operation:
Emergency........................................................................................................................................... 4-70b
Normal................................................................................................................................................. 4-70a
Parking ................................................................................................................................................ 4-70c
Operation in Extreme Cold:
General................................................................................................................................................ 2-18a
Low Temperature Operation................................................................................................................. 2-18d
Lubrication ........................................................................................................................................... 2-18b
Operation Precautions.......................................................................................................................... 2-18c
Operation in Extreme Heat:
Air........................................................................................................................................................ 2-20c
Cooling ................................................................................................................................................ 2-20b
General................................................................................................................................................ 2-20a
Lubrication ........................................................................................................................................... 2-20d
Operation in High Altitude ........................................................................................................................... 2-22
Operation in Salt Water Areas:
Electrical System ................................................................................................................................. 2-2
General................................................................................................................................................ 2-23
Lubrication ........................................................................................................................................... 2-2b
Protection ............................................................................................................................................ 2-2d
Operation Under Dusty or Sandy Conditions:
Cleaning .............................................................................................................................................. 2-21
General................................................................................................................................................ 2-21
Lubrication ........................................................................................................................................... 2-21b
Protective Measures.................................................................................................................................... 2-2k
Operation Under High Humidity Conditions ................................................................................................. 2-19
Operation Under Usual Conditions .............................................................................................................. 2-3
Operator Maintenance Troubleshooting....................................................................................................... 3-7
Organizational Maintenance Troubleshooting .............................................................................................. 4-17
P
Packing Nut Adjustment.............................................................................................................................. 4-105
Pintle .......................................................................................................................................................... 3-19
Pintle Hook:
Cleaning, Inspection and Repair........................................................................................................... 4-80c
Disassembly ........................................................................................................................................ 4-80b
Removal .............................................................................................................................................. 4-80
Points of Lubrication ................................................................................................................................... 3-3
Power Compartment Door:
Disassembly ........................................................................................................................................ 4-85b
Door Removal...................................................................................................................................... 4-85a
Reassembly ......................................................................................................................................... 4-85c
Power Compartment Heater (Ser Nos L-1475-T
through L-1478-T):
Cleaning Inspection and Repair............................................................................................................ 4-115b
Installation ........................................................................................................................................... 4-115c
Removal .............................................................................................................................................. 4-115a
Power Compartment Heater (Serial Nos.
L-1666-T through L-1668-T):
Cleaning, Inspection and Repair........................................................................................................... 4-116b
Installation ........................................................................................................................................... 4-116c
Removal .............................................................................................................................................. 4-116a
Power Transfer Equipment.......................................................................................................................... 3-17
Pressure Switches:
Refrigeration Compressor Pressure Switch
Adjustment........................................................................................................................................... 4-46a
4-57a
Tank Pressure Switch Adjustment ........................................................................................................ 4-46b
4-57b
I-6
Page
4-.44
443
2-1
4-80
4-80
4-80
2-25
2-25
2-25
2-25
2-27
2-26
2-26
2-27
2-27
2-27
2-27
2-27
2-27
2-27
2-27
2-27
2-27
2-26
2-4
3-5
4-11
4-112
3-13
4-84
4-84
4-84
3-1
4-90
4-90
4-2
4-127
4-127
4-127
4-129
4-130
4-127
3-13
4-54
4-71
4-55
4-71
TM 5-3655-210-12
Paragraph
Preventive Maintenance Checks and Services...............................................................................................................................4-15
Preventive Maintenance Checks and Services...............................................................................................................................3-4
General ..................................................................................................................................................................................4-14
Pumping Down the System ............................................................................................................................................................4-90
R
Rear Door Shutter and Control Rod:
Adjustment.............................................................................................................................................................................4-6f
Control and Shutter Cleaning, Inspection and
Repair ............................................................................................................................................................................4-60c
Control Removal and Disassembly ........................................................................................................................................4-60a
Shutter Removal.....................................................................................................................................................................4-60b
Receiver .........................................................................................................................................................................................4-89
Reduced Conversion Cycle ............................................................................................................................................................2-7
Reflectors .......................................................................................................................................................................................4-84
Refrigeration Shutter Control:
Cleaning, Inspection and Repair ............................................................................................................................................4-62b
Control Removal.....................................................................................................................................................................4-62a
Refrigeration System:
General ..................................................................................................................................................................................4-87
Reinstallation After Movement:
General ..................................................................................................................................................................................4-7a
Refrigeration System..............................................................................................................................................................4-7b
Relay Emergency Valve:
Operating and Leakage Test..................................................................................................................................................4-77c
Removal .................................................................................................................................................................................4-77a
Replacement of Suppression Components ....................................................................................................................................4-21
Reservoir:
Inspection...............................................................................................................................................................................4-79c
Removal .................................................................................................................................................................................4--79a
Test........................................................................................................................................................................................4-79d
S
Scope .............................................................................................................................................................................................1-1
Slack Adjuster Replacement ..........................................................................................................................................................4-73
Spark Plugs and Wiring:
Cleaning, Inspection and Repair ............................................................................................................................................4-39b
Removal and Disassembly .............................................................................................................................................................4-39a
Special Tools and Equipment.........................................................................................................................................................4-9
Starter and Solenoid:
Installation ..............................................................................................................................................................................4-43b
Removal .................................................................................................................................................................................4-43
Storage Compartment Door:
Disassembly...........................................................................................................................................................................4-86b
Reassembly ...........................................................................................................................................................................4-86
Removal .................................................................................................................................................................................4-86a
Strainers:
Cleaning and Inspection.........................................................................................................................................................4-103c
Removal .................................................................................................................................................................................4-103c
Suction and Discharge Valves:
Cleaning, Inspection and Repair ............................................................................................................................................4-104c
Discharge Valve Removal ......................................................................................................................................................4-104b
Suction Valve Removal ..........................................................................................................................................................4-104a
T
Tabulated Data:
Identification:
Conversion, Storage and Charging Unit Data
Plate ........................................................................................................................................................................1-7a (3)
I-7
Page
4-10
3-4
4-10
4-95
4-73
4-73
4-73
4-73
4-93
2-13
4-90
4-75
4-74
4-94
4-8
4-8
4-82
4-82
4-27
4-84
4-84
4-8
1-1
4-80
4-48
4-48
4-8
4-53
4-63
4-92
4-92
4-92
4-111
4-111
4-112
4-111
4-111
1-4
TM 5-3655-210-12
Paragraph
Identification (cont'd)
Electric Motor Plate ................................................................................................................................................................1-7a(2)
Engine Plate...........................................................................................................................................................................1-7a(1)
Transportation Data Plate ......................................................................................................................................................1-7a(4)
Tabulated Data:
Carbon Dioxide Conversion, Storage and
Charging Unit.........................................................................................................................................................................1-7b(1)
Capacities ..............................................................................................................................................................................1-7b; (1) (c)
Dimensions and Weights.......................................................................................................................................................1-7(1) (b)
Identification...........................................................................................................................................................................1-7b(1) (a)
Circulating Pump (Conversion Heater)...................................................................................................................................1-7b(6)
Compartment Heater..............................................................................................................................................................1-7b(9)
Conversion Heater .................................................................................................................................................................1-7(5)
Cylinder Filling Compressor ...................................................................................................................................................1-7(4)
Electric Motor .........................................................................................................................................................................1-7b(2)
Electrical ................................................................................................................................................................................1-7b(11)
Gasoline Engine.....................................................................................................................................................................1-7b(3)
Adjustment Date ............................................................................................................................................................1-7b(3) (k)
Air Cleaner.....................................................................................................................................................................1-7b(3) (h)
Carburetor......................................................................................................................................................................1-7b(3) (f)
Fuel Filter 1-7b(3) (j) ......................................................................................................................................................1-5
Fuel Pump .....................................................................................................................................................................1-7b(3) (g)
Generator 1-7b(3) (c).....................................................................................................................................................1-5
Generator Regulator ......................................................................................................................................................1-7b(3) (d)
Identification...................................................................................................................................................................1-7b(3) (a)
Magneto 1-7b(3) (e).....................................................................................................................................................1-5
Nut and Bolt Torque Data ..............................................................................................................................................1-7b(3) (l)
Oil Filter 1-7b(3) (i) ......................................................................................................................................................1-5
Starter............................................................................................................................................................................1-7b(3) (b)
Refrigeration Unit ...........................................................................................................................................................................(1-7b8)
Running Gear.................................................................................................................................................................................1-7b(10)
Brakes ...........................................................................................................................................................................1-7b(10) (b)
Landing Jacks................................................................................................................................................................1-7b(10) (d)
Tandem Axle..................................................................................................................................................................1-7b(10) (a)
Tires and Tubes ............................................................................................................................................................1-7b(10) (c)
Transfer Pump.......................................................................................................................................................................1-7b(7)
Tail Pipe and Muffler:
Inspection and Repair ............................................................................................................................................................4-36b
Removal and Disassembly.....................................................................................................................................................4-36a
Testing of Radio Interference Suppression
Components...........................................................................................................................................................................4-22
Throttles and Choke Controls:
Cleaning, Inspection and Repair ............................................................................................................................................4-25b
Reassembly and Installation...................................................................................................................................................4-2
Removal and Disassembly.....................................................................................................................................................4-25a
Tires and Tubes:
General ..................................................................................................................................................................................3-18
Inspection and Repair ............................................................................................................................................................4-67
Installation ..............................................................................................................................................................................4-67c
Removal .................................................................................................................................................................................4-67
Tools and Equipment .....................................................................................................................................................................4-8
Torque Arms ..................................................................................................................................................................................4 82
Transfer of Liquid Carbon Dioxide from Both
Pressure Vessels Simultaneously..........................................................................................................................................2-11
Transfer of Liquid Carbon Dioxide from One
External Tank into Another External Tank (Liquid
in Both Pressure Vessels) .............................................................................................................................................2-13
Transfer of Liquid Carbon Dioxide from the
Storage Pressure Vessel (Liquid in the Storage
Pressure Vessel Only) ...........................................................................................................................................................2-12
Transfer of Liquid From the Conversion Pressure
Vessel to the Storage Pressure Vessel..................................................................................................................................2-8
Transfer Pump:
Cleaning, Inspection and Repair ............................................................................................................................................4-94b
Installation ..............................................................................................................................................................................4-94c
Troubleshooting, General ...............................................................................................................................................................3-6
4-16
I-8
Page
1-4
1-2
1-4
1-4
1-4
1-4
1-4
1-5
1-6
1-5
1-5
1-4
1-6
1-4
1-6
1-6
1-5
1-5
1-5
1-4
1-5
1-4
1-6
1-6
16
1-6
1-6
1-5
4-46
4-46
4-28
4-32
4-32
4-30
3-13
476
4-76
4-76
4-8
4-90
2-21
2-22
2-21
2-16
4-100
4-100
3-5
4-11
TM 5-3655-210-12
Paragraph
Page
U
Unloading New Conversion and Storage Unit
General ..................................................................................................................................................................................4-la
Unloading by Use of Ramp ....................................................................................................................................................4-c
Unloading with Lifting Device .................................................................................................................................................4-lb
Unpacking New Conversion and Storage Unit
Accessories:
General ..................................................................................................................................................................................4-2a
Installation ..............................................................................................................................................................................4-2c
Removal .................................................................................................................................................................................4-2b
Removal of Protective Material and Devices ..........................................................................................................................4-2d
Services for Cold Weather Operation ....................................................................................................................................4-2e
W
Water Limit Switch and Thermostat
Cleaning, Inspection and Repair ............................................................................................................................................4-113b
Reassembly and Installation...................................................................................................................................................4-113c
Water Manifold:
Cleaning, Inspection and Repair ............................................................................................................................................4-108c
Disassembly...........................................................................................................................................................................4-108
Installation ..............................................................................................................................................................................4-108e
Reassembly ...........................................................................................................................................................................4-108d
Removal .................................................................................................................................................................................4-108a
Wheel Bearings and Hubs:
Cleaning, Inspection and Repair ............................................................................................................................................4-68c
Disassembly...........................................................................................................................................................................4-68b
Installation ..............................................................................................................................................................................4-6e
Removal .................................................................................................................................................................................4-68
Wheel Brake Replacement.............................................................................................................................................................4-72
Wheels:
Removal .................................................................................................................................................................................4-6
Wheels, Tires, Tubes and Bearings:
Description.............................................................................................................................................................................4-65
Winterization Equipment ................................................................................................................................................................3-21
Wiring and Ignition Unit:
Cleaning, Inspection and Repair ............................................................................................................................................4-114b
Installation ..............................................................................................................................................................................4-114c
Removal .................................................................................................................................................................................4-114a
Vibrator Replacement.............................................................................................................................................................4-114
220 Volt AC Electrical System:
Description.............................................................................................................................................................................4 -56
24 Volt Electrical Systems Engine and Vehicular.
Description.............................................................................................................................................................................4-41
I-9
4-1
4-1
4-1
4-1
4-3
4-3
4-3
4-3
4-124
4-125
4-117
4-117
4-117
4-117
4-115
4-77
4-77
4-78
4-76
4-80
4-76
4-76
3-13
4-127
4-127
4-125
4-127
4-71
4-51
TM 5-3655-210-12
By Order of the Secretary of the Army:
FRED C WEYAND
General, United States Army
Official: Chief of Staff
PAUL T SMITH
Major General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-25A, Operator maintenance requirements for Gas Generating.
¶U. S. GOVERNMENT PRINTING OFFICE: 1982 0 - 378-355
PIN: 025570-000
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