TM-9-4120-381-14

TM-9-4120-381-14
*ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Operator's, Unit, Direct Support
and General Support Maintenance Manual
INTRODUCTION
PAGE 1-1
OPERATING INSTRUCTIONS
PAGE 2-1
OPERATOR MAINTENANCEPAGE
PAGE 3-1
UNIT MAINTENANCE P
PAGE 4-1
DIRECT SUPPORT MAINTENANCE
PAGE 5-1
GENERAL SUPPORT MAINTENANCE
PAGE 6-1
REFERENCES
PAGE A-1
MAINTENANCE ALLOCATION CHART
PAGE B-1
COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST PAGE C-1
AIR CONDITIONER, 50,000 BTU
ELECTRIC MOTOR DRIVEN
208 V, 3-PHASE, 50/60 HZ
5 WIRE
MODEL MOAC 640
NSN 4120-01-157-0996
ADDITIONAL AUTHORIZATION LIST
PAGE D-1
EXPENDABLE/DURABLE SUPPLIES
AND MATERIALS LIST PAGE E-1
ALPHABETICAL INDEX
PAGE INDEX 1
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
* This manual supersedes TM 5-4120-381-14, dated 6 October 1989
HEADQUARTERS, DEPARTMENT OF THE ARMY, THE NAVY AND
THE AIR FORCE
1 FEBRUARY 1994
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
WARNING
HIGH VOLTAGE
Is used in the operation of this equipment.
DEATH ON CONTACT
may result if personnel fail to observe safety precautions.
Never work on electrical equipment unless there is another person nearby who is familiar with the
operation and hazards of the equipment and who is competent in administering first aid. When the
technician is aided by operators, he must warn them about dangerous areas.
Whenever possible, the input power supply to equipment must be shut off before beginning work on the
equipment. Take particular care to ground every capacitor likely to hold a dangerous potential. When
working inside the equipment, after the power has been turned off, always ground every part before
touching it.
Be careful not to contact high-voltage connections of 208 volts ac input when installing or operating this
equipment.
Whenever the nature of the operation permits, keep one hand away from the equipment to reduce the
hazard of current flowing through vital organs of the body.
Do not operate the equipment without all panels and covers in place and tightly secured.
Do not be misled by the term "low voltage." Potentials as low as 50 volts may cause death under adverse
conditions.
WARNING
Do not allow anyone under equipment suspended from a lifting device. Do not allow the unit to swing
while suspended from a lifting device. Failure to observe this warning may result in injury to personnel
and damage to the equipment.
Serious injury could occur if heavy equipment is moved/lifted without sufficient personnel to do the job.
Use proper physical lifting procedures or use a suitable lifting device or dolly. Wear safety shoes, gloves
and other suitable protective clothing.
WARNING
Panels and fitlers installed on unit are there for a purpose. Do not operate unit with them off unless
instructions tell you to. When necessary, do so with care.
a
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages used
can KILL. Shutting the unit off at the control panel does not disconnect unit power.
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive. Repeated or
prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area, wear rubber
gloves, and keep away from sparks or flame.
WARNING
Industrial process must be evaluated by the Medical Service Bioenvironmental Engineer in accordance
with local laws and regulations.
Waste treatment/disposal must be approved by the Medical Service Bioenvironmental Engineer and Civil
Engineer in accordance with local laws and regulations.
Solutions will be disposed of in accordance with local State Water Pollution Control Laws. Consult local
Medical Services for guidance.
WARNING
DANGEROUS CHEMICAL (R22) is used in this equipment.
DEATH
or severe damage may result if personnel fail to observe safety precautions. Use great care to avoid
contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and irreversible
tissue damage can result from freezing. Wear thermal protective gloves and a face protector or goggles
in any situation where skin-eye-contact is possible. Prevent contact of refrigerant gas with flame or hot
surfaces. Heat causes the refrigerant to break down and form carbonyl chloride (phosgene), a highly
poisonous and corrosive gas.
REFRIGERANT UNDER PRESSURE
is used in the operation of this equipment.
DEATH
or severe injury may result if you fail to observe safety precautions. Never use a heating torch on any part
that contains refrigerant-22. Do not let liquid refrigerant touch you, and do not Inhale refrigerant gas.
b
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (2.1 kg/cm2). Do not direct compressed
air against the skin. Use goggles or full face shield.
WARNING
All refrigerant - 22 must be discharged from the system and the entire system must be purged with dry
nitrogen before beginning any debrazing operation.
WARNING
The burning of polyurethane foam is dangerous. Toxic fumes are released when it Is burned or heated. If
burned or heated indoors, such as during a welding operation nearby, take care to ventilate the area
thoroughly. An exhaust system like that of a paint spray booth should be used.
Air-supplied respirators, approved by the National Institute for Occupational Safety and Health
Administration or the United States Bureau of Mines, should be used for all welding in confined spaces and
in places where ventilation is inadequate. Persons who have chronic or recurrent respiratory conditions,
including allergies and asthma, should not work in these areas.
WARNING
Personnel injury and/or equipment damage may result If compressor is started when service valves are
not in a backseated (counterclockwise) position.
WARNING
When performing maintenance around condenser or evaporator coil, avoid coming in contact with coil to
avoid injury to personnel and to reduce fin damage on the coil.
WARNING
Heating element can bc extremely hot. Severe burns can be caused by touching with bare skin.
c
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
WARNING
Compressor weighs approximately 300 lbs. Personnel injury and/or internal components can be damaged
if compressor falls off of mounting bracket and shims.
WARNING
Avoid skin contact or inhaling fumes from any acid formed by burnout of oil and refrigerant. Wear a gas
mask if area is not thoroughly ventilated. Wear protective goggles or glasses to protect eyes. Wear
rubber gloves to protect hands.
WARNING
Clean parts in a well ventilated area. Avoid Inhalation of solvent fumes and prolonged exposure of skin to
cleaning solvent. Wash exposed skin thoroughly. Dry cleaning solvent (Fed. Spec. P-D 680) used to
clean parts is potentially dangerous to personnel and property. Do not use near open flame or excessive
heat. Flash point of solvent is 100°F (38°C). Wear eye protection when blowing solvent from parts.
d
*ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
TECHNICAL MANUAL
NO. 9-4120-381-14
HEADQUARTERS
DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE
WASHINGTON D.C., 1 February 1994
Operator, Unit Direct Support, and
General Support Maintenance
For
AIR CONDITIONER, 50, 000 BTU
ELECTRIC MOTOR DRIVEN
208 V, 3-PHASE, 50/60 HZ
5 WIRE
MODEL MOAC 640
NSN 4120-01-157-0996
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications
and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to: Commander, US
Army Aviation and Troop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd., St. Louis, MO 631201798. A reply will be furnished directly to you.
For Air Force, submit AFTO Form 22 (Technical Order System Publication Improvement Report and
Reply) in accordance with paragraph 6-5, Section VI, T.O. 00-5-1. Forward to Commander, San Antonio
Air Logistics Center, ATTN: SA-ALC/TIRTR, Kelly Air Force Base, TX 78241-5000.
For Navy, mail comments to the Commander, Naval Construction Battalion Center, ATTN: Code 157411,
Bldg. 1443, Port Hueneme, CA 93043-5000.
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
TABLE OF CONTENTS
CHAPTER
1
Section I
Section II
Section III
CHAPTER
2
Section I
Section II
Section III
Section IV
CHAPTER
Page
INTRODUCTION .................................................................................................................1-1
General Information.............................................................................................................1-1
Equipment Description.........................................................................................................1-2
Technical Principles of Operation .......................................................................................1-7
OPERATING INSTRUCTIONS ............................................................................................2-1
Description and Use of Operator's Controls and Indicators ..................................................2-1
Operator Preventive Maintenance Checks and Services (PMCS) .......................................2-3
Operation Under Usual Conditions.......................................................................................2-5
Operation Under Unusual Conditions ...................................................................................2-14
3
OPERATOR MAINTENANCE..............................................................................................3-1
Section I
Section II
Section III
Operator Lubrication Instructions .........................................................................................3-1
Operator Troubleshooting ....................................................................................................3-1
Operator Maintenance Procedures ......................................................................................3-5
*This manual supersedes TM 5-4120-381-14, dated 6 October 1989
i
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Page
CHAPTER
4
Section I
Section II
Section III
Section IV
Section V
Section VI
Section VII
CHAPTER
UNIT MAINTENANCE .........................................................................................................4-1
Unit Lubrication Instructions ................................................................................................4-1
Repair Parts, Special Tools, Test, Measurement and Diagnostic Equipment
(TMDE), and Support Equipment ........................................................................................4-1
Service Upon Receipt .........................................................................................................4-2
Unit Preventive Maintenance Checks and Services (PMCS) ...............................................4-15
Unit Troubleshooting ...........................................................................................................4-22
Unit Maintenance Procedures .............................................................................................4-31
Preparation For Storage or Shipment...................................................................................4-182
5
DIRECT SUPPORT MAINTENANCE...................................................................................5-1
Section I
Section II
Section III
Repair Parts, Special Tools, TMDE, and Support Equipment ..............................................5-1
Direct Support Troubleshooting ...........................................................................................5-1
Direct Support Maintenance Procedures..............................................................................5-8
CHAPTER
6
GENERAL SUPPORT MAINTENANCE...............................................................................6-1
Section I
Section II
Repair Parts, Special Tools, TMDE, and Support Equipment ..............................................6-1
General Support Maintenance Procedures ..........................................................................6-1
APPENDIX
A.
REFERENCES ....................................................................................................................A-1
APPENDIX
B.
MAINTENANCE ALLOCATION CHART (MAC) ...................................................................B-1
Section I
Section II
Section III
Section IV
APPENDIX
Introduction .........................................................................................................................B-1
Maintenance Allocation Chart .............................................................................................B-3
Tool and Test Equipment Requirements .............................................................................B-12
Remarks .............................................................................................................................B-14
C.
COMPONENTS OF END ITEM AND BASIC ISSUE ITEM LISTS........................................C-1
Section I
Section II
Section III
Introduction .........................................................................................................................C-1
Components of End Item ....................................................................................................C-1
Basic Issue Items ................................................................................................................C-2
APPENDIX
D.
ADDITIONAL AUTHORIZATION LIST.................................................................................D-1
Section I
Section II
Introduction .........................................................................................................................D-1
Additional Authorization List ................................................................................................D-1
APPENDIX
E.
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST............................................E-1
Section I
Section II
Introduction .........................................................................................................................E-1
Expendable/Durable Supplies and Materials List .................................................................E-2
ALPHABETICAL INDEX .................................................................................................Index 1
ii
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
LIST OF TABLES
Number
2-1
3-1
4-1
4-2
4-3
4-4
5-1
5-2
5-3
5-4
Title
Page
Operator Preventive Maintenance Checks and Services ................................................................. 2-4
Operator Troubleshooting ................................................................................................................ 3-1
Unit Preventive Maintenance Checks and Services
Quarterly Schedule ......................................................................................................................... 4-15
Unit Maintenance Troubleshooting .................................................................................................. 4-23
MODE SELECT SWITCH Positions and Results ............................................................................. 4-35
MODE SELECT SWITCH Test ....................................................................................................... 4-107
Direct Support Troubleshooting ....................................................................................................... 5-2
Pressure-Temperature Relationship of Saturated R-22 Refrigerant ................................................. 5-35
Normal Operating Pressures (in full cooling mode) .......................................................................... 5-36
Compressor Wear Limits ................................................................................................................. 5-116
LIST OF ILLUSTRATIONS
Figure
1-0
1-1
1-2
1-3
1-4
1-5
2-1
2-2
2-3
2-4
2-5
2-6
2-7
3-1
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
Title
Page
MOAC 640 50,000 BTU Air Conditioner .......................................................................................... 1-0
External Components (Front and Top Views) ................................................................................... 1-2
External Components (Rear View) .................................................................................................. 1-3
Internal Components Evaporator Section ........................................................................................ 1-4
Internal Components Condenser and Compressor Section .............................................................. 1-5
Functional Block Diagram ................................................................................................................ 1-8
Controls and Indicators .................................................................................................................... 2-1
Air Inlets and Outlets ....................................................................................................................... 2-6
Auto Mode (Settings and Indicators) ................................................................................................ 2-7
Cool Mode (Settings and Indicators) ................................................................................................ 2-8
Heat Mode (Settings and Indicators) ................................................................................................ 2-9
Remote Mode (Settings and Indicators) ........................................................................................... 2-10
OFF Mode (Settings and Indicators) ................................................................................................ 2-11
Return Air Filter ............................................................................................................................... 3-6
Unit Lubrication ............................................................................................................................... 4-1
Typical Crated Air Conditioner ......................................................................................................... 4-3
Center Front Evaporator Panel Removal ......................................................................................... 4-5
Left Front Evaporator Panel Removal ............................................................................................. 4-5
Right Front Evaporator Panel Removal ........................................................................................... 4-5
Right Front Condenser Panel Removal ........................................................................................... 4-6
Left Front Condenser Panel Removal ............................................................................................. 4-6
Left Electric Plate ............................................................................................................................ 4-6
Right Electric Plate .......................................................................................................................... 4-7
Rear Evaporator Panel Removal ..................................................................................................... 4-7
Rear Condenser Panel Removal ..................................................................................................... 4-7
Pulley Locations .............................................................................................................................. 4-8
Rear Condenser Panel Installation .................................................................................................. 4-9
Rear Evaporator Panel Installation .................................................................................................. 4-9
Electrical Connections ..................................................................................................................... 4-11
Fan Contractors (K8 and K9) Switches............................................................................................. 4-11
Condenser and Evaporator Fan Rotation ......................................................................................... 4-12
Right Electric Plate .......................................................................................................................... 4-12
Left Electric Plate ............................................................................................................................ 4-12
iii
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
LIST OF ILLUSTRATIOINS
Figure
4-20
4-21
4-22
4-23
4-24
4-25
4-26
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
4-41
4-42
4-43
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
4-58
4-59
4-60
4-61
4-62
4-63
4-64
4-65
4-66
4-67
4-68
Title
Page
Right Front Condenser Panel Installation ........................................................................................ 4-13
Right Front Evaporator Panel Installation ......................................................................................... 4-13
Left Front Condenser Panel Installation ........................................................................................... 4-13
Left Front Evaporator Panel Installation .......................................................................................... 4-14
Center Front Evaporator Panel Installation ...................................................................................... 4-14
Control Circuits ............................................................................................................................... 4-34
Center Front Evaporator Panel......................................................................................................... 4-37
Left Front Evaporator Panel ............................................................................................................ 4-39
Fresh Air Inlet Filter Box (Evaporator Front Panel) .......................................................................... 4-42
Right Front Evaporator Panel .......................................................................................................... 4-44
Information Plates ........................................................................................................................... 4-46
Left Front Condenser Panel ............................................................................................................ 4-49
Right Front Condenser Panel ........................................................................................................... 4-51
Front Service Valve Panel .............................................................................................................. 4-54
Left Electric Plate ............................................................................................................................ 4-57
Right Electric Plate .......................................................................................................................... 4-59
Control Wire J-Box .......................................................................................................................... 4-62
Fresh Air Connecting Link ............................................................................................................... 4-65
Thermostat Bracket ......................................................................................................................... 4-67
Circulating Air In RFI Filter .............................................................................................................. 4-69
Fresh Air Filter ................................................................................................................................ 4-71
Fresh Air RFI Filter .......................................................................................................................... 4-72
Condenser Air Out RFI Filter ........................................................................................................... 4-73
Condenser Air In RFI Filter .............................................................................................................. 4-74
Circulating Air Out RFI Filter ............................................................................................................ 4-76
RFI Filter ......................................................................................................................................... 4-78
Fuses (F1-F4) ................................................................................................................................. 4-80
Varsities (VR-1 thru VR-4) ............................................................................................................... 4-82
Control Box and Components .......................................................................................................... 4-84
Rectifier (CR1) ................................................................................................................................ 4-86
Suppression Diodes (CR2-CR11) .................................................................................................... 4-88
Indicator Lights (DS1-DS7, DS9) ..................................................................................................... 4-90
Control Relays (K1-K7, K18-K20) .................................................................................................... 4-92
Relay Sockets (11-Pin) .................................................................................................................... 4-94
Fan Contractors (K8 and K9) ........................................................................................................... 4-96
Compressor Contactor (K10) ........................................................................................................... 4-99
Heater Contactor (K11) ................................................................................................................... 4-101
Time Delay (10 and 60 sec) Relays (K21 and K22) ......................................................................... 4-103
Resistors (R1 and R2) ..................................................................................................................... 4-105
Mode Select Switch (S1) ................................................................................................................. 4-107
Knob (Mode Select Switch (S1)) ...................................................................................................... 4-109
Service Light Switch (S2) ................................................................................................................ 4-111
Fault Reset Switch (S12).................................................................................................................. 4-113
Transformer (T1).............................................................................................................................. 4-115
Terminal Boards (TB1-TB3) ............................................................................................................ 4-117
Circuit Breakers (CB1 and CB2) ...................................................................................................... 4-119
Control Box ..................................................................................................................................... 4-121
Terminal Board (TB4) ...................................................................................................................... 4-124
Service Light (DS8) ......................................................................................................................... 4-126
iv
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
LIST OF ILLUSTRATIONS
Figure
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
4-91
4-92
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
5-16
5-17
5-18
5-19
5-20
5-21
5-22
5-23
5-24
5-25
Title
Page
Fresh Air Damper Solenoid (L3) ...................................................................................................... 4-128
Fan Belt (Evaporator Motor and Housing Assembly) ....................................................................... 4-133
Evaporator Motor (B1) ..................................................................................................................... 4-135
Circulator Fan (Evaporator) ............................................................................................................. 4-137
Pulleys 60 Hz, Green (Evaporator Motor and Circulator Fan) .......................................................... 4-140
Pulleys 50 Hz, Red (Evaporator Motor and Circulator Fan) ............................................................. 4-142
Fan Belt (Condenser Motor and Housing Assembly) ........................................................................ 4-145
Condenser Motor (B3) ..................................................................................................................... 4-147
Circulator Fan (Condenser) ............................................................................................................. 4-149
Pulleys 60 Hz, Green (Condenser Motor and Circulator Fan) .......................................................... 4-152
Pulleys 50 Hz, Red (Condenser Motor and Circulator Fan) .............................................................. 4-154
Electric Heater ................................................................................................................................ 4-156
Compressor Crankcase Heater ........................................................................................................ 4-159
Dirty Filter Switch (S3) .................................................................................................................... 4-161
High Temperature Switch (S6) ........................................................................................................ 4-163
Air Flow Switch (S8) ........................................................................................................................ 4-165
Heat Control Thermostat (S9) ......................................................................................................... 4-167
Low Ambient Temperature Thermostat (S13) .................................................................................. 4-169
Cool Control Thermostat (S14) ........................................................................................................ 4-171
Solenoid Valve (L1 and L2) Coil Removal........................................................................................ 4-173
Condenser Fan Connecting Link Assembly ..................................................................................... 4-175
Condenser Coil Cleaning ................................................................................................................. 4-177
Evaporator Coil Cleaning ................................................................................................................ 4-179
Drain Areas ..................................................................................................................................... 4-181
Evaporator Motor (B1) ..................................................................................................................... 5-12
Condenser Motor (B3) ..................................................................................................................... 5-15
Service Manifold Installation ........................................................................................................... 5-19
Discharging Refrigeration System ................................................................................................... 5-21
Purging Refrigerant System ............................................................................................................. 5-23
Evacuating Refrigerant System........................................................................................................ 5-30
Charging Refrigerant System .......................................................................................................... 5-32
Discharging Compressor ................................................................................................................. 5-38
Purging Compressor ....................................................................................................................... 5-40
Pump Down .................................................................................................................................... 5-42
Start Up After Repairs ..................................................................................................................... 5-44
High Refrigerant Pressure Switch (S4) ............................................................................................ 5-46
Low Refrigerant Pressure Switch (S5) ............................................................................................. 5-49
Low Oil Pressure Switch (S7) .......................................................................................................... 5-52
Drier Filter ....................................................................................................................................... 5-55
Refrigerant Strainer ......................................................................................................................... 5-58
Sight Glass ..................................................................................................................................... 5-60
Service Valves (Head and Hotgas Bypass) ..................................................................................... 5-62
Service Valve (Expansion) .............................................................................................................. 5-64
Service Valve (Actuator) ................................................................................................................. 5-66
Service Valves (Schrader) .............................................................................................................. 5-68
Discharge Valve (Compressor) ........................................................................................................ 5-70
Suction Valve (Compressor) ............................................................................................................ 5-72
Solenoid Valve (L1 and L2) ............................................................................................................. 5-74
Thermostatic Expansion Valve (Liquid Quench) .............................................................................. 5-76
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ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
LIST OF ILLUSTRATIONS
Figure
5-26
5-27
5-28
5-29
5-30
5-31
5-32
5-33
5-34
5-35
5-36
5-37
5-38
5-39
5-40
5-41
5-42
5-43
5-44
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
6-12
6-13
6-14
6-15
6-16
FO-1
FO-2
FO-3
Title
Page
Hot Gas Bypass Valve .................................................................................................................... 5-80
Thermostatic Expansion Valve (Primary) ........................................................................................ 5-84
Manual Valve (Bypass) ................................................................................................................... 5-87
Vibration Eliminators ........................................................................................................................ 5-89
Condenser Fan Damper Actuator .................................................................................................... 5-91
Receiver ......................................................................................................................................... 5-94
Distributor ....................................................................................................................................... 5-95
Pressure Regulator Valve ................................................................................................................ 5-97
Compressor Oil Removal ................................................................................................................ 5-102
Adding Compressor Oil ................................................................................................................... 5-103
Compressor .................................................................................................................................... 5-105
Valve Plate Assembly ..................................................................................................................... 5-110
Pump End Bearing Head Assembly ................................................................................................. 5-112
Crankshaft, Pistons and Rods ......................................................................................................... 5-114
Electrical Box Assembly .................................................................................................................. 5-119
Terminal Plate ................................................................................................................................. 5-121
Current Overloads (K23 and K24) ................................................................................................... 5-124
Condenser Coil ............................................................................................................................... 5-126
Evaporator Coil ............................................................................................................................... 5-128
Rear Evaporator Panel .................................................................................................................... 6-3
Thermostat Box and Cover ............................................................................................................. 6-6
Fresh Air Inlet Box .......................................................................................................................... 6-8
Fresh Air Damper Operator Bracket ................................................................................................ 6-10
Rear Condenser Panel .................................................................................................................... 6-12
Fresh Air RFI Filter .......................................................................................................................... 6-14
Condenser Air Out RFI Filter ........................................................................................................... 6-16
Condenser Air In RFI Filter .............................................................................................................. 6-18
RFI Filter ......................................................................................................................................... 6-20
Fuse Holder (RFI Box) .................................................................................................................... 6-22
Varistors (VR-1 thru VR-4) .............................................................................................................. 6-24
Thermostatic Expansion Valve (Primary) ........................................................................................ 6-26
Distributor ....................................................................................................................................... 6-29
Pressure Regulator Valve ................................................................................................................ 6-31
Condenser Coil Removal ................................................................................................................ 6-35
Evaporator Coil Removal ................................................................................................................ 6-40
Electrical schematic ........................................................................................................................ FP-1
Dimensions ..................................................................................................................................... FP-3
Wiring Diagram (2 sheets) ............................................................................................................... FP-5
vi
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure 1-0. MOAC 640 50,000 BTU Air Conditioner
1-0
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
CHAPTER 1
INTRODUCTION
Section I. GENERAL INFORMATION
1-1. SCOPE. This manual is for use by personnel responsible for the operation and maintenance of the MOAC 640 air
conditioner.
a. Type of Manual. Operator, Unit, Direct Support and General Support Maintenance Manual.
b. Model Number and Equipment Name. Ellis and Watts, Corporation, Model MOAC 640, 50,000 BTU/HR Cooling,
34,150 BTU/HR Heating, 208 volt, 3 Phase, 50/60 Hertz air conditioner.
c. Purpose of Equipment. The air conditioner is designed for cooling and heating air to a desired predetermined
range and circulating the conditioned air to provide heating and cooling of equipment and/or personnel within the
conditioned area.
1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS. Department of the Army forms and procedures used for
equipment maintenance will be those prescribed by DA Pam 738-750, The Army Maintenance Management System
(TAMMS). Air Force personnel will use AFR 66-1 for maintenance reporting and TO-00-35D54 for unsatisfactory
equipment reporting. Navy personnel will report maintenance performed utilizing the Maintenance Data Collection
Subsystem (MDCS) IAW OPNAVINST 4790.2, Vol 3 and unsatisfactory material/conditions (UR submissions) IAW
OPNAVINST 4790.2, Vol 2, chapter 17.
1-3. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR).
a. Army. If your air conditioner needs improvement, let us know. Send us an EIR. You, the user, are the only one
who can tell us what you don't like about your equipment. Let us know why you don't like the design or
performance. Put it on an SF 368 (Product Quality Deficiency Report). Mail it to: Commander, US Army
Aviation and Troop Command, ATTN: AMSAT-I-MDO, 4300 Goodfellow Blvd., St Louis, Mo. 63120-1798. We'll
send you a reply.
b. Air Force. Air Force personnel are encouraged to submit EIR's in accordance with AFR 900-4.
c. Navy. Navy personnel are encouraged to submit EIR's through their local Beneficial Suggestion Program.
1-4. WARRANTY INFORMATION. The air conditioner, model MOAC 640, is warranted by Ellis and Watts
Corporation for a period of one year from date of shipment when properly installed. Warranty starts on the date found in
block 23 of DA Form 24089 in the logbook. Report all defects in material or workmanship to your supervisor who will
take appropriate action.
1-5.
LIFT OF ABBREVIATIONS.
CBR
CGV
EIR
EMI
CV
MAC
MEK
MTOE
PGV
PMCS
RFI
TMDE
VAC
VPV
Chemical, biological radiological hazard
Compound gage valve
Equipment Improvement Recommendation
Electro magnetic interference
Charging valve
Maintenance Allocation Chart
Methyl ethyl ketone (solvent)
Modified Table of Organization and Equipment
Pressure gage valve
Preventive Maintenance Checks and Services
Radio frequency interference
Test, Measurement and Diagnostic Equipment
Vacuum
Vacuum/purge valve
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1-6. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE. Command decisions, according to tactical
situation, will determine when destruction of the air conditioning unit will be accomplished. A destruction plan will be
prepared by the user organization unless one has been prepared by higher authority. For general destruction procedures
for this equipment, refer to TM 750-244-3, Procedures for Destruction of Equipment to Prevent Enemy Use.
1-7. PREPARATION FOR STORAGE OR SHIPMENT. Contact unit maintenance for air conditioning unit preparation
for storage or shipment. See para 4-93 for instructions.
Section II. EQUIPMENT DESCRIPTION
1-6. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES. The MOAC 640 air conditioning unit is
designed to ventilate, cool or heat, and to filter and circulate air in enclosures.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Provides a maximum of 50,000 BTU/HR of cooling and 34,150 BTU/HR of heating.
Has one stage of heat.
Provides a source of filtered outside (fresh) ventilation air.
Is self contained in single cabinet that is suited for van, shelter or other enclosed areas.
Operates in environmental conditions from arctic to tropic.
Is EMI/RFI shielded; compatible with electronic equipment.
Capable of control and interface for operation with remote control panel.
Capable of supply or return air temperature control.
Automatic unit shut down in fault condition, with manual reset.
Provides for local and remote fault indications.
The hot gas bypass system permits continuous running of the compressor.
1-9. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.
a. External Components (Front View).
Figure 1-1. External Components (Front and Top Views).
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LIFTING EYEBOLTS (1). Used to hoist unit.
RETURN AIR INLET (2). Contains return air filter and circulating air in RFI filter.
LEFT FRONT EVAPORATOR PANEL (3). Covers return air thermostats and electric heater.
CENTER FRONT EVAPORATOR PANEL (4). Covers evaporator coil, control box components, and sight glass located
behind control box (5).
OPERATOR'S CONTROL PANEL (5). Contains five position mode switch, service light switch, fault reset switch, and
fault indicators.
RIGHT FRONT EVAPORATOR PANEL (6). Covers evaporator fan and motor.
FRONT SERVICE VALVE PANEL (7). Covers service valves.
RIGHT FRONT CONDENSER PANEL (8). Covers compressor and condenser coil.
LEFT FRONT CONDENSER FRONT PANEL (9). Covers condenser fan and motor.
b. External Components (Rear View)
Figure 1-2. External Components (Rear View)
REAR EVAPORATOR PANEL (1). Covers evaporator section components.
FRESH AIR INLET and FRESH AIR RFI FILTER (2). Provides for fresh air and controls RFI.
CONDENSER AIR OUTLET and CONDENSER AIR OUT RFI FILTER (3). Provides for condenser air outlet and controls
RFI.
CONDENSER AIR INLET and CONDENSER AIR IN RFI FILTER (4). Provides for condenser air inlet and controls RFI.
REAR CONDENSER PANEL (5). Covers condenser and compressor section components.
SUPPLY AIR OUTLET (6). Provides for conditioned air to equipment or shelter.
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1-9. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Continued.
c. Internal Components Evaporator Section
Figure 1-3. Internal Components Evaporator Section
THERMOSTAT (S9) (1). Senses return air temperature. Controls electric heaters and limits space temperature during
warm up cycle.
ELECTRIC HEATER (EH) (2). Heats supply air.
EVAPORATOR COIL (3). Cools supply air.
EVAPORATOR FAN MOTOR (B1) (4). Drives evaporator fan.
EVAPORATOR FAN (5). Draws mixed return air through evaporator and electric heater. Forces conditioned supply air
through duct work.
DRIER FILTER (6). Used for filtering out refrigerant contaminants in the liquid side of the system.
AIR FLOW SWITCH (S8) (7). Opens if evaporator fan stops and causes EVAPORATOR FAN FAILURE fault light to
come on.
SIGHT GLASS (8). Used for checking refrigerant level in air conditioner.
THERMOSTAT (S14) (9). Senses return air temperature. Controls cooling when operating in return air mode.
TERMINAL BOARD (TB4) (10). Interface for remote operation.
RFI FILTER BOX (11). Input for ac power. Holds fuses F1-F4.
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d. Internal Components Condenser and Compressor Sections
Figure 1-4. Internal Components Condenser and Compressor Section
COMPRESSOR RELAY/JUNCTION BOX (1). Connects power to compressor.
SERVICE LIGHT (DS8) (2). Lights compressor section.
COMPRESSOR (B2) (3). Pumps refrigerant through system during operation.
CRANKCASE HEATER (CCH) (4). Heats crankcase oil for compressor.
CONDENSER COIL (5). Condenses hot refrigerant gas to liquid.
LOW OIL PRESSURE SWITCH (S7) (6). Safety switch, protects compressor when oil pressure is abnormally low.
CONDENSER FAN (7). Draws air through condenser coil. Exhausts hot air.
CONDENSER FAN MOTOR (B3) (8). Drives condenser fan.
PULLEYS (9). Permit 50 Hz or 60 Hz fan motor operation. Green pulleys are for 60 Hz operation. Red pulleys are for
50 Hz operation.
HIGH (S4) AND LOW (S5) PRESSURE SWITCHES (10). Safety switches protect compressor when refrigerant pressure
is too high or low.
1-10. EQUIPMENT DATA.
Physical Data
Dimensions (See figure FO-1.)
Height ............................................................................60 inches (1524.0 mm)
Width .............................................................................60 inches (1524.0 mm)
Depth..............................................................................30 inches (762.0 mm)
Weight ...........................................................................1410 pounds (640.0 kg)
Cabinet
Material .........................................................................Aluminum
Finish ............................................................................Semi-gloss enamel (air-dried)
.......................................................................................color no. 26250 (gray) per FED-STD-595
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1-10. EQUIPMENT DATA - Continued.
Performance Data
Capacities
Cooling ..........................................................................50,000 Btu/hr at 125°F (52°C) ambient
condenser air inlet temperature below
the altitude of 10,000 ft.
Supply Air.......................................................................55°F (dry bulb) ± 3°F
12.7°C (dry bulb)± 1.7°C
Heating .........................................................................34,150 BTU/HR (10 KW)
Air Circulating ................................................................1700 CFM (47.6m³/min) at 1.5 in. (3.81 cm) water
gage external static pressure.
Fresh Air Flow ...............................................................0 to 100 CFM (to 2.8 m³/min, adjustable)
Environmental Limits
Ambient Air Temperature
Operating-Cooling .........................................................0°F to +125°F (-17.70°to +52°C)
-Heating .........................................................-40°F to + 90°F (-40°C to +32°C)
Mechanical Data
Refrigeration,
Number of stages ..........................................................One (1)
Refrigerant ....................................................................R-22
Condenser Section
Compressor ...................................................................Reciprocating semi-hermetic, 8 hp motor
Condenser Coil ..............................................................Copper tubes, fins and end plates; all tin plated
Condenser Fan...............................................................Forward curved centrifugal, 1725 rpm with 3-hp motor
Evaporator Section
Evaporator Valve ...........................................................Thermostatic
Evaporator Coil ..............................................................Copper tubes, fins and end plates; all tin plated
Evaporator Fan...............................................................Forward curved centrifugal, 1725 rpm with 1-1/2 hp
motor
Air Filter .........................................................................Permanent, cleanable type
Electrical Data
Power
Input Voltage .................................................................208 V ac, 3-phase, 50/60 Hz, 5-wire
Power Consumption (total) .............................................15 KW cooling, 12 KW heating
Continuous Transients ...................................................±10% voltage (187.2 to 228.8 V ac)
±5% frequency (47.5 to 52.5/57 to 63 Hz)
Fan Motors
Type
..........................................................................3-phase, induction, ball bearing
Protection ......................................................................Currents overloads and internal thermal overloads.
Heating
Number of stages ..........................................................One (1)
Type
..........................................................................208 V ac, single phase, six (6) elements
Controls..........................................................................Thermostat
Safety switches ..............................................................Air flow and over temperature cutouts
Cooling
Controls .........................................................................EPR Valve or thermostat
Safety Switches .............................................................High and low refrigerant pressure cutouts, low
compressor oil pressure cutout, dirty air filter cutout
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1-11. SAFETY, CARE, AND HANDLING. Read and understand all instructions relating to the specific function you are
to perform before starting task.
a. Carefully read and understand all notes, cautions, and warnings contained in this manual that pertain to the task
you are to perform.
b. Carefully read and understand all WARNING and CAUTION plates located on the air conditioner.
c. Never operate the air conditioner with any covers, air filters, or panels removed unless the instructions
specifically instruct you to do so. Then do so only with extreme caution.
d. Carefully plan all maintenance tasks and never take unnecessary risks.
Section III. TECHNICAL PRINCIPLES OF OPERATION
1-12. SCOPE. This section tells how the air conditioner works in its various configurations and operating cycles (see
Figure 1-5).
1-13. OPERATING CONFIGURATIONS. This air conditioner can be operated as either a redundant, remotely
controlled unit or as a single, locally controlled unit. Two separate control systems are provided in the air conditioner for
these configurations.
a. Redundant Unit, Remote Control Configuration. In this configuration, the air conditioner is paired with at least
one other air conditioner and controlled from a remotely located control panel. The air conditioner MODE
SELECT SWITCH must be positioned to REMOTE. When cooling is remotely selected, a pressure regulator
valve (V3) is used to control supply air temperature. When heating is remotely selected, a heat control
thermostat located in the return air section of the air conditioner monitors the return air and controls the electric
heaters. The heat control thermostat shuts off the electric heaters when the return air reaches 80°F (27°C). The
remote control operation modes can be overridden at any time by LOCAL mode selections on the air conditioner
MODE SELECT SWITCH.
b. Single Unit, Local Control Configuration. Operation of the air conditioner as a single, stand alone unit requires
the installation of three jumper wires on terminal board TB2 and opening the manual bypass valve (V7). With
the pressure regulator valve (V3) bypassed, cooling control is performed by the cycling of a solenoid valve (L1)
located in the refrigerant line upstream of the primary expansion valve (V12). A cool control thermostat located
in the return air section of the air conditioner will deenergize the solenoid valve (L1) when the return air drops
below the nominal set point of 70°F (21 °C). This thermostat also provides automatic heat/cool changeover.
1-14. OPERATING CYCLES. Normal operation of this air conditioner includes cooling, bypass, and heating cycles.
These cycles are described in the following paragraphs, with explanations added for different modes of operation.
a. Cooling Cycle. Air conditioner operation when cooling is initiated.
(1) Evaporator fan (B1), compressor (B2), and condenser fan (B3) start.
(2) The compressor (B2) receives low pressure superheated refrigerant gas and compresses it to a high
pressure, high temperature gas. This gas flows through metal tubing to the condenser coil (C).
(3) The condenser fan (B3) draws outside ambient air over and through the condenser coil (C). The high
pressure, high temperature gas from the compressor (B2) is cooled by the flow of air and condensed into a
high pressure liquid. If ambient air temperature increases, the gas entering the condenser coil (C) will
increase in pressure, causing the condenser fan damper actuator (A) to open the damper and allow an
increased flow of air across the condenser coil (C).
(4) The receiver (R) stores excess refrigerant during periods of decreased load or low ambient temperature, or
during maintenance pump down procedures.
(5) The high pressure liquid from the condenser is subcooled by the tube-in-tube heat exchanger (H), which at
the same time superheats the low pressure refrigerant gas returning to the compressor (B2).
(6) A drier filter (F1) removes any moisture (water vapor) or dirt that may be carried by the refrigerant leaving
the heat exchanger (H).
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1-14. OPERATING CYCLES - Continued.
Figure 1-5. Functional Block Diagram (Sheet 1 of 4)
B1
B2
B3
F1
F2
L1
L2
V1
V2
V3
V4
V5
V6
V7
V8
V9
EVAPORATOR FAN
COMPRESSOR
CONDENSER FAN
DRIER FILTER
REFRIGERANT STRAINER
SOLENOID VALVE
SOLENOID VALVE
SERVICE VALVE (ACTUATOR)
SERVICE VALVE (HEAD)
PRESSURE REGULATOR VALVE
SERVICE VALVE (EXPANSION)
HOT GAS BYPASS VALVE
SERVICE VALVE (HOT GAS BYPASS)
MANUAL VALVE (BYPASS)
SERVICE VALVE (SCHRADER)
SERVICE VALVE (SCHRADER)
LEGEND
V10
DISCHARGE VALVE (COMPRESSOR)
V11
SUCTION SERVICE VALVE (COMPRESSOR)
V12
THERMOSTATIC EXPANSION VALVE (PRIMARY)
V13
THERMOSTATIC EXPANSION VALVE (LIQUID QUENCH)
S4
SWITCH, HIGH REFRIG.PRESSURE
S5
SWITCH, LOW REFRIG.PRESSURE
S7
SWITCH, LOW OIL PRESSURE
A
CONDENSER FAN DAMPER ACTUATOR
C
CONDENSER COIL
D
DISTRIBUTOR
E
EVAPORATOR COIL
G
SIGHT GLASS
H
HEAT EXCHANGER
R
RECEIVER
VE1
VIBRATION ELIMINATOR
VE2
VIBRATION ELIMINATOR
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(7) The sight glass (G) indicates the quantity of refrigerant in the system.
(8) A solenoid valve (L1) is used to control refrigerant flow to the primary expansion valve (V12). When the air
conditioner is operated in redundant unit, remote control configuration the solenoid valve (L1) is always open.
When operated in single unit, local control configuration the solenoid valve (L1) is cycled open and closed by the
cool control thermostat located in the return air section of the air conditioner. The cool control thermostat also
opens and closes solenoid (L2) during the bypass cycle in all modes of operation.
(9) The primary expansion valve (V12) controls the amount and pressure of liquid refrigerant to the evaporator coil
(E). By use of a sensing bulb and external equalizer line, the primary expansion valve (V12) senses the
temperature and pressure of the refrigerant as it leaves the evaporator coil (E) and constantly adjusts the flow of
liquid refrigerant.
(10) As the liquid refrigerant leaves the primary expansion valve (V12) it passes through a distributor (D) and enters
the evaporator coil (E). The evaporator fan (B1) circulates warm air from the conditioned space over and
through the evaporator coil (E). As the liquid refrigerant enters the coil at reduced pressure, the combination of
pressure reduction and warmer air being forced across the tubes of the coil causes the refrigerant to boil and
change from a liquid to a gas. Refrigerant absorbs heat when it changes from a liquid to a gas. As the air from
the conditioned space comes in contact with the evaporator coil (E), the air is cooled.
(11) After the refrigerant gas leaves the evaporator coil (E), it flows through the pressure regulator valve (V3) in
redundant unit configuration, or through the manual bypass valve (V7) if in single unit configuration. The
pressure regulator valve (V3) responds to supply air temperature in redundant unit, remote control configuration
and opens or closes to regulate evaporator coil (E) temperature and pressure. A temperature rise in the supply
air will cause the pressure regulator valve (V3) to open and decrease the evaporator temperature. A
temperature drop will cause the pressure regulator valve (V3) to close and increase evaporator temperature.
In single unit, local control configuration the pressure regulator valve (V3) is bypassed by opening the manual
bypass valve (V7). Temperature control is then performed by the return air cool control thermostat and solenoid
valve (L1) .
(12) After the refrigerant gas passes through either the pressure regulator valve (V3) or manual bypass valve (V7),
the low pressure refrigerant gas then flows through the other half of the heat exchanger (H) where it is
superheated by the high pressure liquid refrigerant leaving the condenser coil (C).
(13) The superheated refrigerant gas flows through a refrigerant strainer (F2) to remove any particles from the gas
before it flows into the compressor (B2).
(14) The refrigerant gas is then drawn back to the compressor (B2) and the cycle is repeated.
(15) A service valve (V1) allows the condenser fan damper actuator (A) to be isolated from, the refrigerant lines
during maintenance. A second service valve (V2) located between the receiver (R) and the heat exchanger (H)
isolates the low side-from the high side of the refrigerant lines during pump down. Another service valve (V6)
upstream of the hot gas bypass valve (V5) aids in isolating refrigerant flow during pump down.
(16) Service valves (V8, V9) are provided for charging and general servicing of the high and low sides of the
refrigerant system.
(17) Discharge service valve (V10) and suction service valve (V11) are provided for isolation of the compressor (B2)
during maintenance or replacement procedures.
(18) The high refrigerant pressure switch (S4), low refrigerant pressure switch (S5), and low oil pressure switch (S7)
are provided to protect the compressor (B2) from damage due to pressure extremes.
(19) Vibration eliminators (VE1, VE2) are installed in the compressor (B2) suction and discharge lines to isolate
compressor vibration from the other refrigerant piping.
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1-14. OPERATING CYCLES - Continued.
Figure 1-5. Functional Block Diagram (Sheet 2 of 4)
B1
B2
B3
F1
F2
L1
L2
V1
V2
V3
V4
V5
V6
V7
V8
V9
EVAPORATOR FAN
COMPRESSOR
CONDENSER FAN
DRIER FILTER
REFRIGERANT STRAINER
SOLENOID VALVE
SOLENOID VALVE
SERVICE VALVE (ACTUATOR)
SERVICE VALVE (HEAD)
PRESSURE REGULATOR VALVE
SERVICE VALVE (EXPANSION)
HOT GAS BYPASS VALVE
SERVICE VALVE (HOT GAS BYPASS)
MANUAL VALVE (BYPASS)
SERVICE VALVE (SCHRADER)
SERVICE VALVE (SCHRADER)
V10
V11
V12
V13
S4
S5
S7
A
C
D
E
G
H
R
VE1
VE2
LEGEND
DISCHARGE VALVE (COMPRESSOR)
SUCTION SERVICE VALVE (COMPRESSOR)
THERMOSTATIC EXPANSION VALVE (PRIMARY)
THERMOSTATIC EXPANSION VALVE (LIQUID QUENCH)
SWITCH, HIGH REFRIG.PRESSURE
SWITCH, LOW REFRIG.PRESSURE
SWITCH, LOW OIL PRESSURE
CONDENSER FAN DAMPER ACTUATOR
CONDENSER COIL
DISTRIBUTOR
EVAPORATOR COIL
SIGHT GLASS
HEAT EXCHANGER
RECEIVER
VIBRATION ELIMINATOR
VIBRATION ELIMINATOR
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Figure 1-5. Functional Block Diagram (Sheet 3 of 4)
B1
B2
B3
F1
F2
L1
L2
V1
V2
V3
V4
V5
V6
V7
V8
V9
EVAPORATOR FAN
COMPRESSOR
CONDENSER FAN
DRIER FILTER
REFRIGERANT STRAINER
SOLENOID VALVE
SOLENOID VALVE
SERVICE VALVE (ACTUATOR)
SERVICE VALVE (HEAD)
PRESSURE REGULATOR VALVE
SERVICE VALVE (EXPANSION)
HOT GAS BYPASS VALVE
SERVICE VALVE (HOT GAS BYPASS)
MANUAL VALVE (BYPASS)
SERVICE VALVE (SCHRADER)
SERVICE VALVE (SCHRADER)
V10
V11
V12
V13
S4
S5
S7
A
C
D
E
G
H
R
VE1
VE2
LEGEND
DISCHARGE VALVE (COMPRESSOR)
SUCTION SERVICE VALVE (COMPRESSOR)
THERMOSTATIC EXPANSION VALVE (PRIMARY)
THERMOSTATIC EXPANSION VALVE (LIQUID QUENCH)
SWITCH, HIGH REFRIG.PRESSURE
SWITCH, LOW REFRIG.PRESSURE
SWITCH, LOW OIL PRESSURE
CONDENSER FAN DAMPER ACTUATOR
CONDENSER COIL
DISTRIBUTOR
EVAPORATOR COIL
SIGHT GLASS
HEAT EXCHANGER
RECEIVER
VIBRATION ELIMINATOR
VIBRATION ELIMINATOR
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1-14. OPERATING CYCL.ES Continued.
b. Bypass Cycle. The air conditioner has a bypass cycle which allows cooling operation during low cooling loads
without cycling the compressor (B2) on and off. In bypass cycle, the refrigerant is routed from the compressor
discharge (high) side to the suction (low) side of the compressor, bypassing the evaporator coil (E).
(1) During low load cooling conditions, excess cooling capacity causes a reduction in suction line pressure.
This low pressure condition is caused by closing the pressure regulator valve (V3) during redundant unit,
remote control operation or closing of the solenoid valve (L1) during redundant unit, remote control
operation.
(2) The low cooling loads produce decreasing return air temperature, causing the cool air thermostat to open
solenoid valve (L2). As the compressor suction pressure starts to drop, the hot gas bypass valve (V5)
opens to allow flow of hot gas to the suction line between the evaporator coil (E) and pressure regulator
valve (V3).
(3) The liquid quench expansion valve (V13) senses the temperature of the hot gas being bypassed through
the hot gas valve (V5) to the suction line. To prevent excessively hot gas from reaching the compressor,
the liquid quench expansion valve (V13) opens when necessary to allow liquid refrigerant to mix with the
hot gas.
c. Heating Cycle. In redundant unit, remote control configuration, the heating cycle is designed to warm the
conditioned area to approximately 80°F (27°C) and to provide a load before the cooling cycle is started. In this
configuration, the heating cycle is not used for personnel comfort. Duct heaters in the conditioned area external
to this air conditioning unit provide for personnel space heating.
In the single unit, local control configuration, two levels of heating control can be provided. In all modes of
operation, heating is controlled by return air temperature only.
(1) In redundant unit, remote control configuration, the air conditioner MODE SELECT SWITCH is normally
set to REMOTE. Selection of heating function is made at the evaporator coil (E) to be energized. Heating
is then controlled to a nominal 80°F (27°C) by the heat control thermostat located in the return air section
of the air conditioner.
(2) In single unit, local control configuration, the heating cycle can be controlled by two methods. When
MODE SELECT SWITCH is positioned to either AUTO or REMOTE, the electric heating element is
automatically capable of being energized. The electric heating element is then controlled to a nominal
70°F (21°C) return air temperature by the cool control thermostat located in the return air section of the air
conditioner.
When MODE SELECT SWITCH is positioned to HEAT in this configuration, the electric heating element is
controlled to a nominal 80°F (27°C) return air temperature by the heat control thermostat located adjacent
to the cool control thermostat.
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Figure 1-5. Functional Block Diagram (Sheet 4 of 4)
B1
B2
83
F1
F2
L1
L2
V1
V2
V3
V4
V5
V6
V7
V8
V9
EVAPORATOR FAN
COMPRESSOR
CONDENSER FAN
DRIER FILTER
REFRIGERANT STRAINER
SOLENOID VALVE
SOLENOID VALVE
SERVICE VALVE (ACTUATOR)
SERVICE VALVE (HEAD)
PRESSURE REGULATOR VALVE
SERVICE VALVE (EXPANSION)
HOT GAS BYPASS VALVE
SERVICE VALVE (HOT GAS BYPASS)
MANUAL VALVE (BYPASS)
SERVICE VALVE (SCHRADER)
SERVICE VALVE (SCHRADER)
LEGEND
V10
DISCHARGE VALVE (COMPRESSOR)
V11
SUCTION SERVICE VALVE (COMPRESSOR)
V12
THERMOSTATIC EXPANSION VALVE (PRIMARY)
V13
THERMOSTATIC EXPANSION VALVE (LIQUID QUENCH)
S4
SWITCH, HIGH REFRIG.PRESSURE
S5
SWITCH, LOW REFRIG.PRESSURE
S7
SWITCH, LOW OIL PRESSURE
A
CONDENSER FAN DAMPER ACTUATOR
C
CONDENSER COIL
D
DISTRIBUTOR
E
EVAPORATOR COIL
G
SIGHT GLASS
H
HEAT EXCHANGER
R
RECEIVER
VE1
VIBRATION ELIMINATOR
VE2
VIBRATION ELIMINATOR
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CHAPTER 2
OPERATING INSTRUCTIONS
Section I. DESCRIPTION AND USE OF OPERATOR'S CONTROLS AND INDICATORS
2-1. GENERAL. The air conditioner is designed for a variety of installations and for operation under a wide range of
climate conditions. Operators must be aware of any peculiarities or operational limitations for their specific installation.
See the appropriate shelter or system manual for instructions peculiar to your specific installation.
2-2. OPERATOR'S CONTROLS AND INDICATORS. See Figure 2-1 for a general description of the controls and
indicators with which an operator will normally be concerned. For specific operating instructions, see Section III and
Section IV of this chapter.
CRANKCASE HEATER (CB1). Provides circuit breaker protection for crankcase heater.
CONTROL CIRCUIT (CB2). Provides circuit breaker protection for the control circuitry.
NOTE
Circuit breakers CB1 and CB2 are located behind the center front evaporator panel.
Figure 2-1. Controls and Indicators (Sheet 1 of 2)
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2-2.
OPERATOR'S CONTROLS AND INDICATORS Continued.
AC POWER ON (1) (green). Indicates ac input power on.
CONTROL POWER (24 VDC) FAULT (2) (red). Indicates dc power supply failure.
HIGH DISCHARGE PRESSURE (3) (red). Indicates excessive refrigerant pressure in compressor discharge line.
DIRTY FILTER (4) (red). Indicates dirty return air filter.
EVAPORATOR FAN FAILURE (5) (red). Indicates loss of air flow in supply air duct.
MODE SELECT Rotary SWITCH (6). Allows operation of air conditioner in LOCAL (HEAT, COOL and AUTO) or
REMOTE modes.
FAULT RESET Push Button (7). Used to reset fault indication circuits after repair.
SERVICE LIGHT Toggle Switch (8). Operates lamp in compressor compartment. Used for illumination during servicing.
LOW OIL PRESSURE (9) (red). Indicates loss of oil pressure in compressor crankcase.
HIGH AIR TEMPERATURE (10) (red). Indicates excessive air temperature at electric heater.
LOW SUCTION PRESSURE (11) (red). Indicates excessive low pressure in compressor suction line.
Figure 2-1. Controls and Indicators (Sheet 2 of 2)
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Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
2-3.
a.
b.
INTRODUCTION.
General. Operator preventive maintenance checks and services (PMCS) are essential to the efficient
operation of the air conditioner and to prevent possible damage that might occur through neglect or failure to
observe warning symptoms in a timely manner. Checks and services performed by operators are limited to
these functions which are described in Table 2-1. Your preventive maintenance checks and services table
lists the inspections and care of your equipment required to keep it in good operating condition.
(1)
Before you operate. Always keep in mind the CAUTIONS and WARNINGS. Perform your before
PMCS.
(2)
While you operate. Always keep in mind the CAUTIONS and WARNINGS. Perform your during
PMCS
(3)
After you operate. Be sure to perform your after PMCS.
(4)
If your equipment fails to operate. If your equipment does not perform as required, refer to Table 3-1
for possible problems. Report any malfunctions or failures on the proper DA Form 2404, or refer to DA
PAM 738-750.
PMCS columnar entries. The PMCS table column headings and column entries are defined in the following
subparagraphs.
(1)
Item number column. This is the order in which you perform checks and services on the air
conditioner. The entry in this column will also be used as a source of item numbers for the "TM Item
number" column on DA Form 2404, Equipment Inspection and Maintenance Worksheet, in recording
results of PMCS.
(2)
Interval columns. The interval column of your PMCS table tells you when to do a certain check or
service.
(3)
Item to check/service column. Identification of item to be inspected.
(4)
Procedures column. The procedures column of your PMCS table tells you how to do the required
checks and services. Carefully follow these instructions. If you do not have the tools, or if the
procedure tells you to, have the next higher level of maintenance do the work.
(5)
Not fully mission capable if: column. Entries in this column will be keyed specifically to checks listed in
the "procedures" column for the purpose of identifying, for the check, the criteria that will cause the
equipment to be classified as not fully mission capable because of inability to perform its primary
combat mission. An entry in this column will:
· Identify conditions that make the equipment not fully mission capable for readiness reporting.
· Deny use of the equipment until corrective maintenance has been performed.
NOTE
Within designated interval, these checks are to be performed in the order listed. If the
equipment must be kept in continuous operation, check and service only those items that
can be checked and serviced without disturbing operation. Make the complete checks
and services when the equipment can be shut down.
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Table 2-1. Operator Preventive Maintenance Checks and Services
Item
No.
InterVal
1
Before
Panels
Items to
Check/
Service
Outside
Procedure
a. Check that panels are in place.
b. Check panels for cracks, dents, or
missing hardware.
2
Before
Inlets/
Outlets
Not Fully Mission
Capable If:
Panels missing or
damage that
would cause operating hazard.
a. Check for obvious damage and missing parts.
Control panel
damaged.
b. Check for obstructions, damage and
loose or missing hardware.
Obstructions
exist.
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Table 2-1. Operator Preventive Maintenance Checks and Services - Continued
Item
No.
InterVal
3
Before
Items to
Check/
Service
Control
Panel
During
4
After
Air
Conditioner
Procedure
Not Fully Mission
Capable If:
a. Check for obvious damage and missing parts.
Control panel
damaged.
b. Check for proper operation.
Unit not operating
properly.
Check for obstructions, damage, and loose or
missing hardware
Obstructions,
damage, loose or
missing hardware.
Section III. OPERATION UNDER USUAL CONDITIONS
2-4.
GENERAL. The following section covers initial setup procedures and the modes of operation for the air
conditioner.
2-5.
ASSEMBLY AND PREPARATION FOR USE. Contact unit maintenance personnel for original unpacking,
installation,
and preparation for use.
2-6.
INITIAL ADJUSTMENTS AND CHECKS. Inspect panels for loose mounting or shipping damage. Report
any deficiencies to unit maintenance.
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2-7.
OPERATING PROCEDURE.
CAUTION
Before operating the air conditioner, ensure that MODE SELECT SWITCH is in the
OFF position and that ac power has been applied to air conditioner for at least 30
minutes. This is necessary so that the crankcase heater has sufficient time to
operate. Heating the compressor is necessary to remove all liquid refrigerant from
the crankcase, thereby eliminating the possibility of damage during starting
operations at low ambient temperatures.
a.
Before Operation.
(1)
Perform the before (B) operator preventive maintenance checks and services listed in Table 2-1.
(2)
Check to see that the power cable has been connected from a source of 208 V ac, 3-phase, 50/60
hertz power to the input power connector on the unit.
(3)
Check that the following air inlet and outlet openings are clear (Figure 2-2):
·
·
·
·
·
Return air inlet
Fresh air inlet
Supply air outlet
Condenser air outlet
Condenser air inlet
Figure 2-2. Air Inlets and Outlets
b.
General Information.
(1)
During warm or cold weather (air conditioner operation in AUTO mode):
· Limit traffic through doors as much as possible.
· Keep doors and windows tightly closed.
(2)
During cold weather. Adjust shades, blinds, etc., (when applicable); admit sunlight during day. Close
them at night.
(3)
During hot weather. Adjust shades, blinds, etc., (when applicable); block out sunlight during day.
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2-8.
3).
OPERATION IN AUTO MODE (See Figure 2-
a.
Check that AC POWER ON light is on.
CAUTION
Ensure ac power has been on a
minimum
of
30
minutes
for
compressor
crankcase
heater
warmup. If compressor slugs, turn
mode select switch to OFF, then turn
to AUTO position.
b.
Turn MODE SELECT SWITCH to AUTO.
c.
Check the following lights are off:
·
·
·
·
·
·
·
CONTROL POWER (24VDC) FAULT
LOW SUCTION PRESSURE
HIGH DISCHARGE PRESSURE
HIGH AIR TEMPERATURE
DIRTY FILTER
LOW OIL PRESSURE
EVAPORATOR FAN FAILURE
NOTE
If any light (except AC POWER ON) is
on, turn MODE SELECT SWITCH to
OFF. Contact unit maintenance.
Figure 2-3. Auto Mode (Settings and Indicators)
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2-9.
4).
OPERATION IN COOL MODE (See Figure 2-
a.
Check that AC POWER ON light is on.
CAUTION
Ensure ac power has been on a minimum
of 30 minutes for compressor crankcase
heater warmup. If compressor slugs, turn
mode select switch to OFF, then turn to
AUTO position.
b.
Turn MODE SELECT SWITCH to COOL.
c.
Check the following lights are off:
·
·
·
·
·
·
·
CONTROL POWER (24VDC) FAULT
LOW SUCTION PRESSURE
HIGH DISCHARGE PRESSURE
HIGH AIR TEMPERATURE
DIRTY FILTER
LOW OIL PRESSURE
EVAPORATOR FAN FAILURE
NOTE
If any light (except AC POWER ON) is
on, turn MODE SELECT SWITCH to
OFF. Contact unit maintenance.
Figure 2-4. Cool Mode (Settings and Indicators)
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2-10. OPERATION IN HEAT MODE (See Figure 25).
a.
Check that AC POWER ON light is on.
CAUTION
Ensure ac power has been on a
minimum of 30 minutes for compressor
crankcase
heater
warmup.
If
compressor slugs, turn mode select
switch to OFF, then turn to AUTO
position.
b.
Turn MODE SELECT SWITCH to HEAT.
c.
Check the following lights are off:
·
·
·
·
·
·
·
CONTROL POWER (24VDC) FAULT
LOW SUCTION PRESSURE
HIGH DISCHARGE PRESSURE
HIGH AIR TEMPERATURE
DIRTY FILTER
LOW OIL PRESSURE
EVAPORATOR FAN FAILURE
NOTE
If any light (except AC POWER ON) is
on, turn MODE SELECT SWITCH to
OFF. Contact unit maintenance.
Figure 2-5. Heat Mode (Settings and Indicators)
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2-11.
6).
OPERATION IN REMOTE MODE (See Figure 2-
a.
Check that AC POWER ON light is on.
CAUTION
Ensure ac power has been on a minimum
of 30 minutes for compressor crankcase
heater warmup. If compressor slugs, turn
mode select switch to OFF, then turn to
AUTO position.
b.
Turn MODE SELECT SWITCH to
REMOTE.
c.
Check the following lights are Off:
·
·
·
·
·
·
·
CONTROL POWER (24VDC) FAULT
LOW SUCTION PRESSURE
HIGH DISCHARGE PRESSURE
HIGH AIR TEMPERATURE
DIRTY FILTER
LOW OIL PRESSURE
EVAPORATOR FAN FAILURE
NOTE
If any light (except AC POWER ON) is on, turn MODE
SELECT SWITCH to OFF. Contact unit maintenance.
Figure 2-6. Remote Mode (Settings and Indicators)
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2-12.
SHUTDOWN (OFF) (See Figure 2-7).
NOTE
Do not disconnect or turn off power to the air conditioner
during periods of normal shutdown. Power should be
disconnected only for maintenance, if unit is to be
serviced during emergency conditions, or during periods
of extended shutdown.
a.
Turn MODE SELECT SWITCH to OFF.
b.
Check that AC POWER ON light is on.
CAUTION
To prevent equipment damage, always turn MODE
SELECT switch to OFF before breaking the main
power supply to the unit.
c.
Perform "after operation (A)" preventive
maintenance checks and services (Table 21).
Figure 2-7. OFF Mode (Settings and Indicators)
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2-13. PREPARATION FOR MOVEMENT. When the unit is to be moved, the services of unit maintenance shall be
employed for the necessary preparation.
2-14.
INFORMATION PLATES. A number of instructions and identification plates are provided with the unit.
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Section IV. OPERATION UNDER UNUSUAL CONDITIONS
2-15. GENERAL. The air conditioner is designed to operate normally within a wide range of climatic conditions.
However, some extreme conditions require special operating and servicing procedures to prevent undue loading and
excessive wear in the equipment.
2-16. OPERATION IN EXTREME HEAT. The air conditioner is designed to operate in temperatures up to 125°F
(52°C). Extra care should be taken to minimize the cooling load when operating in extremely high temperatures. Some
of the steps that may be taken are:
NOTE
Weather stripping, the installation of storm doors and windows (if appropriate), and
insulation of surfaces exposed to the outside is recommended when operating in
extremely high temperatures for extended periods is anticipated.
a.
Check all openings in the shelter or enclosure, especially doors and windows, to be sure they are tightly
closed. Limit in and out traffic, if possible.
b.
When possible, use shades or awnings to shut out direct rays of the sun.
c.
Limit the use of electric lights and other heat producing equipment.
d.
Limit the amount of hot, outside air introduced through the fresh air inlet to that needed for ventilation.
2-17. OPERATION IN EXTREME COLD. The air conditioner is designed to operate in temperatures down to -40°F (40°C). Extra care should be taken to minimize the heating load when operating in extremely low temperatures. Some
steps that may be taken are:
CAUTION
Do not disturb electrical wiring that has been exposed to extremely low
temperatures. Both the wire and insulation become brittle when cold and are easily
broken.
Before operating the air conditioner, ensure that MODE SELECT SWITCH is in the
OFF position and that ac power has been applied to air conditioner for at least 30
minutes (can take up to 24 hours). This is necessary so that the crankcase heater
has sufficient time to operate. Heating the compressor is necessary to remove all
liquid refrigerant from the crankcase thereby eliminating the possibility of damage
during starting operations at low ambient temperatures.
If compressor begins to slug, turn MODE SELECT SWITCH to OFF, wait a few
minutes, then turn MODE SELECT SWITCH to AUTO position. Turning the MODE
SELECT SWITCH to OFF then to AUTO mode prevents the compressor from
slugging, thereby eliminating the possibility of damage during starting operations at
low ambient temperatures.
NOTE
Weather stripping, the installation of storm doors and windows, (if appropriate), and
insulation of surfaces exposed to the outside is recommended when operating in
extremely low temperatures for extended periods is anticipated.
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a.
Check all openings in the enclosure, especially doors and windows, to be sure they are tightly closed. Limit
in and out traffic, if possible.
b.
Open shades and awnings to permit entry of direct rays of the sun, if appropriate.
c.
Limit the amount of cold, outside air introduced through the fresh air inlet to that needed for ventilation.
2-18. OPERATION IN DUSTY OR SANDY CONDITIONS. Dusty and sandy conditions can seriously reduce the
efficiency of the air conditioner by clogging the air filters and thereby causing a restriction of the volume of airflow.
Accumulation of dust or sand in the condenser coil and/or in the compressor compartment may cause overheating of the
refrigeration system. Dust or sand may also clog the condensate trap, and water drain lines. Some of the steps that may
be taken are:
a.
Frequent cleaning of filters and all other areas of dust and sand accumulation. In extreme conditions, daily
cleaning of filters may be necessary.
b.
Limit the amount of dusty or sandy outside air introduced through the fresh air inlet to that essential for
ventilation.
2-19. OPERATION IN UNUSUALLY WET CONDITIONS. The air conditioner is designed for normal exposure to the
elements, so it is reasonably waterproof. Some of the steps that should be taken in an extremely wet climate are:
a.
More frequent inspection and cleaning of the condensate trap and drain lines to insure proper drainage and
prevent accumulation of water inside the cabinet.
b.
Cover the fresh air inlet on the back of the cabinet during periods of wet windy weather when the air
conditioner is not in operation.
2-20. OPERATION IN SALT AIR OR SEA SPRAY. Salt air or sea spray may cause many of the same clogging
problems encountered when operating in a dusty or sandy environment. In addition, the nature of salt presents serious
corrosion problems. Frequent cleaning is necessary during which all exposed surfaces should be thoroughly spray rinsed
or sponged with fresh water to remove salt.
2-21.
OPERATION UNDER EMERGENCY CONDITIONS.
a.
b.
Chemical, Biological, Radiological Hazard (CBR). Should it be necessary to operate in conditions requiring
use of CBR filtration equipment, see specific instructions for your shelter or facility installation. The following
are general suggestions and do not apply if they conflict with instructions for your shelter or facility
installation.
(1)
The fresh air inlet should be closed, the opening should be covered with a suitable material, and
sealed air tight.
(2)
The return air inlet should be partially or completely closed with a suitable material. This will cause a
more positive pressure on inside of shelter or enclosure and keep air from being drawn in from outside
the enclosure.
Power Conservation. During periods when full 208 V ac, 3-phase power is in critically short supply, if the air
conditioner cannot be turned off completely, it should be operated in AUTO mode only.
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CHAPTER 3
OPERATOR MAINTENANCE
Section I. OPERATOR LUBRICATION INSTRUCTIONS
3-1.
GENERAL. There are no lubrication instructions at operator level.
Section II. OPERATOR TROUBLESHOOTING
3-2.
The table lists the common malfunctions which you may find during the operation or maintenance of the air
conditioner or its components. You should perform the tests/inspections and corrective actions in the order listed.
3-3.
This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a
malfunction is not listed or is not corrected by listed corrective actions, notify your supervisor.
Table 3-1. Operator Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1.
AIR CONDITIONER WILL NOT START IN AUTO MODE.
Step 1. Check that MODE SELECTOR is set to AUTO.
Set switch to AUTO.
Step 2. Check that AC POWER ON light is ON.
Contact Unit Maintenance.
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Table 3-1. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2.
REDUCED COOLING CAPACITY.
Step 1. Check that all doors, windows, and other openings in the room or enclosure are tightly closed.
Tightly close all openings.
Step 2. Check to be sure that excessive hot outside air is not being introduced through the fresh air inlet.
Shade inlet; then, if condition improves adjust fresh air damper to limit amount of hot air intake.
Step 3. Check to be sure condenser air inlet and outlet are not obstructed.
Remove obstructions.
3.
REDUCED HEATING CAPACITY.
Step 1. Check that all doors, windows, and other openings in the room or enclosure are tightly closed.
Tightly close all openings.
Step 2. Check to be sure that excessive cold, outside air is not being introduced through fresh air inlet.
Partially cover inlet; then, if condition improves, adjust fresh air damper to reduce amount of cold air
intake.
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Table 3-1. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4.
ONE OR MORE CONTROL PANEL FAULT INDICATOR LIGHTS ARE ON.
Step 1. Check that AC POWER ON light is on.
If it is not on, contact Unit Maintenance.
Step 2. Check that no red light on control panel is on.
If a red light is on, contact Unit Maintenance.
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Table 3-1. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5.
EXCESSIVELY NOISY OPERATION.
Step 1. Isolate source of noise as near as possible, both by ear and touch.
Contact Unit Maintenance.
Step 2. Check all external panels and filters for looseness, vibration, and security.
Contact Unit Maintenance.
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Section III. OPERATOR MAINTENANCE PROCEDURES
3-4. This section contains maintenance procedures which are authorized to operator (C) by the Maintenance Allocation
Chart (MAC) Appendix B.
3-5. RETURN AIR FILTER.
This task consists of:
Removal
Inspection
Cleaning
Installation
INITIAL SET-UP:
Personnel : 1
Materials:
Rags (Item 12, Appendix E)
Detergent, dishwashing (Item 20, Appendix E).
Oil, air filter (Item 23, Appendix E)
REMOVAL
1.
Open latch (2).
2.
Remove filter (1).
INSPECTION
1.
Check filter for punctures, cuts and damaged edges that would allow passage of unfiltered air.
2.
Check filter for packed or mashed areas that would block air flow.
3.
Replace filter if defective.
CLEANING
1.
Wash filter in mild detergent and water solution.
2.
Rinse thoroughly in water.
3.
Shake out excess water.
4.
Spray filter with air filter oil.
INSTALLATION
1.
Position filter (1)in place.
2.
Close latch (2).
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Figure 3-1. Return Air Filter
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CHAPTER 4
UNIT MAINTENANCE
Section I. UNIT LUBRICATION INSTRUCTIONS
4-1.
GENERAL. The compressor crankcase oil level should be checked quarterly and oil added by Direct Support
Maintenance as necessary during preventive maintenance service. The evaporator and condenser fan motors should be
checked and lubricated as necessary during preventive maintenance service.
4-2.
MOTOR LUBRICATION/COMPRESSOR CRANKCASE OIL.
a.
Condenser and Evaporator Motor Unit Lubrication.
Quarterly, Access condenser motor (para 4-76) and evaporator motor (para 4-70). Apply two strokes of
grease (Item 2, Appendix E) at lubrication fittings.
b.
Compressor Crankcase Oil.
Quarterly. Check compressor sight glass (Figure 5-34) for proper refrigerant oil level.
Figure 4-1. Unit Lubrication
Section II. REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT
(TMDE), AND SUPPORT EQUIPMENT
4-3.
COMMON TOOLS AND EQUIPMENT. For authorized common tools and equipment, refer to the Modified
Table of Organization and Equipment (MTOE) applicable to your unit.
4-4.
SPECIAL TOOLS, TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE), AND SUPPORT
EQUIPMENT. Special tools required for maintenance of the equipment are listed in Appendix B. Test, measurement,
and diagnostic equipment (TMDE), and support equipment include standard equipment found in any unit maintenance
shop. Appendix B, Section III, contains a list of the tools.
4-5.
REPAIR PARTS. Repair parts are listed and illustrated in the Repair Parts and Special Tools List (RPSTL) TM
9-4120-381-24P, covering unit, direct support, and general support maintenance for this equipment.
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Section III. SERVICE UPON RECEIPT
4-6.
UNLOADING. The air conditioner is packaged in a container designed for shipment and handling with the
cabinet in an upright position. The base of the container is constructed as a shipping pallet with provisions for the
insertion of the tongs of a fork on material handling equipment (see Figure 4-2).
a.
Remove Tiedowns. Remove all blocking and tiedowns that may have been used to secure the container to
the carrier.
WARNING
Do not allow anyone under equipment suspended from a lifting device. Do not allow
the unit to swing while suspended from a lifting device. Failure to observe this
warning may result in injury to personnel and damage to the equipment.
CAUTION
Use care in handling to avoid damage to the air conditioner. If an overhead lifting
device must be used, use an appropriate sling so that the weight of the unit is
supported by the shipping container. b. Material Handling. Use a forklift truck or
other suitable material handling equipment to remove the unit from the carrier.
4-7.
UNPACKING. Normally, the packaged air conditioner should be moved into the immediate area in which it is to
be installed before it is unpacked.
NOTE
The shipping container is of such a design that it may be retained for reuse if frequent
relocation of the air conditioner is anticipated.
a.
Remove shipping container. Cut the metal bands that hold the top and sides of the container to the base.
Lift the container vertically and remove it from the base and cabinet.
b.
Remove packaging. Remove the cushioning around the top of the cabinet and retain, if reuse is anticipated.
Remove the technical publications envelope and accessory sack that are taped to the cabinet and put them
in a safe place.
WARNING
Do not allow anyone under equipment suspended from a lifting device. Do not allow
the unit to swing while suspended from lifting device. Failure to observe this
warning may result in injury to personnel and damage to the equipment.
c.
Remove pallet. Attach an overhead hoist with an appropriate sling and spreader bar to the lifting eyes
provided at top of the cabinet. Raise the cabinet and remove the carriage bolt assemblies that hold the
tiedown boards to the pallet from the underside of the pallet. Remove the bolts that hold the tiedown boards
to the unit base. Remove and retain the pallet and carriage bolt assemblies and the tiedown boards and
bolts, if reuse is anticipated. Be sure to remove all remaining barrier material from the underside of the
cabinet base. Lower the cabinet to the floor in the desired position and remove the sling and hoist.
NOTE
Bolts used to anchor cabinet base to tiedown bars may be used to anchor it in place in
installed location if installation method allows for anchoring from beneath.
4-2
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Figure 4-2. Typical Crated Air Conditioner
4-8.
RECEIVING INSPECTION. Perform receiving inspection of the air conditioner as follows:
a.
Inspect. Inspect the unit for damage incurred during shipment. If the equipment has been damaged report
the damage on DD Form 6, Packaging Improvement Report.
b.
Check. Check the unit against the packing slip to see if shipment is complete. Report all discrepancies in
accordance with the instructions of DA PAM 738750.
c.
Modified. Check to see whether the equipment has been modified.
4-9.
INSTALLATION SITE PREPARATION. The air conditioner is designed so that it is adaptable to a variety of
installation arrangements. Most typical installations are made by preparing an opening in an exterior wall of the room or
enclosure to be conditioned and positioning the air conditioner so that the front of the cabinet is inside the room or
enclosure and the back is outside. Alternate installations may be made with the entire cabinet either inside or outside the
conditioned area.
a.
General. The following are minimum requirements for all installations. (See Figure FO-2 for installation
dimensions).
(1)
A relatively level surface capable of bearing the weight of the air conditioner on which to set the base.
To insure proper condensation drainage, the surface should be level within 5 degrees from front to
back and side to side.
(2)
An unobstructed flow of air from outside the conditioned area to the inlet and outlet of the condenser.
(3)
An unobstructed flow of air from inside the conditioned area to the conditioned air intake and
discharge.
(4)
An unobstructed flow of air from outside the conditioned area to the fresh air intake.
(5)
The supply air outlet is discharged from the bottom of the air conditioner (see Figure FO-2 ).
(6)
Access to the front (and back, if possible) of the cabinet for routine operation and servicing and for
necessary maintenance actions.
4-3
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
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4-9.
INSTALLATION SITE PREPARATION - Continued.
(7)
Access to the top of the cabinet for removal of the return air filter.
(8)
A source of 208 V ac, 3-phase, 50/60 hertz input power rated at 60 amps. The power source outlet
should be located as near as possible to the installed location of the air conditioner. The power source
wiring must include a disconnect switch. However, provisions should be made to insure that power is
not disconnected during normal operation and that the disconnect is not used to turn off the air
conditioner for normal shutdown.
(9)
An earth ground capable of handling 60 amps.
(10) Remove four shipping bolts from evaporator motor fan mounting bracket (refer to Figure FO-2 ).
(11) Check that no source of dangerous or objectionable fumes is located near the fresh air intake.
(12) If possible, make use of terrain features such as trees and buildings to provide a shaded location. This
will minimize the cooling load on the air conditioner.
(13) If possible, avoid locations where the condenser and fresh air intakes will be laden with dust, dirt, soot,
smoke, or other debris.
b.
Inside Installation. Manufacture an arrangement of ducts for the condenser intake and discharge air
openings, and the fresh air intake.
NOTE
Easy access to fresh or return air filters must be provided. Filters may be left in position
in unit or relocated in duct work. Some installations (filters relocated in duct work) may
require different size filters. Access to underside of air conditioner is required for
electrical, ground wire, drain line, etc.
c.
Outside Installation. Manufacture an arrangement of ducts for the conditioned air intake and discharge air.
Ducts may be made for attachment to the air conditioner cabinet using the mounting holes for the
conditioned air intake or some other arrangement may be made. Ducts may also be made for installation of
conditioned air intake on the inside ends or replacements ducts may be used. Prepare appropriate openings
in the wall for the ducts.
4-10. PREPARATION OF AIR CONDITIONER FOR INSTALLATION. No preparation is necessary if the air
conditioner is to be installed by the typical exterior wall method and operated as a self contained unit. For alternate
installation methods, some preparation is necessary.
Instructions. The unit is designed to provide for limited basic types of installation. See the following paragraphs for
instructions only if they are applicable to your requirements.
4-11.
a.
Access panels removed (para 4-11).
b.
Pulley checks (para 4-12).
c.
Installation Instructions (para 4-13).
d.
Front access panel installation (para 4-14).
ACCESS PANELS REMOVED.
WARNING
Be sure input power is disconnected before doing any work inside the air
conditioner cabinet. Voltages used can KILL.
4-4
ARMY TM 9-4120-381-14
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a.
Remove Center Front Evaporator Panel. Loosen eight captive fasteners (1)and remove panel (2)(see Figure
4-3).
Figure 4-3. Center Front Evaporator Panel Removal
b.
Remove Left Front Evaporator Panel. Loosen five captive fasteners (1), loosen clamp (2), disconnect hose
(3), and remove panel (4)(see Figure 4-4).
Figure 4-4. Left Front Evaporator Panel Removal
c.
Remove Right Front Evaporator Panel. Loosen six captive fasteners (1)and remove panel (2)(see Figure 4-5).
Figure 4-5. Right Front Evaporator Panel Removal
4-5
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
4-11.
ACCESS PANEL REMOVED - Continued.
d.
Remove Right Front Condenser Panel. Loosen eight captive fasteners (1)and remove panel (2)(see Figure
4-6).
Figure 4-6. Right Front Condenser Panel Removal
e.
Remove Left Front Condenser Panel. Loosen six captive fasteners (1)and remove panel (2)(see Figure 4-7).
Figure 4-7. Left Front Condenser Panel Removal
f.
Open Left Electric Plate. Loosen six captive fasteners (1)and open panel (2)(see Figure 4-8).
Figure 4-8. Left Electric Plate
4-6
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
g.
Open Right Electric Plate. Loosen ten captive fasteners (1)and open panel (2)(see Figure 4-9).
Figure 4-9. Right Electric Plate
h.
Open Rear Evaporator Panel. Remove 10 screws (1), lockwashers (2), flat washers (3), and open panel (4).
Support panel with cables and fresh air hose connected (see Figure 4-10).
Figure 4-10. Rear Evaporator Panel Removal
i.
Remove Rear Condenser Panel. Remove 42 screws (3), lockwashers (2), flat washers (1), and remove
panel (4)(see Figure 4-11).
Figure 4-11. Rear Condenser Panel Removal
4-7
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NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-12. PULLEY CHECKS. Two sets of color-coded pulleys are provided with the unit. Green pulleys are for 60 Hz
operation. Red pulleys are for 50 Hz operation. One set of pulleys (either the 50 Hz or 60 Hz) is installed on each of the
two fans and fan motors within the unit. The other set is bolted to the side panel inside the unit. See Figure 4-12 for
pulley locations.
CAUTION
a.
Do not operate unit on 60 Hz power with 50 Hz pulleys installed. Fans will overspeed resulting in fan motor overload.
Determine operating frequency of unit.
NOTE
Measure the diameters of the pulleys to ensure that dimensions are as follows:
Pulley
Condenser fan
50 Hz (red)
Dia (inches)
6-1/2
60 Hz (green)
Dia (inches)
6-3/4
Condenser motor
5-1/4
4-1/2
Evaporator fan
4-3/4
4-7/8
Evaporator motor
4-3/4
4-7/8
b.
Check that correct pulleys are installed on fans and fan motors.
c.
If correct pulleys are installed, go to paragraph 4-14. If pulleys must be exchanged, go to paragraph 4-72
and 4-78 (60 Hz pulley), or 4-73 and 4-79 (50 Hz pulley).
Figure 4-12. Pulley Locations
4-8
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
4-13. INSTALLATION INSTRUCTIONS. All alterations to the enclosure into which the air conditioner is to be
installed should be complete before installation of the air conditioner.
a.
Install Rear Condenser Panel. Position panel (1)and install 42 screws (4), lockwashers (3), and flat washers
(2)(see Figure 4-13).
Figure 4-13. Rear Condenser Panel Installation
b.
Install Rear Evaporator Panel. Rotate and position panel (1)and install 14 screws (2), lockwashers (3), flat
washers (4)(see Figure 4-14).
Figure 4-14. Rear Evaporator Panel Installation
4-9
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-13.
INSTALLATION INSTRUCTIONS - Continued.
WARNING
Do not allow anyone under equipment suspended from a lifting device. Do not allow
the unit to swing while suspended from a lifting device. Failure to observe this
warning may result in injury to personnel and damage to the equipment.
CAUTION
Use care in handling to avoid damage to the air conditioner. If an overhead lifting
device must be used, use an appropriate sling and spreader bar so that the weight
of the unit is supported equally by the lifting eyes.
c.
Position Unit. Position unit with an overhead hoist or fork lift per site installation instructions.
NOTE
For van or some shelter installations the lifting eyebolts must be removed.
(1)
Overhead Hoist. Attach an overhead hoist, sling and spreader bar to the lifting rings on top of cabinet
and move the air conditioner into position with supply air duct work fastened and sealed to bottom of
unit and align mounting holes (see Figure FO-2).
(2)
Fork lift. Position fork lift on either end of cabinet and move the air conditioner into position with
supply air duct work fastened and sealed to bottom of unit and align mounting holes (see Figure FO-2).
(3)
Pull site input power cables through conduit.
d.
Secure Unit. Secure unit with appropriate mounting hardware per site installation instructions.
e.
Seal Unit. Seal all openings around cutouts for air conditioner, air and water tight. Use gasket, caulking, or
other suitable material.
_.
f.
Prepare Drain Hole. The air conditioner is provided with one drain hole in the base. Install 4-inch long drain
tube with four self-tapping screws (#8 X 3/8). Connect drain line to 4-inch long drain tube. The drain line
should lead to an appropriate facility drain, storm sewer, dry sump, or an acceptable outside area. Be sure
the entire length of the drain line is slightly lower than the unit base and sloping away to ensure gravity
drainage.
g.
Install Ground. Install a 6-AWG minimum ground wire between the air conditioner cabinet and an adequate
earth ground.
h.
Connect Electrical Connections (see Figure 4-15).
(1)
Turn control panel MODE SELECT SWITCH to OFF.
WARNING
Shut off input power source to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
(2) Using No.6 AWG wires, route wires from power source through 1-inch fitting located in bottom of
condenser section to terminals within RFI box. Connect wires as shown in Figure 4-15.
(3)
Connect wires to a power source of 208 V ac, 3-phase, 50 or 60 Hz.
i.
See air conditioner schematic Figure FO-1 and wiring diagram Figure FO-3 for additional wiring information.
j.
Fan Contactors (K8 and K9). Set four AUTO/MAN switches to MAN (see Figure 4-16).
k.
Condenser and Evaporator Fan Rotation (see Figure 4-17).
(1)
Momentarily turn MODE SELECT SWITCH to COOL then back to OFF.
(2) Verify fan rotation is clockwise viewed from front of left condenser section.
(3) If fan rotation is backward unit power is not wired properly. Disconnect power at source and exchange
wires connected to RFI box terminals A and B. (see step h above)
4-10
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
4-15. Electrical Connections
Figure 4-16. Fan Contactors (K8 and K9) Switches
4-11
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
4-13. INSTALLATION INSTRUCTIONS - Continued.
Figure 4-17. Condenser and Evaporator Fan Rotation
4-14. FRONT ACCESS PANELS INSTALLATION.
a. Close Right Electric Plate. Close panel (1) and tighten ten captive fasteners (2) (see Figure 4-18).
Figure 4-18. Right Electric Plate
b. Close Left Electric Plate. Close panel (1) and tighten six captive fasteners (2) (see Figure 4-19).
Figure 4-19. Left Electric Plate
4-12
ARMY TM 9-4120-381-14
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c. Install Right Front Condenser Panel. Install panel (1) and tighten eight captive fasteners (2). Ensure inspection/
service door (3) is closed (see Figure 4-20).
Figure 4-20. Right Front Condenser Panel Installation
d. Install Right Front Evaporator Panel. Install panel (2) and tighten six captive fasteners (1) (see Figure 4-21).
Figure 4-21. Right Front Evaporator Panel Installation
e. Install Left Front Condenser Panel. Install panel (1) and tighten six captive fasteners (2) (see Figure 4-22).
Figure 4-22. Left Front Condenser Panel Installation
4-13
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-14. FRONT ACCESS PANELS INSTALLATION - Continued.
f. Install Left Front Evaporator Panel. Connect hose (1), tighten clamp (2), install panel (3), and tighten five captive
fasteners (4) (see Figure 4-23).
Figure 4-23. Left Front Evaporator Panel Installation
g. Install Center Front Evaporator Panel. Install panel (1) and tighten eight captive fasteners (2) (see Figure 4-24).
Figure 4-24. Center Front Evaporator Panel Installation
4-14
ARMY TM 94120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9136-31
Section IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
4-15. INTRODUCTION.
a. General
(1) Systematic, periodic, preventive maintenance checks and services (PMCS) are essential to ensure that the air
conditioner is ready for operation at all times. The purpose of a preventive maintenance program is to
discover and correct defects and deficiencies before they can cause serious damage or complete failure of
the equipment. Any effective preventive-maintenance program must begin with the indoctrination of
operators to report all unusual conditions noted during daily checks or actual operation to unit maintenance.
All defects and deficiencies discovered during maintenance inspections must be recorded, together with
corrective action taken, on DA Form 2404 (Equipment Inspection and Maintenance Worksheet).
(2) A schedule for unit preventive maintenance inspection and service should be established immediately after
installation of the air conditioner. A quarterly interval, equal to three calendar months or 250 hours of
operation (whichever occurs first) is recommended for usual operating conditions. When operating under
unusual conditions, such as very dusty or sandy environment, it may be necessary to reduce the interval to
monthly or even less if conditions are extreme.
(3) Table 4-1 lists the unit preventive maintenance checks and services that should be performed at quarterly (or
otherwise established) intervals. The PMCS items in the table have been arranged and numbered in a logical
sequence to provide for greater personnel efficiency and the least amount of required maintenance downtime.
b. PMCS Columnar Entries.
(1) Item number column. This is the order in which you perform checks and services on the air conditioner. The
entry in this column will also be used as a source of item numbers for the '"TM Item Number" column on DA
form 2404, Equipment Inspection and Maintenance Worksheet, in recording results of PMCS.
(2) Interval. This is the timeframe when a certain check or service should be performed.
(3) Item to check/service column. Identification of item to be inspected.
(4) Procedures column. The procedures column of your PMCS table tells you how to do the required checks and
services. Carefully follow these instructions. If you do not have the tools, or if the procedure tells you to,
have the next higher level of maintenance do the work.
(5) Not fully mission capable if: Entries in this column will be keyed specifically to checks listed in the
"procedures" column for the purpose of identifying, for the check, the criteria that will cause the equipment to
be classified as not fully mission capable because of inability to perform its primary combat mission.
WARNING
Disconnect input power before disassembly of the air conditioner for PMCS to prevent dangerous, possible fatal,
electrical shock.
Table 4-1. Unit Preventive Maintenance Checks and Services
Item
No.
InterVal
Items to
Check/
Service
Procedure
1
Quarterly
Information
Plates
a. Check that information plates are readable
and in place.
b. Replace plates if damaged (para 4-26).
4-15
Not Fully Mission
Capable If:
Plates are
damaged.
ARMY TM 9-4210-381-14
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AIR FORCE TO 35E9-136-31
Table 4-1. Unit Preventive Maintenance Checks and Services - Continued
Item
No.
InterVal
2
Quarterly
Items to
Check/
Service
Left Electric
Plate
Procedure
Not Fully Mission
Capable If:
a. Access panel (para 4-27).
b. Check that plate is not bent, cracked or
punctured.
Plate is
damaged.
c. Repair plates (para 4-27).
d. Replace plate if damaged (para 4-27).
3
Quarterly
Right
Electric Plate
a. Access panel (para 4-28).
b. Check that plate is not bent, cracked or
punctured.
Plate is
damaged.
c. Repair plate (para 4-28).
d. Replace plate if damaged (para 4-28).
4
Quarterly
Control Wire
J-Box
Inspect, repair, and replace as necessary (para
4-33).
Equipment is
damaged.
5
Quarterly
Fresh Air
Connecting
Link
Assembly
Inspect, adjust, repair, and replace as necessary
(para 4-34).
Assembly is out of
adjustment or
damaged.
6
Quarterly
Damper
Solenoid
Fresh Air
Inspect and replace as necessary (para 4-66).
Equipment is
damaged.
7
Quarterly
Bracket
Thermostat
Inspect, repair, and replace as necessary (para
4-35).
Bracket is
damaged or
missing.
8
Quarterly
Circulating
Air In RFI
Filter
a. Access filter (para 4-36).
b. Vacuum filter.
c. Replace filter and RFI gasket if damaged
(para 4-36).
9
Quarterly
Fresh Air
Filter
Filter is dogged or
damaged.
a. Access filter (para 4-37).
b. Check filter for punctures, cuts, and
damaged areas that would allow for
entry of unfiltered air.
c. Wash filter in mild detergent and water
solution. Rinse thoroughly in clean water.
Shake out excess water. Spray filter with
air filter oil.
4-16
Filter is damaged
or dogged.
Replace if damaged.
ARMY TM 9-4210-381-14
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AIR FORCE TO 35E9-136-31
Table 4-1. Unit Preventive Maintenance Checks and Services - Continued
Item
No.
InterVal
Items to
Check/
Service
Fresh Air
Filter (cont.)
Procedure
d. Replace captive fastener, ejector spring,
thermoplastic wear washer, and split ring
retainer.
e. Replace filter if damaged (para 4-37).
10
Quarterly
Fresh Air
RFI Filter
a. Access filter (para 4-38).
Not Fully Mission
Capable If:
Captive fastener,
ejector spring,
thermo plastic
wear washer or
split ring retainer
are damaged.
b. Check filter for punctures, cuts, and
damaged areas that would allow for entry
of unfiltered air. Replace if damaged.
c. Vacuum filter.
d. Replace filter and gasket. If damaged,
contact General Support Maintenance.
11
Quarterly
Condenser
Air Out RFI
Filter
Filter is clogged or
damaged.
a. Access filter (para 4-39).
b. Check filter for punctures, cuts, and
damaged areas that would allow for
entry of unfiltered air. Replace if damaged.
c. Vacuum filter.
d. Replace filter and gasket. If damaged,
contact General Support Maintenance.
12
Quarterly
Condenser
Air Out RFI
Filter
Filter is clogged or
damaged.
a. Access filter (para 4-40).
b. Check filter for punctures, cuts, and
damaged areas that would allow for
entry of unfiltered air. Replace if damaged.
c. Vacuum filter.
d. Replace filter and gasket. If damaged,
contact General Support Maintenance.
13
Quarterly
Circulating
Air Out RFI
Filter
Filter is clogged or
damaged.
a. Access filter (para 4-41).
b. Check filter for punctures, cuts, and
damaged areas that would allow for
entry of unfiltered air. Replace if damaged.
c. Vacuum filter.
d. Replace filter and gasket if damaged (para
4-41).
14
Quarterly
RFI Filter
Filter is clogged or
damaged.
a. Access filter (para 4-42).
b. Check filter for punctures, cuts, and
damaged areas. If damaged contact
General Support Maintenance.
Filter is clogged or
damaged.
c. Inspect varistors for signs of overheating
or other obvious damage (para 4-42).
Varistors are
damaged or
overheating.
4-17
ARMY TM 9-4210-381-14
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AIR FORCE TO 35E9-136-31
Table 4-1. Unit Preventive Maintenance Checks and Services - Continued
Item
No.
15
InterVal
Quarterly
Items to
Check/
Service
RFI Filter
(cont.)
Control Box
Procedure
d.
Inspect fuses and fuse holders (para 4-42).
Not Fully Mission
Capable If:
Fuses are burnt
out.
a. Check operations of controls for stiffness
or binding (para 4-45).
Controls are stiff
or bind.
b. Inspect wiring harness for damage or
chafing, and all electrical connections for
tightness.
Wiring harness is
damaged.
c. Repair control box (para 4-63).
d. Replace control box if damaged (para 4-63).
16
Quarterly
Fan Belts
Control box is
damaged.
a. Access fan belts (para 4-69 and 4-75).
b. Check that belts are not cut, worn, frayed,
or cracked. Replace if damaged. At a point
halfway between the motor pulley and fan
pulley, press the belt by hand. Belt should
not depress more than ½ inch. Adjust if
loose.
Belts are
damaged or belt
depresses more
than ½ inch.
c. Adjust belts (para 4-69 and 4-75).
d. Replace belt if damaged (para 4-69 and
4-75).
17
Quarterly
Evaporator
Motor
a. Access motor (para 4-70).
b. Check motor for rotational freedom by
spinning shaft. If there is stiffness or
binding, replace motor. Check motor
bearings for shaft end play. If there is
excessive end play, replace motor.
There is stiffness
or binding, or
there is excessive
end play in motor
bearings.
c. Lubricate motor (para 4-2).
d. To repair motor contact Direct Support
Maintenance.
e. Replace motor if damaged (para 4-70).
18
Quarterly
Evaporator
Fan
Motor is
damaged.
a. Access fan (para 4-71).
b. Check fan for cracked or broken blades.
Replace if damaged.
Fan blades are
cracked or
broken.
c. Repair fan (para 4-71).
d. Replace fan if damaged (para 4-71).
4-18
Fan is damaged.
ARMY TM 9-4210-381-14
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AIR FORCE TO 35E9-136-31
Table 4-1. Unit Preventive Maintenance Checks and Services - Continued
Item
No.
InterVal
19
Quarterly
Items to
Check/
Service
Pulleys
Procedure
Not Fully Mission
Capable If:
a. Access pulleys; evaporator fan motor
(50/60 Hz) para 4-72 and 4-73, condenser
fan motor (50/60 Hz) para 4-78 and 4-79.
b. Check pulleys for dents and burrs. Replace
if damaged. Check that 60 Hz pulleys are
painted red and 50 Hz pulleys are painted
green.
c. Adjust pulleys.
d. Replace pulleys if damaged.
20
Quarterly
Condenser
Motor
Pulleys are
damaged.
a. Access motor (para 4-76).
b. Check motor for rotational freedom by
spinning shaft. If there is stiffness or
binding, replace motor. Check motor
bearings for shaft end play. If there is
excessive end play, replace motor.
There is stiffness
or binding. There
is excessive shaft
end play.
c. Lubricate motor (para 4-2).
d. To repair motor contact Direct Support
Maintenance.
e. Replace motor if damaged (para 4-76).
21
Quarterly
Condenser
Fan
Motor is
damaged.
a. Access fan (para 4-77).
b. Check fan for cracked or broken blades.
Replace if damaged.
Blades are
cracked or
broken.
c. Repair fan (para 4-77).
d. Replace fan if damaged (para 4-77).
22
Quarterly
Electric
Heater
Fan is damaged.
a. Access heater (para 4-80).
b. Check heater elements for deformation,
damaged terminals, threads, cracked or
broken terminals. Replace if damaged.
Heater elements
are deformed,
terminals
damaged.
c. Replace heater if damaged (para 4-80).
Heater is
damaged.
4-19
ARMY TM 9-4210-381-14
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AIR FORCE TO 35E9-136-31
Table 4-1. Unit Preventive Maintenance Checks and Services - Continued
Item
No.
InterVal
23
Quarterly
Items to
Check/
Service
Compressor
Crankcase
Heater
Procedure
a. Access heater (para 4-81).
b. Visually inspect for damage.
c. Replace heater if damaged (para 4-81).
24
25
26
27
Quarterly
Quarterly
Quarterly
Quarterly
Heat Control
Thermostat
Low Ambient
Temperature
Thermostat
Cool Control
Thermostat
High/Low
Refrigerant
and Low Oil
Pressure
Switches
Not Fully Mission
Capable If:
Heater is
damaged.
a. Access heat control thermostat (para 4-85).
b. Check that leads are properly connected
(see Figure FO-3).
Leads are
improperly
connected.
c. Check that sensing coil is not damaged.
Sensing coil is
damaged.
d. Replace heat control thermostat if damaged
(para 4-85).
Heat control
thermostat is
damaged.
a. Access low ambient temperature thermostat
(para 4-86).
b. Check that leads are properly connected
(see Figure FO-3).
Leads are
improperly
connected.
c. Check that sensing coil is not damaged.
Sensing coil is
damaged.
d. Replace low ambient temperature thermostat
(para 4-86).
Thermostat is
damaged.
a. Access cool control thermostat (para 4-87).
b. Check that leads are properly connected
(see Figure FO-3).
Leads are
improperly
connected.
c. Check that sensing coil is not damaged.
Sensing coil is
damaged.
d. Replace cool control thermostat if damaged
(para 4-87).
Cool control
thermostat is
damaged.
a. Access switch, remove right front condenser
panel (para 4-11).
b. Check that clamp is not dented, broken, or
split. Check that switch cover is not dented,
broken, or cracked.
4-20
Switches are
damaged.
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Table 4-1. Unit Preventive Maintenance Checks and Services - Continued
Item
No.
28
InterVal
Quarterly
Items to
Check/
Service
Procedure
High/Low
Refrigerant
and Low Oil
Pressure
Switches
(cont.)
c. To replace switch contact Direct Support
Maintenance.
Compressor
a. Remove right front condenser panel
(para 4-11) to access compressor.
b. Check compressor sight glass
(see Figure 4-1). Refrigerant oil should
be between ¼ min and ½ max levels.
Not Fully Mission
Capable If:
Improper
refrigerant oil
level.
c. To add or remove compressor oil contact
Direct Support Maintenance.
WARNING
This inspection performed with power on. Proceed with extreme caution to prevent dangerous
possible fatal shock.
29
Quarterly
Sight Glass
a. Access sight glass, remove right front
evaporator panel (para 4-11).
b. Check that glass window is not broken or
cracked. Check for evidence of leakage.
Check for bubbles. Contact Direct Support
Maintenance for any deficiency.
Glass window is
broken or leakage
is evident.
c. Check for milky appearance.
Milky appearance
in sight glass.
d. If sight glass has milky appearance, dean
the condenser air in RFI filter (para 4-40) and
condenser coil (para 4-90).
e. To repair or replace sight glass contact
Direct Support Maintenance
4-21
Sight glass is
damaged.
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section V. UNIT TROUBLESHOOTING
4-16. GENERAL. This section contains unit troubleshooting information for locating and correcting most of the
operating troubles which may develop in the air conditioner.
NOTE
Before you use the table, be sure you have performed all applicable PMCS (Table 4-1).
4-17. TROUBLESHOOTING. Each malfunction for an individual component is listed in Table 4-2. The malfunction is
followed by a list of tests or inspections which help to determine probable causes and corrective actions to take. All
malfunctions that may occur and all tests or inspections and corrective actions may not be listed. If a malfunction is not
listed or is not corrected by corrective action, notify your supervisor.
WARNING
· HIGH VOLTAGE
is used in the operation of this equipment.
DEATH ON CONTACT
may result if personnel fail to observe safety precautions.
l Never work on electrical equipment unless there is another person nearby who
is familiar with the operation and hazards of the equipment and who is
competent in administering first aid.
When the technician is aided by
operators, he must warn them about dangerous areas.
l Whenever possible, the input power supply to equipment must be shut off
before beginning work on the equipment. Take particular care to ground every
capacitor likely to hold a dangerous potential. When working inside the
equipment, after the power has been turned off, always ground every part
before touching it.
l Be careful not to contact high-voltage connections of 208 volts ac input when
installing or operating this equipment.
l Whenever the nature of the operation permits, keep one hand away from the
equipment to reduce the hazard of current flowing through vital organs of the
body.
l Do not operate the equipment without all panels and covers in place and tightly
secured.
l Do not be misled by the term "low voltage." Potentials as low as 50 volts may
cause death under adverse conditions.
4-22
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Table 4-2. Unit Maintenance Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. AIR CONDITIONER DOES NOT START IN ANY MODE.
WARNING
Disconnect input power before performing internal electrical troubleshooting. Voltages used can be deadly.
Step 1. Check to see if input power has been disconnected.
Connect input power.
Step 2. Make sure that power is 208 V ac, 3-phase, 50/60 hertz.
Connect correct input power (para 4-13).
Step 3. Check to see if control circuit breaker (CB1) is tripped (para 4-62).
Reset control circuit breaker (CB1).
Step 4. Check operation of control circuit breaker (CB1).
Test control circuit breaker (para 4-62). Replace control circuit breaker, if defective.
Step 5. Check operation of MODE SELECT SWITCH (S1).
Test switch (para 4-56). Replace switch, if defective.
Step 6. Check for loose or damaged electrical connections or damaged wires in wiring harnesses (see Figure
FO-3).
Tighten or replace lugs, or repair damaged wires.
Step 7. Check RFI filter (para 4-42).
Replace bad fuses (para 4-43).
Step 8. Check all terminals (para 4-42) and internal wiring within RFI filter for tightness and damage.
Tighten electrical connections. Perform RFI test (para 4-42). If wires are damaged, replace as
necessary.
WARNING
Disconnect input power before performing internal electrical troubleshooting. Voltage used can be deadly.
Step 9. Check operation of transformer (T1).
Check output (25.2 to 30.8 V ac) and input (120 V ac) voltages (see Figure FO-3); if output voltages
are not correct, test transformer (T1) (para 4-60). Replace transformer, if defective.
Step 10. Check operation of rectifier (CR1).
Test rectifier (para 4-46). Replace defective rectifier.
4-23
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Table 4-2. Unit Maintenance Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. EVAPORATOR AND CONDENSER FANS BOTH RUN, BUT COMPRESSOR DOES NOT START AFTER TIME
DELAY.
Step 1. Check operation of MODE SELECT SWITCH (S1) (para 4-56).
Set switch to OFF, then reset to COOL.
NOTE
Allow 60 seconds time delay before compressor starts.
WARNING
Disconnect input power before performing Internal electrical troubleshooting.
Voltage used can be deadly.
Step 2. Check for loose or damaged electrical connections, or damaged wires in wiring harnesses (see
Figure FO-3).
Tighten or replace connections and lugs. If wires are damaged, replace as necessary.
Step 3. Check operation of time delay relay (K22).
Test relay (para 4-54). Replace relay, if defective.
Step 4. Check operation of compressor contactor (K10).
Test contactor (para 4-52). Replace contactor, if defective.
Step 5. Check operation of compressor (B1).
If not operating, contact Direct Support Maintenance for refrigeration system troubleshooting.
3. COMPRESSOR STARTS NORMALLY, BUT CONTROL CIRCUIT BREAKER (CB1) SOON TRIPS.
Check circuit breaker (CB1).
Test circuit breaker (para 4-62). Replace circuit breaker if defective. Restart air conditioner in COOL
mode.
CAUTION
If circuit breaker trips again soon after restart in COOL mode, do not attempt
another restart, damage may occur to compressor. Contact Direct Support Maintenance for refrigeration system troubleshooting.
4. REDUCED COOLING CAPACITY.
Step 1. With unit operating in COOL mode, check condition of refrigerant in sight glass (Table 4-1, item 28).
a. Check sight glass (Table 4-1, item 28).
b. Clean condenser coil (para 4-90).
Step 2. Check operation of cool control thermostat (SI4).
Test thermostat (para 4-87). Replace thermostat, if defective.
4-24
ARMY TM 9-4120.381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Table 4-2. Unit Maintenance Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. REDUCED HEATING CAPACITY.
Step 1. Check that all doors, windows, and other openings in the room or enclosure are tightly closed.
Tightly close all openings.
Step 2. Check to be sure that excessive cold, outside air is not being introduced through the fresh air inlet.
Cover inlet; then, if condition improves, adjust damper as required.
Step 3. Check operation of heat control thermostat (S9).
Test thermostat (para 4-85). Replace thermostat, if defective.
WARNING
Disconnect unit power before performing internal electrical troubleshooting.
Voltages used can be deadly.
Step 4. Check for loose or damaged electrical connections or damaged wires in wiring harnesses (see
Figure FO-3).
Tighten or replace lugs, or repair damaged wires.
Step 5. Check individual elements of heater (EH).
Test electric heater elements (para 4-80). Replace element(s), if defective.
Step 6. Check operation of heater contactor (K11).
Test contactor (para 4-53). Replace contactor, if defective.
6. EVAPORATOR FAN MOTOR (B1) DOES NOT OPERATE.
WARNING
Disconnect input power before performing internal electrical troubleshooting.
Voltages used can be deadly.
Step 1. Using wiring diagram (see Figure FO-3), check electrical connections and individual wires for tightness.
Tighten or replace electrical connectors, or repair damaged wires.
Step 2. Check operation of fan motor contactor (K8).
Test contactor (para 4-51). Replace contactor, if defective.
Step 3. Check operation of evaporator fan motor (B1).
Test motor (para 4-70). Replace motor, if defective.
4-25
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Table 4-2. Unit Maintenance Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
6. EVAPORATOR FAN MOTOR (B1) DOES NOT OPERATE - Continued.
Step 4. Check operation of MODE SELECT SWITCH (Si).
Inspect switch (para 4-56). Replace switch, if defective.
7. CONDENSER FAN MOTOR (B3) DOES NOT OPERATE.
WARNING
Disconnect input power before performing internal electrical troubleshooting.
Voltages used can be deadly.
Step 1. Using wiring diagram (see Figure FO-3), check electrical connections and individual wires for tightness.
Tighten or replace electrical connectors, or repair damaged wires.
Step 2. Check operation of fan motor contactor (K9).
Test contactor (para 4-51). Replace contactor, if defective.
Step 3. Check operation of condenser fan motor (B3).
Test motor (para 4-76). Replace motor, if defective.
Step 4. Check operation of MODE SELECT SWITCH (S1).
Inspect switch (para 4-56). Replace switch, if defective.
8. EXCESSIVE NOISE.
Step 1. Examine noises heard during compressor operation.
CAUTION
If a knocking or hammering sound Is heard when compressor starts, turn MODE
SELECT SWITCH to OFF, immediately. Such noise is usually caused by liquid refrigerant in compressor, which can seriously damage or destroy compressor.
a. If knocking or hammering sound is heard when compressor starts, turn MODE SELECT SWITCH to
OFF IMMEDIATELY.
b. Isolate source of noise as near as possible, both by ear and touch. Listen and feel at both front and
back of cabinet.
4-26
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Table 4-2. Unit Maintenance Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WARNING
Disconnect input power before performing internal electrical troubleshooting.
Voltages used can be deadly.
8. EXCESSIVE NOlSE - Continued.
Step 2. Check fans for looseness or damage, and for rotational clearance.
Tighten loose fans (para 4-71 and 4-77).
Step 3. Check all internal components for looseness, vibration, and security.
Tighten, adjust, and secure as necessary.
9. FAULT RESET SWITCH (S12) DOES NOT RESET.
WARNING
Disconnect input power before performing internal electrical troubleshooting.
Voltages used can be deadly.
Step 1. Check operation of reset switch (S12).
Test switch (para 4-59). Replace switch, if defective.
Step 2. Check operation of fault relay (K6).
Test relay (para 4-49). Replace relay, if defective.
Step 3. Check operation of relay (K6).
Test socket (para 4-50). Replace socket, if defective.
Step 4. Check operation of suppression diode (CR11).
Test diode (para 4-47). Replace diode, if defective.
10. DIRTY FILTER LIGHT (DS2) ON.
Step 1. Check return air filter.
Clean filter (para 3-5).
Step 2. Check operation of dirty filter relay (K20).
Test relay (para 4-49). Replace relay, if defective.
Step 3. Check operation of relay (K20) 11-pin socket.
Test socket (para 4-50). Replace socket, if defective.
Step 4. Check operation of suppression diode (CR5).
Test diode (para 4-47). Replace diode, if defective.
Step 5. If dirty filter light is still on, unit has possible defective air flow switch (S3).
Test dirty filter switch (S3) (para 4-82). Replace dirty filter switch, if defective.
4-27
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Table 4-2. Unit Maintenance Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
11. LOW OIL PRESSURE LIGHT (DS6) ON.
Step 1. Check operation of low oil pressure relay (K4).
Test relay (para 4-49). Replace relay, if defective.
Step 2. Check operation of relay (v(4) 11-pin socket.
Test socket (para 4-50). Replace socket, if defective.
Step 3. Check operation of suppression diode (CR9).
Test diode (para 4-47). Replace diode, if defective.
Step 4. Check operation of low oil pressure switch (S7).
To test switch contact Direct Support Maintenance.
Step 5. Check operation of time delay relay (K22).
Test relay (para 4-54). Replace relay, if defective.
Step 6. If low oil pressure light is still on, notify Direct Support Maintenance that compressor crankcase has low
oil pressure.
12. HIGH DISCHARGE PRESSURE LIGHT (DS3) ON.
Step 1. Check that condenser fan motor (B3) runs.
Go to malfunction No. 7.
WARNING
Disconnect input power before performing internal electrical troubleshooting.
Voltages used can be deadly.
Step 2. Feel condenser coil.
If coil is exceptionally hot, contact Direct Support Maintenance for refrigeration system troubleshooting.
Step 3. Check condenser coil for cleanliness.
If dirty, clean coil (para 4-90).
Step 4. With unit operating in COOL mode, check condition of refrigerant in sight glass (Table 4-1, item 28).
Check sight glass (Table 4-1, item 28).
Step 5. Check operation of high discharge pressure relay (K1).
Test relay (para 4-49). Replace relay, if defective.
4-28
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Table 4-2. Unit Maintenance Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
12. HIGH DISCHARGE PRESSURE LIGHT (DS3) ON - Continued
Step 6. Check operation of relay (K1) 11-pin socket.
Test socket (para 4-50). Replace socket, if defective.
Step 7. Check operation of suppression diode (CR6).
Test diode (para 4-47). Replace diode, if defective.
Step 8. If high discharge pressure light (DS3) is still on, contact Direct Support Maintenance for refrigeration
system troubleshooting.
13. LOW SUCTION PRESSURE LIGHT (DS4) ON.
Step 1. With unit operating in COOL mode, check condition of refrigerant in sight glass (Table 4-1, item 28).
a. Check sight glass (Table 4-1, item 28).
b. Clean evaporator coil (para 4-91).
Step 2. Feel outlet line of drier filter (1-9).
If outlet line is much cooler than inlet line, contact Direct Support Maintenance.
Step 3. Check all piping and connections for leaks.
If leaks are suspected, contact Direct Support Maintenance for refrigeration system troubleshooting.
Step 4. Check operation of low pressure relay (K2).
Test relay (para 4-49). Replace relay, if defective.
Step 5. Check operation of relay socket (K2).
Test socket (para 4-50). Replace socket, if defective.
Step 6. Check operation of suppression diode (CR7).
Test diode (para 4-47). Replace diode, if defective.
Step 7. If low suction pressure light (DS4) is still on, contact Direct Support Maintenance.
4-29
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Table 4-2. Unit Maintenance Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
14. CONTROL POWER (24 VDC) FAULT LIGHT (DS9) ON.
Step 1. Check operation of transformer (T1).
Test transformer (para 4-60). Replace transformer, if defective.
Step 2. Check operation of control power faults relay (K19).
Test relay (para 4-49). Replace relay, if defective.
Step 3. Check operation of relay (K19) 11-pin socket.
Test socket (para 4-50). Replace socket, if defective.
Step 4. Check operation of suppression diode (CR4).
Test diode (para 4-47). Replace diode, if defective.
Step 5. Check operation of rectifier (CR1).
Test rectifier (para 4-46). Replace rectifier, if defective.
15. COMPRESSOR STARTS NORMALLY, BUT CRANKCASE HEATER CIRCUIT BREAKER (CB2) SOON
TRIPS.
Step 1. Check operation of circuit breaker (CB2).
Test circuit breaker (para 4-62). Replace circuit breaker, if defective.
Step 2. Check operation of compressor crankcase heater (CCH).
Test heater (para 4-81). Replace heater, if defective.
16. SERVICE LIGHT (DS8) DOES NOT COME ON WHEN LIGHT SWITCH (S2) IS SET TO ON.
Step 1. Check operation of service light (DS8).
Test light (para 4-65). Replace bulb, guard or holder, if defective.
Step 2. Check operation of service light switch (S2).
Test switch (para 4.58). Replace switch, if defective.
4-30
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section VI. UNIT MAINTENANCE PROCEDURES
Para
4-18
4-19
4-20
4-21
4-22
4-23
4-24
4-25
4-26
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
4-41
4-42
4-43
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
4-58
4-59
4-60
4-61
4-62
4-63
4-64
4-65
4-66
4-67
Title
Functional Description ........................................................................................................
Air conditioner Control ........................................................................................................
Heater Control ....................................................................................................................
General Maintenance .........................................................................................................
Center Front Evaporator Panel ...........................................................................................
Left Front Evaporator Panel.................................................................................................
Fresh Air Inlet Filter Box (Evaporator Front Panel) .............................................................
Right Front Evaporator Panel .............................................................................................
Information Plates ..............................................................................................................
Left Front Condenser Panel ................................................................................................
Right Front Condenser Panel ..............................................................................................
Front Service Valve Panel ..................................................................................................
Left Electric Plate ...............................................................................................................
Right Electric Plate .............................................................................................................
Rear Evaporator Panel .......................................................................................................
Control Wire J-Box .............................................................................................................
Fresh Air Connecting Link Assembly ...................................................................................
Thermostat Bracket ............................................................................................................
Circulating Air In RFI Filter .................................................................................................
Fresh Air Filter ....................................................................................................................
Fresh Air RFI Filter .............................................................................................................
Condenser Air Out RFI Filter ..............................................................................................
Condenser Air In RFI Filter .................................................................................................
Circulating Air Out RFI Filter ...............................................................................................
RFI Filter ............................................................................................................................
Fuses (F1-F4) .....................................................................................................................
Varistors (VR-1 thru VR-4) ..................................................................................................
Control Box and Components .............................................................................................
Rectifier (CR1) ....................................................................................................................
Suppression Diodes (CR2-CR11) ........................................................................................
Indicator Lights (DS1-DS7, DS9) ........................................................................................
Control Relays (K1-K7, K18-K20) .......................................................................................
Relay Sockets .....................................................................................................................
Fan Contactors (K8 and K9) ...............................................................................................
Compressor Contactor (K10) ..............................................................................................
Heater Contactor (Kl1) ........................................................................................................
Time Delay (10 and 60 Sec) Relays (K21 and K22) ............................................................
Resistors (R1 and R2) .........................................................................................................
Mode Select Switch (S1) .....................................................................................................
Knob (Mode Select Switch (S1)) .........................................................................................
Service Light Switch (S2) ....................................................................................................
Fault Reset Switch (S 12) ...................................................................................................
Transformer (T1) ................................................................................................................
Terminal Boards (TB1-TB3) ................................................................................................
Circuit Breakers (CB1 and CB2) .........................................................................................
Control Box ........................................................................................................................
Terminal Board (TB4) .........................................................................................................
Service Light (DS8) ............................................................................................................
Fresh Air Damper Solenoid (L3) .........................................................................................
Wire Harness ......................................................................................................................
4-31
Page
4-32
4-32
4-33
4-35
4-36
4-38
4-41
4-43
4-46
4-47
4-50
4-53
4-56
4-58
4-60
4-61
4-64
4-66
4-68
4-70
4-72
4-73
4-74
4-75
4-77
4-79
4-81
4-83
4-85
4-87
4-89
4-91
4-93
4-95
4-98
4-100
4-102
4-104
4-106
4-109
4-110
4-112
4-114
4-116
4-118
4-120
4-123
4-125
4-127
4-129
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Para
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
4-91
4-92
4-93
Title
Evaporator (Circulator) Motor and Housing Assembly .........................................................
Fan Belt (Evaporator Motor and Housing Assembly) ...........................................................
Evaporator Motor (B1) .........................................................................................................
Circulator Fan (Evaporator) ................................................................................................
Pulleys 60 Hz, Green (Evaporator Motor and Circulator Fan) ..............................................
Pulleys 50 Hz, Red (Evaporator Motor and Circulator Fan) .................................................
Condenser Motor and Housing Assembly ............................................................................
Fan Belt (Condenser Motor and Housing Assembly) ...........................................................
Condenser Motor (B3) .........................................................................................................
Circulator Fan (Condenser) .................................................................................................
Pulleys 60 Hz, Green (Condenser Motor and Circulator Fan) ..............................................
Pulleys 50 Hz, Red (Condenser Motor and Circulator Fan) .................................................
Electric Heater (EH).............................................................................................................
Compressor Crankcase Heater (CCH) .................................................................................
Dirty Filter Switch (S3).........................................................................................................
High Temperature Switch (S6).............................................................................................
Air Flow Switch (S8) ............................................................................................................
Heat Control Thermostat (S9) .............................................................................................
Low Ambient Temperature Thermostat (S 3) ......................................................................
Cool Control Thermostat (S14) ...........................................................................................
Solenoid Valves (LI and L2) Coil Removal ..........................................................................
Condenser Fan Connecting Link Assembly .........................................................................
Condenser Coil ...................................................................................................................
Evaporator Coil ...................................................................................................................
Drain Areas ........................................................................................................................
Preparation for Storage or Shipment ...................................................................................
Page
4-131
4-132
4-134
4-136
4-139
4-141
4-143
4-144
4-146
4-148
4-151
4-153
4-155
4-158
4-160
4-162
4-164
4-166
4-168
4-170
4-172
4-174
4-176
4-178
4-180
4-182
4-18. FUNCTIONAL DESCRIPTION. The air conditioner control circuits are described in the following paragraphs (see
NO TAG and Figure FO-1).
4-19. AIR CONDITIONER CONTROL.
NOTE
The air conditioner utilizes a hot gas bypass system to maintain temperature control
instead of switching the compressor on and off each time air temperature crosses the
threshold of the control setting.
a. Control Power. Transformer (T1) and rectifier (CR1) form a simple, unfiltered power supply providing +24 V dc
for operation of control relays and LED fault indicators. When +24 V dc is present in the unit, control relay (K19)
remains energized and interrupts ac power to fault lamp indicator (DS9) (control power fault). When control
power fails, K19 is de-energized and restores ac power to DS9.
b. Mode Select Switch. When set to AUTO or REMOTE, MODE SELECT SWITCH (St) applies ac power to
thermostats, contactors, and solenoids. When set to cool, S1 applies dc control power (+24 V dc) to energize
control relay (K1 8), and operate contactors (K8 thru K10), and relay (K21). When set to COOL, only cooling or
pumpdown operations are allowed. When set to HEAT position, S1 applies dc control power to energize control
relay (K7) and operates contactor (Kl1). When set to HEAT, cooling thermostat (S14) is disabled, and switch
(S9) controls heating operation.
c. Evaporator Fan Circuit. Three phase ac power is applied to evaporator fan motor (81) when contactor (K8) is
energized. The contactor may be energized by select switch (S1), control relay (K7), or control relay (K18).
Current overloads (K12 thru K14) are integral to the contactor (K8).
d. Heater Circuit. Three phase ac power is applied to electric heater elements (EH) when contactor (K 1) is
energized.
4-32
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure 4-25. Control Circuits
4-33
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
4-19. AIR CONDITIONER CONTROL - Continued.
e. Compressor Circuit. Three phase ac power is applied to compressor motor (B2) when contactor (K10) is
energized. The contactor may be energized by cooling thermostat (S14) or by control relay (K18). Contactor
(K9) is wired in parallel with contactor K10, and when energized, applies three phase ac power to condenser
fan motor (B3). Current overloads (K15 thru K17) are integral to contactor (K9). Current overloads (K23. K24,
and S15) are integral to motor (B2). Circuit breaker (CB2) protects compressor crankcase heater.
f.
Time Delay. Time delay relays (K21 thru K22) temporarily disable two fault detection circuits on start-up.
Time delay relay K21 disables evaporator fan failure circuit for 10 seconds to allow the fan to reach normal
operating speed. Time delay relay K22 disables low oil pressure circuit for 60 seconds to allow compressor to
build up oil pressure in the crankcase.
g. Fault Circuits. Control relays (K1 thru K6) are part of critical fault circuits. If any of five critical faults occurs,
the appropriate relay (K1 thru K5) is energized by the fault-detecting sensor. The relay applies dc power to the
appropriate LED fault indicator and to summary fault relay (K6). These relays remain energized until FAULT
RESET switch (S1 2) is pressed. When energized, K6 interrupts ac power to MODE SELECT SWITCH (S1)
and contactors (K8 thru K11). Loss of ac power causes unit to shutdown heating or cooling operation if a
critical fault occurs. Control relay (K20), when energized, does not cause a complete shutdown of unit
operations. The remote fault signal is generated if K6 or K20 is energized. Control relay K20 will also remain
energized until S12 is pressed. Sensors are provided to automatically shut down the air conditioner as follows:
CRITICAL
FAULT
HIGH DISCHARGE
PRESSURE
LOW SUCTION
PRESSURE
HIGH AIR
TEMPERATURE
LOW OIL
PRESSURE
EVAPORATOR FAN
FAILURE
CONTROL POWER
SENSOR
SWITCH
CONTROL
RELAY
FAULT
INDICATOR
S4
K1
DS3
S5
S6
K2
DS4
K3
DS5
S7
K4
DS6
S8
K5
DS7
K19
DS9
4-20. HEATER CONTROL.
a. The heater section of the air conditioner uses six electric heaters. The heaters are thermostatically controlled
by heating control thermostat (S9) in redundant configuration and (S14) in single configuration.
b. Single Configuration. When heating is selected by placing MODE SELECT SWITCH (S1) into either the HEAT
or the AUTO position, and the temperature is below the minimum thermostat (S14) setting, the heaters are
activated by energizing heater contactor (K11) and thus closing K11 contactors and applying power to the
heating elements. The elements will remain on as long as the air temperature is below the thermostat (S14)
setting.
c. Dual Configuration (Remotely Controlled). When heating is selected from a remotely located control panel (air
conditioner MODE SELECT SWITCH in REMOTE), and the temperature is below the minimum heat control
thermostat (S9) setting, the heaters are activated by energizing heater contactor (Kl1) and thus closing K11
contactors and applying power to the heating elements. The heating elements will remain on as long as the air
temperature is below the heat control thermostat (S9) setting.
d. A safety circuit is provided to ensure that if, for any reason, the heating elements remain on after the thermostat
(S9) or (S14) should have deactivated them, high air temperature switch (S6) will open and activate the fault
circuit (see 4-19 g).
4-34
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
4-21. GENERAL MAINTENANCE. This section contains maintenance procedures which are authorized to Unit
Maintenance (0) by the Maintenance Allocation Chart (MAC) Appendix B and Source Maintenance and Recoverability
(SMR) coded items. Each paragraph covers a complete maintenance procedure but may require other tasks to be
included (i.e. initial setups, references and follow on procedures). Perform procedures/tasks in designated order. Table
4-3 shows air conditioner control settings and results of switch settings.
WARNING
*
Panels, covers, screens, grilles and guards installed on unit are there for a
purpose. Do not operate unit with them off unless instructions tell you to.
When necessary, do so with care.
*
Moving machinery exists behind front and back condenser panels, and front
and back evaporator panels. Don't stick your fingers in, get your loose
apparel or jewelry caught. Failure to observe this warning could cause injury
to personnel.
Table 4-3. MODE SELECT SWITCH Positions and Results
4-35
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-22. CENTER FRONT EVAPORATOR PANEL.
This task consists of: Removal
Inspection
Repair/Replace Installation
INITIAL SET-UP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Blind riveter (Item 8, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Bulk insulation material
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (MEK) (Item 13, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control
panel does not disconnect unit power.
Disconnect air conditioner input power at source.
REMOVAL
1.
2.
Loosen eight captive fasteners (1) (see Figure 4-26).
Remove panel (2).
INSPECTION
1.
2.
3.
4.
Check that panel is not bent, cracked, or punctured, replace if damaged.
Check that gaskets (3) and insulation (5) are not torn, loose, or missing.
Check that information plates are readable and in place.
For replacement of information plates refer to para 4-26.
NOTE
Repair consists of replacing gasket, insulation, and captive fasteners.
REPAIR/REPLACE
1. Gasket.
a. Remove captive fasteners (1).
b. Remove gasket (3) from panel (2).
4-36
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure 4-26. Center Front Evaporator Panel
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can
be explosive. Repeated or prolonged skin contact or inhalation of vapors
can be toxic. Use a well ventilated area, wear gloves, and keep away from
sparks or flame.
c. Clean area for new gasket, using acetone or MEK and a stiff brush.
d. Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
to fingers.
e. Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
f.
Install captive fasteners.
2. Insulation.
a. Cut and remove damaged section of insulation (5).
b. Clean area for new insulation, using acetone or MEK and a stiff brush.
c. Cut replacement insulation to fit.
d. Coat surfaces of metal and insulation with adhesive. Let both surfaces dry until adhesive is tacky but will not
stick to fingers.
e. Starting with an end, carefully attach insulation to metal surface. Press into firm contact all over.
f.
If insulation retainer (4) is removed, install new retainer (4) with rivet (6).
3. Captive Fasteners.
a. Remove split ring retainer (7), fastener (10), themoplastic wear washer (8), and ejector spring (9).
b. Install ejector spring (9), thermoplastic wear washer (8), fastener (10), and split ring retainer (7).
INSTALLATION
1. Position panel (2) in place.
2. Tighten eight captive fasteners (1).
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
4-37
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-23. LEFT FRONT EVAPORATOR PANEL.
This task consists of: Removal
Inspection
Repair/Replace
Installation
INITIAL SET-UP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Blind riveter (Item 8, Appendix B)
Riveter (Rivnut) (Item 9, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Bulk insulation material
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (MEK) (Item 13, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control
panel does not disconnect unit power.
1.
2.
Disconnect air conditioner input power at source.
Remove center front evaporator panel (para 4-22).
REMOVAL
1.
2.
3.
Loosen five captive fasteners (1) (see Figure 4-27).
Loosen clamp (15) and remove hose (16).
Remove panel (3).
INSPECTIO
N
1.
Check that panel is not bent, cracked, or punctured.
2.
Check that gaskets (2) and insulation (9) are not torn, loose, or missing.
REPAIR/REPLACE
NOTE
Repair consists of replacing flange, gasket, insulation, captive fasteners and panel.
1.
Flange.
a.
b.
c.
d.
Remove two rivets (6) and receptacle (7).
Remove ten rivets (5).
Remove flange (4).
Position replacement flange (4) in place.
4-38
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
e. Install ten rivets (5).
f. Install receptacle (7) with two rivets (6).
Figure 4-27. Left Front Evaporator Panel
2. Gasket.
a. Remove captive fasteners.
b. Remove damaged gasket (2) from panel (3).
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can
be explosive. Repeated or prolonged skin contact or inhalation of vapors
can be toxic. Use a well ventilated area, wear gloves, and keep away from
sparks or flame.
c. Clean area for new gasket, using acetone or MEK and a stiff brush.
d. Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
to fingers.
e. Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
f.
Install captive fasteners.
4-39
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-23. LEFT FRONT EVAPORATOR PANEL - Continued.
3. Insulation.
a. Remove fresh air inlet hose and filter box (para 4-24), if necessary.
b. Remove damaged section of insulation (9).
c. Clean area for new insulation, using acetone or MEK and a stiff brush.
d. Cut replacement insulation to fit.
e. Coat surfaces of metal and insulation with adhesive. Let both surfaces dry until adhesive is tacky but will not
stick to fingers.
f.
Starting with an end, carefully attach insulation to metal surface. Press into firm contact all over.
g. If insulation retainer (8) is removed, install new insulation retainer (8) with rivet (10).
4. Captive Fasteners.
a. Remove split ring retainer (11), fastener (14), thermoplastic wear washer (12), and ejector spring (13).
b. Install ejector spring (13), thermoplastic wear washer (12), fastener (14), and split ring retainer (11).
INSTALLATION
1. Position panel (3) in place.
2. Install hose (16) and tighten clamp (15).
3. Tighten five captive fasteners (1).
FOLLOW
PROCEDURES
ON
1. Install center front evaporator panel (para 4-22).
2. Connect air conditioner input power at source.
4-40
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-24. FRESH AIR INLET FILTER BOX (EVAPORATOR FRONT PANEL).
This task covers:
Inspection
Removal
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Blind riveter (Item 8, Appendix B)
Riveter (Rivnut) (Item 9, Appendix B)
Personnel : 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front evaporator panel (para 4-23).
INSPECTION
1.
2.
Check that box (3) is not bent, cracked, or punctured (see Figure 4-28).
Check for damaged, loose, or missing mounting hardware.
REMOVAL
1.
2.
3.
Loosen clamp (1) and remove hose (2).
Remove four screws (8) and lockwashers (7).
Remove fresh air filter box (3).
REPAIR/REPLACE
NOTE
Repair consists of replacing receptacles (9), rivnuts (6), and filter box (3).
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Loosen two captive fasteners (4).
Remove filter (5).
Remove four rivets (10).
Remove two receptacles (9).
Remove four rivnuts (6).
Install four rivnuts (6) on replacement filter box (3).
Position two receptacles (9) in place.
Install four rivets (10).
Position filter (5) in place.
Tighten two captive fasteners (4).
4-41
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-24. FRESH AIR INLET FILTER BOX (EVAPORATOR FRONT PANEL) - Continued
Figure 4-28. Fresh Air Inlet Filter Box (Evaporator Front Panel)
INSTALLATION
1.
2.
3.
Position fresh air filter box (3) in place.
Install four lockwashers (7) and screws (8).
Install hose (2) and clamp (1).
FOLLOW ON PROCEDURE
1.
2.
Close left front evaporator panel (para 4-23).
Connect air conditioner input power at source.
4-42
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-25. RIGHT FRONT EVAPORATOR PANEL.
This task covers:
Removal
Inspection
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Blind riveter (Item 8, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Bulk insulation material
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (MEK) (Item 13, Appendix E)
Equipment Conditions:
WARNING
Disconnect Input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL Shutting the unit off at the control panel does not disconnect unit power.
Disconnect air conditioner input power at source.
REMOVAL
1.
2.
Loosen six captive fasteners (1) (see Figure 4-29).
Remove panel (3).
INSPECTION
1.
2.
3.
4.
Check that panel is not bent, cracked, or punctured.
Check that gaskets (2) and insulation (7) are not torn, loose, or missing.
Check that information plates are readable and in place.
For replacement of information plates, refer to para 4-26.
REPAIR/REPLACE
NOTE
Repair consists of replacing gasket, insulation, and captive fasteners or panel.
1.
Gasket.
a. Remove captive fasteners.
b. Remove damaged gasket (2) from panel (3).
4-43
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-25. RIGHT FRONT EVAPORATOR PANEL-Continued.
REPAIR/REPLACE-Continued.
1.
Gasket-Continued.
Figure 4-29. Right Front Evaporator Panel
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive.
Repeated or prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area,
wear gloves, and keep away from sparks or flame.
c. Clean area for new gasket, using acetone or MEK and a stiff brush.
d. Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
to fingers.
e. Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
f. Install captive fasteners
2.
Insulation.
a.
b.
c.
d.
Cut and remove damaged section of insulation (7).
Clean area for new insulation, using acetone or MEK and a stiff brush.
Cut replacement insulation to fit.
Coat surfaces of metal and insulation with adhesive. Let both surfaces dry until adhesive is tacky but will not
stick to fingers.
e. Starting with an end, carefully attach insulation to metal surface. Press into firm contact all over.
f. If insulation retainer (9) is removed, install new retainer (9) with rivet (8).
4-44
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
3.
Captive Fasteners.
g. Remove split ring retainer (4), fastener (10), thermoplastic wear washer (6), and ejector spring (3).
h. Install ejector spring (3), thermoplastic wear washer (6), fastener (10), and split ring retainer (4).
INSTALLATION
1.
2.
Position panel (3) in place.
Tighten six captive fasteners (1).
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
4-45
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-25. RIGHT FRONT EVAPORATOR PANEL-Continued.
This task covers:
Inspection
Replace
INITIAL SETUP:
Tools
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Blind riveter (Item 8, Appendix B)
Personnel : 1
Equipment Conditions:
Disconnect air conditioner input power at source.
INSPECTION
1.
2.
Check that information plates are readable and in place (see Figure 4-30).
Check for missing rivets.
REPLACE
NOTE
Replace consists of replacing rivets or damaged information plates.
1.
2.
3.
4.
Remove rivets (2).
Remove information plate (1).
Position replacement information plate (1) in place.
Install rivets (2).
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
Figure 4-30. Information Plates
4-46
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-27. LEFT FRONT CONDENSER PANEL.
This task covers:
Removal
Inspection
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Blind riveter (Item 8, Appendix B)
Riveter (Rivnut) (Item 9, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Bulk insulation material
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (MEK) (Item 13, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
Disconnect air conditioner input power at source.
REMOVAL
1.
Loosen six captive fasteners (1) (see Figure 4-31).
2.
Remove panel (2).
INSPECTION
1.
Check that panel (2) is not bent, cracked, or punctured.
2.
Check that gaskets (3) and insulation (5) are not torn, loose, or missing.
3.
Check that captive fasteners (1) are not damaged or missing.
REPAIR/REPLACE
NOTE
Repair consists of replacing gasket, insulation, captive fasteners or panel.
1.
Gasket.
a. Remove captive fasteners
b. Remove damaged gasket (3) from panel (2).
4-47
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-27. LEFT FRONT CONDENSER PANEL-Continued.
REPAIR/REPLACE-Continued.
1.
Gasket-Continued.
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive.
Repeated or prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area,
wear gloves, and keep away from sparks or flame.
a. Clean area for new gasket, using acetone or MEK and a stiff brush.
b. Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
to fingers.
c. Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
d. Install captive fasteners.
2.
Insulation.
a.
b.
c.
d.
Cut and remove damaged section of insulation (5).
Clean area for new insulation, using acetone or MEK and a stiff brush.
Cut replacement insulation to fit.
Coat surfaces of metal and insulation with adhesive. Let both surfaces dry until adhesive is tacky but will not
stick to fingers.
e. Starting with an end, carefully attach insulation to metal surface. Press into firm contact all over.
f. If insulation retainers were removed, install new retainers (4) with rivet (6).
3.
Capture Fasteners.
a. Remove split ring retainer (7), fastener (10), thermoplastic wear washer (8), and ejector spring (9).
b. Install ejector spring (9), thermoplastic wear washer (8), fastener (10), and split ring retainer (7).
INSTALLATION
1.
2.
Position panel (2) in place.
Tighten six captive fasteners (1).
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
4-48
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure 4-31. Left Front Condenser Panel
4-49
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-28. RIGHT FRONT CONDENSER PANEL.
This task covers:
Removal
Inspection
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Blind riveter (Item 8, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive .(Item 1, Appendix E)
Bulk gasket material
Bulk insulation material
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (MEK) (Item 13, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
Disconnect air conditioner input power at source.
REMOVAL
1.
Loosen eight captive fasteners (6) (see Figure 4-32).
2.
Remove panel (1).
INSPECTION
1.
Check that panel (1) is not bent, cracked, or punctured.
2.
Check that gasket (5) and insulation (3) are not torn, loose, or missing.
3.
Check that captive fasteners (6) are not damaged or missing.
4.
Check front service valve panel for missing rivets (8) or damaged hinge (7).
5.
For removal and repair of front service valve panel refer to paragraph 4-29.
NOTE
Repair consists of replacing gasket, insulation, captive fasteners, rivets or panel.
REPAIR/REPLACE.
1.
Gasket.
a. Remove captive fasteners.
b. Remove damaged gasket (5) from panel (1).
4-50
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure 4-32. Right Front Condenser Panel
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive.
Repeated or prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area,
wear gloves, and keep away from sparks or flame.
c. Clean area for new gasket, using acetone or MEK and a stiff brush.
d. Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
to fingers.
e. Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
f. Install captive fasteners.
2.
Insulation.
a.
b.
c.
d.
Cut and remove damaged section of insulation (3).
Clean area for new insulation, using acetone or MEK and a stiff brush.
Cut replacement insulation to fit.
Coat surfaces of metal and insulation with adhesive. Let both surfaces dry until adhesive is tacky but will not
stick to fingers.
e. Starting with an end, carefully attach insulation to metal surface. Press into firm contact all over.
f. If insulation retainer (2) is removed, install new retainer (2) with rivet (4).
4-51
ARMY TM 9-4120-381-14
NAVY EE-000- CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-28. RIGHT FRONT CONDENSER PANEL-Continued.
REPAIR/REPLACE-Continued.
3.
Captive Fasteners.
g. Remove split ring retainer (10), fastener (13), thermoplastic wear washer (11), and ejector spring (12).
h. Install ejector spring (12), thermoplastic wear washer (11), fastener (13) and split ring retainer (10).
4.
Hinge.
a.
b.
c.
d.
e.
Remove eight rivets (8)
Remove hinge (7) from panel and door.
Cut replacement hinge (7) to length.
Position hinge (7) in place.
Install eight rivets (8).
INSTALLATION
1.
2.
Position panel (1) in place.
Tighten eight captive fasteners (6).
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
4-52
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-29. FRONT SERVICE VALVE PANEL.
This task covers:
Inspection
Removal
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Blind riveter (Item 8, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Bulk insulation material
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (MEK) (Item 13, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any Internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
Disconnect air conditioner input power at source.
INSPECTION
1.
Check that panel (2) is not bent, cracked, or punctured (see Figure 4-33).
2.
Check that insulation (NO TAG) is not tom, loose, or missing.
3.
Check that gasket (4) is not tom, loose, or missing; replace gasket if damaged or missing (para 4-28)
4.
Check that captive fasteners (5) or receptacles (7) are not damaged or missing.
5.
Check front service valve panel (2) for missing rivets (1) or damaged hinge.
6.
If hinge needs to be replaced, refer to para 4-28.
REMOVAL
1.
Loosen two captive fasteners (5) and open panel (2).
2.
Remove four rivets (1) from front service valve panel (2).
3.
Remove front service valve panel (2).
NOTE
Repair consists of replacing insulation, captive fasteners receptacle, receptacle or panel.
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AIR FORCE TO 35E9-136-31
4-29. FRONT SERVICE VALVE PANEL-Continued.
Figure 4-33. Front Service Valve Panel
REPAIR/REPLACE
1.
Insulation.
a. Cut and remove damaged section of insulation (3).
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive.
Repeated or prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area,
wear gloves, and keep away from sparks or flame.
b. Clean area for new insulation, using acetone or MEK and a stiff brush.
c. Cut replacement insulation to fit.
d. Coat surfaces of metal and insulation with adhesive. Let both surfaces dry until adhesive is tacky but will not
stick to fingers.
e. Starting with an end, carefully attach insulation to metal surface. Press into firm contact all over.
2.
Captive Fastener.
a. Remove split ring retainer (8), fastener (11), ejector spring (10), and thermoplastic wear washer (9).
b. Install ejector spring (10), thermoplastic wear washer (9), fastener (11), and split ring retainer (8).
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ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
REPAIR/REPLACE-Continued.
3.
Receptacle.
c.
d.
e.
f.
Remove two rivets (6).
Remove turn receptacle (7).
Position replacement receptacle (7) in place.
Install two rivets (6).
INSTALLATION
1.
2.
3.
Position front service valve panel (2) in place.
Install four rivets (1).
Close panel (2) and tighten two captive fasteners (5).
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
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ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-30. LEFT ELECTRIC PLATE.
This task covers:
Inspection
Removal
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (MEK) (Item 13, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
Disconnect air conditioner input power at source.
Remove center front evaporator panel (4-22).
INSPECTION
1.
Check that electric plate (3) is not bent, cracked, or punctured (see Figure 4-34).
2.
Check that gasket (2) is not torn, loose, or missing.
3.
Check that captive fasteners (1) are not damaged or missing.
REMOVAL
1.
Loosen six captive fasteners (1).
2.
Open electric plate (3).
REPAIR/REPLACE
NOTE
Repair consists of replacing gasket, captive fasteners or electric plate.
1.
Gasket.
a. Remove captive fasteners.
b. Remove damaged gasket (2) from plate (3).
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive. Repeated or
prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area, wear gloves, and
keep away from sparks or flames.
c. Clean area for new gasket, using acetone or MEK and a stiff brush.
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d. Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
to fingers.
e. Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
f. Install captive fasteners.
Figure 4-34. Left Electric Plate
2.
Captive Fasteners.
a. Remove split ring retainer (4), fastener (7), thermoplastic wear washer (5), and ejector spring (6).
b. Install ejector spring (6), thermoplastic wear washer (5), fastener (7), and install split ring retainer (4).
3.
Electric Plate.
a. Remove circuit breakers CB1 and CB2 (para 4-62) from damaged plate (3).
b. Remove electric plate (3).
c. Install six captive fasteners (1).
d. Install gasket (2).
e. Install circuit breakers CB1 and CB2 (para 4-62).
INSTALLATION
1.
Close electric plate (3).
2.
Tighten six captive fasteners (1).
FOLLOW ON PROCEDURE
1.
Install center front evaporator panel (4-22).
2.
Connect air conditioner input power at source.
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ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
4-31. RIGHT ELECTRIC PLATE.
This task covers:
Inspection
Removal
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (MEK) (Item 13, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
Disconnect air conditioner input power at source.
Remove center front evaporator panel (4-22).
INSPECTION
1.
Check that plate (3) is not bent, cracked, or punctured (see Figure 4-35).
2.
Check that gasket (2) is not torn, loose, or missing.
3.
Check that captive fasteners (1) are not damaged or missing.
REMOVAL
1.
Loosen ten captive fasteners (1).
2.
Open electric plate (3).
REPAIR/H/REPLACE
NOTE
Repair consists of replacing gasket, fasteners, or electric plate.
1.
Gasket.
a. Remove captive fasteners (1).
b. Remove damaged gasket (2) from plate (3).
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive. Repeated or
prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area, wear gloves, and
keep away from sparks or flame.
c. Clean area for new gasket, using acetone or MEK and a stiff brush.
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Figure 4-35. Right Electric Plate
d. Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
to fingers.
e. Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
f. Install captive fasteners (1).
2.
Captive Fasteners.
a. Remove split ring retainer (4), fastener (7), thermoplastic wear washer (5), and ejector spring (6).
b. Install ejector spring (6), thermoplastic wear washer (5), fastener (7), and split ring retainer (4).
3.
Electric Plate.
a. Remove indicator lights, mode select switch, service light switch, and fault reset switch (para 4-45).
b. Remove electric plate (3).
c. Install ten captive fasteners (1).
d. Install gasket (2).
e. Install service lights, mode select switch, service light switch, and fault reset switch (para 4-45).
INSTALLATION
1.
2.
Close electric plate (3).
Tighten ten captive fasteners (1).
FOLLOW ON PROCEDURE
1.
2.
Connect air conditioner input power at source.
Install center front evaporator panel (para 4-22).
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AIR FORCE TO 35E9-136-31
4-32. REAR EVAPORATOR PANEL.
This task covers:
Inspection
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
Disconnect air conditioner input power at source.
INSPECTION
NOTE
See the following paragraphs for individual component inspection and replacement.
1.
2.
3.
Control wire J-box (para 4-33).
Fresh air connecting link assembly (para 4-34).
Thermostat bracket (para 4-35).
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
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4-33. CONTROL WIRE J-BOX.
This task covers:
Inspection
Removal
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Blind riveter (Item 8, Appendix B)
Riveter (Rivnut) (Item 9, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Rags (Item 12, Appendix E)
Sealing compound (Item 6, Appendix E)
Methyl-ethyl ketone (Item 13, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
Disconnect air conditioner input power at source.
Remove left front evaporator panel (para 4-23).
INSPECTION
1.
Check that box (6) is not bent, cracked, or punctured (see Figure 4-36).
2.
Check for damaged, loose, or missing mounting hardware.
REMOVAL
1.
Loosen clamp and remove hose (19).
2.
Remove four screws (1), lockwashers (2), and flat washers (3).
3.
Remove control wire J-box cover (18).
4.
Remove two screws (16), lockwashers (15), and thermostat box cover (14).
5.
Remove terminal board (para 4-64).
6.
Remove two screws (10), lockwashers (9), and flat washers (8) from top of J-box (6).
7.
Remove two screws (11), four flat washers (12), and two locknuts (13) from bottom of J-box (6).
8.
Remove control wire J-box (6).
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4-33. CONTROL WIRE J-BOX-Continued.
REPAIR/REPLACE
NOTE
Repair consists of replacing bushing, gasket, conduit fitting, rivnuts, and/or J-box.
1.
2.
3.
Remove insulator bushing (4).
Install insulator bushing (4).
Remove damaged gasket (17) from cover (18).
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive.
Repeated or prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area,
wear gloves, and keep away from sparks or flame.
4.
5.
6.
7.
8.
9.
Clean area for new gasket, using acetone or MEK and a stiff brush.
Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick to
fingers.
Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
Remove conduit fitting (5).
Install conduit fitting (5).
If J-box is replaced, install eight rivnuts (7).
Figure 4-36. Control Wire J-Box
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INSTALLATION
1.
Position Control wire J-box (6) in place.
2.
Install two flat washers (8), lockwashers (9), and screws (10) to top of J-box.
3.
Install four flat washers (12), two screws (11), and locknuts (13) to bottom of J-box.
4.
Position control wire J-box cover (18) in place.
5.
Install four flat washers (3), lockwashers (2), and screws (1).
6.
Use sealing compound to seal holes between boxes, bushing, and conduit fitting.
7.
Install hose and tighten clamp (19).
FOLLOW ON PROCEDURE
1.
Install terminal board (para 4-64).
2.
Install left front evaporator panel (para 4-23).
3.
Connect air conditioner input power at source.
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4-34. FRESH AIR CONNECTING LINK ASSEMBLY.
This task covers:
Inspection
Adjust
Removal
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
Disconnect air conditioner input power at source.
Remove left front evaporator panel (para 4-23).
INSPECTION
1.
Check that connecting link rod (6) is not bent or damaged (see Figure 4-37).
2.
Check that connector swivel (11), damper operator (12), and counter weight (10) are not damaged.
3.
Check for damaged, loose, or missing mounting hardware.
ADJUST
1.
Adjust damper operator counter weight (10) to line up with outside edge of fresh air inlet box (16)
2.
Loosen bolt (7) on damper connector swivel (11).
3.
Pull solenoid switch arm (3) to full out position and close damper (17).
4.
Tighten bolt (7) on damper connector swivel (11).
REMOVAL
1.
Loosen screw (4) and locknut (2) On solenoid connector (3).
2.
Loosen bolt (7) on damper connector swivel (11);
3.
Remove control rod (6) and note location of spacers (5).
4.
Loosen nut (1) and remove damper operator (12).
5.
Remove locknut (15) and connector swivel (11).
6.
Remove locknut (13), two flat washers (9), bolt (8), and counter weight (10).
REPAIR/REPLACE
Repair consists of replacing damper operator (12), counter weight (10), control rod (6), and connector swivel (11).
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INSTALLATION
1.
Install counter weight (10), two flat washers (9), bolt (8), and locknut (13).
2.
Install connector swivel (11) with flat washer (14) and locknut (15).
3.
Install damper operator (12) and tighten nut (1).
4.
Install control rod (6) and align spacers (5) noted in removal.
5.
Tighten screw (4) and locknut (2) on solenoid connector.
6.
Adjust fresh air connecting link.
FOLLOW ON PROCEDURE
1.
Install left front evaporator panel (para 4-23).
2.
Connect air conditioner input power at source.
Figure 4-37. Fresh Air Connecting Link
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ARMY TM 9-4210-381-14
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AIR FORCE TO 35E9-136-31
4-35. THERMOSTAT BRACKET.
This task covers:
Inspection
Removal
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Riveter (Rivnut) (Item 9, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
Disconnect air conditioner input power at source.
Remove left front evaporator panel (para 4-23).
INSPECTION
1.
Check that bracket (2) is not cracked or punctured (see Figure 4-38).
2.
Check for damaged or missing rivnuts or missing mounting hardware.
REMOVAL
1.
Remove low ambient temperature thermostat (para 4-86).
2.
Remove three screws (3), lockwashers (4), and flat washers (5).
3.
Remove bracket (2).
REPAIR/REPLACE
Repair consists of replacing damaged or missing rivnuts (1), or bracket.
INSTALLATION
1.
Position bracket (2) in place.
2.
Install three lockwashers (4), flat washers (5), and screws (3).
3.
Install low ambient temperature thermostat (para 4-86).
FOLLOW ON PROCEDURE
1.
Install left front evaporator panel (para 4-23).
2.
Connect air conditioner input power at source.
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AIR FORCE TO 35E9-136-31
Figure 4-38. Thermostat Bracket
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ARMY TM 9-4210-381-14
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AIR FORCE TO 35E9-136-31
4-36. CIRCULATING AIR IN RFI FILTER.
This task covers:
Removal
Service
Inspection
Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Rags (Item 12, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
Disconnect air conditioner input power at source.
Remove return air filter (para 3-5).
REMOVAL
1.
Remove seven screws (1) (see Figure 4-39).
2.
Remove filter (2).
SERVICE
Vacuum all dust or dirt from filter.
INSPECTION
1.
Check filters for punctures, cuts and damaged edges that would allow passage of unfiltered air.
2.
Check filters for packed or mashed areas that would block air flow.
3.
Replace filter if defective.
REPLACE
Replace filter if found to be damaged.
INSTALLATION
1.
If RFI gasket is not to be installed on replacement filter, proceed to step 4.
2.
On replacement filter, coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is
tacky but will not stick to fingers.
3.
Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
4.
Position filter (2) in place.
5.
Install seven screws (1).
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FOLLOW ON PROCEDURE
1. Install return air filter (para 3-5)
2. Connect air conditioner input power at source
Figure 4-39. Circulating Air in RFI Filter
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ARMY TM 9-4210-381-14
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AIR FORCE TO 35E9-136-31
4-37. FRESH AIR FILTER
This task covers:
Removal
Service
Inspection
Repair/Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Rags (Item 12, Appendix E)
Detergent, dishwashing (item 20, Appendix E)
Oil, air filter (Item 23, Appendix E)
Equipment Conditions:
WARNING
Disconnect Input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
Disconnect air conditioner input power at source.
Remove left front evaporator panel (para 4-23).
REMOVAL
1.
Loosen two captive fasteners (5) (see Figure 4-40).
2.
Remove filter (6).
SERVICE
1.
Wash filter in mild detergent and water solution.
2.
Rinse thoroughly in water.
3.
Shake out excess water.
4.
Spray filter with air filter oil.
INSPECTION
1.
Check filters for punctures, cuts and damaged edges that would allow passage of unfiltered air.
2.
Check filters for packed or mashed areas that would block air flow.
3.
Replace filter if defective.
REPAIR/REPLACE
Repair consists of replacing, captive fastener (1), ejector spring (2), thermoplastic wear washer (3), and split ring retainer
(4), or fresh air filter (6).
INSTALLATION
1.
Position filter (6) in place.
2.
Tighten two captive fasteners (5).
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FOLLOW ON PROCEDURE
1
Install left front evaporator panel (para 4-23).
2.
Connect air conditioner input power at source.
Figure 4-40.
Fresh Air Filter
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4-38.
FRESH AIR RFI FILTER.
This task consists of: Service
Inspection
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Vacuum (Item 13, Appendix B)
Personnel: 1
Materials:
Rags (Item 12, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
Disconnect air conditioner input power at source.
SERVICE
Vacuum all dust or dirt from filter (see Figure 4-41).
INSPECTION
1.
Check filters for punctures, cuts and damaged edges that would allow passage of unfiltered air.
2.
Check filters for packed or mashed areas that would block air flow.
3.
If filter is defective and needs to be replaced, contact General Support Maintenance.
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
Figure 4-41.
Fresh Air RFI Filter
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4-39.
CONDENSER AIR OUT RFI FILTER.
This task consists of: Service
Inspection
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Vacuum (Item 13, Appendix B)
Personnel: 1
Materials:
Rags (Item 12, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
Disconnect air conditioner input power at source.
SERVICE
Vacuum all dust or dirt from filter (see Figure 4-42).
INSPECTION
1.
Check filters for punctures, cuts and damaged edges that would allow passage of unfiltered air.
2.
Check filters for packed or mashed areas that would block air flow.
3.
If filter is defective and needs to be replaced, contact General Support Maintenance.
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
Figure 4-42.
Condenser Air Out RFI Filter
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AIR FORCE TO 35E9-136-31
4-40.
CONDENSER AIR IN RFI FILTER.
This task consists of: Service
Inspection
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Vacuum (Item 13, Appendix B)
Personnel: 1
Materials:
Rags (Item 12, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
Disconnect air conditioner input power at source.
SERVICE
Vacuum all dust or dirt from filter (see Figure 4-43).
INSPECTION
1.
Check filters for punctures, cuts and damaged edges that would allow passage of unfiltered air.
2.
Check filters for packed or mashed areas that would block air flow.
3.
If filter is defective and needs to be replaced, contact General Support Maintenance.
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
Figure 4-43.
Condenser Air In RFI Filter
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4-41.
CICULATING AIR OUT RFI FILTER.
This task consists of: Removal
Service
Inspection
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Vacuum (Item 13, Appendix B)
Personnel: 1
Materials:
Rags (Item 12, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1
2.
Disconnect air conditioner input power at source.
Remove right front condenser panel (para 4-28).
REMOVAL
1.
Remove six screws (3), lockwashers (2), and flat washers (4) (see Figure 4-44).
2.
Remove cover (1).
3.
Remove eight screws (5), flat washers (7), and lockwashers (6).
4.
Remove filter (8).
SERVICE
Vacuum all dust or dirt from filter
INSPECTION
1.
Check filters for punctures, cuts and damaged edges that would allow passage of unfiltered air.
2.
Check filters for packed or mashed areas that would block air flow.
INSTALLATION
1.
Install filter (8).
2.
Install eight flat washers (7), lockwashers (6), and screws (5).
3.
Position cover (1) in place.
4.
Install six lockwashers (2), flat washers (4), and screws (3).
FOLLOW ON PROCEDURE
1.
Install right front condenser panel (para 4-28).
2.
Connect air conditioner input power at source.
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4-41.
CICULATING AIR OUT RFI FILTER. - Continued
Figure 4-44 Circulating Air Out RFI Filter
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4-42.
RFI FILTER.
This task consists of: Inspection
Testing
Repair
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Bulk gasket
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
4.
Disconnect air conditioner input power at source.
Open left front evaporator panel (para 4-23).
Remove 22 screws (1) and top cover (2) (see Figure 4-45).
Remove 10 screws (NO TAG) and bottom cover (3).
INSPECTION
1.
Check for signs of overheating or other visible damage.
2.
Verify fuses F1-F4 are 20A, 250V.
3.
Inspect fuses (para 4-43), varistors (para 4-44), area for cracks, corrosion, loose electrical terminal connections (6),
and loose mounting hardware. If wires are damaged, replace as necessary.
4.
Check RFI gasket (5) on top cover. Replace gasket if damaged.
TESTING
Check input and output voltages (208 ± 20.8 V ac) (see Figure FO-3).
REPAIR
NOTE
Repair consists of replacing fuses, or gaskets and inspecting varistors.
1.
2.
3.
4.
Fuses F1-F4 (para 4-43).
Varistors (para 4-44).
Remove damaged gasket (5) from panel (2).
Install replacement gasket (5).
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4-42.
RFI FILTER - Continued..
Figure 4-45.
FOLLOW ON PROCEDURE
1.
2.
3.
4.
Install top cover (2) with 22 screws (1).
Install bottom cover (3) with 10 Screws (4).
Close left front evaporator panel (para 4-23).
Connect air conditioner input power at source.
4-78
RFI Filter
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4-43.
FUSES ( F1-F4 ).
This task consists of:
Removal
Inspection
Testing
Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1
2.
3.
Disconnect air conditioner input power at source.
Open left front evaporator panel (para 4-23).
Remove RFI filter top cover (para 4-42).
REMOVAL
Remove fuses (F1- F4) (see Figure 4-46).
INSPECTION
Check fuse and fuse holder for cracks, corrosion; loose electrical connections, and loose mounting hardware.
TESTING
1.
Using multimeter, check fuse continuity. If there is no continuity, replace fuse.
2.
Using multimeter on R x 10,000 position, measure between each terminal and ground and note resistance
measurement. If continuity exists, contact General Support Maintenance.
REPLACE
Replace defective fuses.
INSTALLATION
Install fuses (F1-F4).
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FUSES ( F1-F4 ). - Continued
FOLLOW ON PROCEDURE
1.
2.
3.
Install RFI filter top cover (para 4-42).
Close left front evaporator panel (para 4-23).
Connect air conditioner input power at source.
Figure 4-46. Fuses (F1 -F4)
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4-44.
VARISTORS ( VR-1 THRU VR-4 ).
This task consists of: Inspection
Testing
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
Disconnect air conditioner input power at source.
Open left front evaporator panel (para 4-23).
Remove RFI filter top cover (para 4-42).
INSPECTION
1.
Check varistors for cracks, corrosion, loose electrical connections, and loose mounting hardware (see Figure 4-47).
2.
Check for signs of overheating or other visible damage. Contact General Support Maintenance to replace
varistors.
TESTING
Using multimeter, check varistors continuity (Figure FO-3).
Maintenance to replace varistors.
4-81
If there is no continuity, contact General Support
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4-44
VARISTORS (VR-1 THRU VR-4) - Continued.
FOLLOW ON PROCEDURE
1.
Install RFI filter top cover (para 4-42).
2.
Close left front evaporator panel (para 4-23).
3.
Connect air conditioner input power at source.
Figure 4-47. Varistors (VR-1 thru VR-4)
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4-45.
CONTROL BOX AND COMPONENTS.
This task consists of: Inspection
Testing
Repair
Replacement
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages used can
KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
Disconnect air conditioner input power at source.
Open right front evaporator panel (para 4-25).
Remove center front evaporator panel (para 4-22).
4.
5.
6.
7.
NOTE
Access can be made to components located on right electric plate without removing right front evaporator
panel.
Open left electric plate (para 4-30).
Open right electric plate (para 4-31).
Remove two screws (1) (see Figure 4-48).
Swing open control box (2).
INSPECTION TESTING AND REPLACEMENT
NOTE
Applicable inspection, testing, repair, and replacement of the control box components and control box is
covered in the following referenced paragraphs.
1.
Control Box.
a.
Rectifier CR1 (para 4-46).
b.
Suppression diodes' CR2-CR11 (para 4-47).
c.
Control relays K1-K7, K18-K20 (para 4-49).
d.
Relay sockets (11-pin) (para 4-50).
e.
Fan contactors K8 and K9 (para 4-51).
f.
Compressor contactor K10 (para 4-52).
g.
Heater contactor K11 (para 4-53).
h.
Time delay (10 and 60 sec) relays K21 and K22 (para 4-54).
i.
Resistors R1 and R2 (para 4-55).
j.
Transformer T1 (para 4-60).
k.
Terminal boards TB1-TB3 (para 4-61).
I.
Control box (para 4-63).
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4-45.
CONTROL BOX AND COMPONENTS. - Continued
INSPECTION, TESTING, REPAIR, AND REPLACEMENT - Continued.
2.
Left Electric Plate.
Circuit breakers CB1 and CB2 (para 4-62).
3. Right Electric Plate.
a.
Indicator lights DS1-DS7, DS9 (para 4-48).
b.
Mode Select Switch SI (para 4-56).
c.
Knob (para 4-57).
d.
Service light switch S2 (para 4-58).
e.
FAULT RESET switch S12 (para 4-59).
FOLLOW ON PROCEDURE
1.
Close left electric plate (para 4-30).
2.
Close right electric plate (para 4-31).
3.
Close control box (2).
4.
Install two screws (1).
5.
Install center front evaporator panel (para 4-22).
6.
Install right front evaporator panel (para 4-25).
Figure 4-48. Control Box and Components
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4-46.
RECTIFIER ( CR1 ).
This task consists of: Inspection / Testing
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
Disconnect air conditioner input power at source.
Open left electric plate (para 4-30).
Open right electric plate (para 4-31).
INSPECTION / TESTING
1.
Check that wire leads are properly connected to rectifier and are not damaged (see Figure 4-49 and Figure FO-3).
2.
If rectifier is suspected bad, tag and remove rectifier leads.
NOTE
A diode bridge will sometimes act differently under a power test than resistance test.
3.
Apply 28 volts ac across terminals 1 and 4 and use a dc voltmeter with negative probe on terminal 2 and positive
probe on terminal 3 to test output voltage. The meter should read 24 ± 5 V dc. If output voltage is not within
limits, replace rectifier.
4.
Use multimeter to test for continuity between each of four rectifier terminals and mounting plate. If continuity is
found between any rectifier terminal and mounting plate, replace rectifier.
5.
Use multimeter to test forward and reverse resistance across rectifier bridge terminals 1 and 4, and 2 and 3. If
resistance is less than 1000 ohms, replace rectifier.
REMOVAL
1.
Tag and disconnect leads.
2.
Remove screw (1), two flat washers (3), and nut (4).
3.
Remove rectifier (2).
INSTALLATION
1.
Fungus proof replacement rectifier per MIL-V-173.
2.
Place rectifier (2) in mounting position.
3.
Reconnect leads and remove tags.
4.
Install screw (1), two flat washers (3), and nut (4).
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4-46.
RECTIFIER (CR1 ) - Continued.
FOLLOW ON PROCEDURE
1.
Close right electric plate (para 4-31).
2.
Close left electric plate (para 4-30).
3.
Install center front evaporator panel (para 4-22).
4.
Install right front evaporator panel (para 4-25).
5.
Connect air conditioner input power at source.
Figure 4-49.
Rectifier (CR1)
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4-47.
SUPPRESSION DIODES (CR2-CR11)
This task consists of:
Inspection
Testing
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Heat gun (Item 2, Appendix B)
Soldering iron (Item 16, Appendix B)
Goggles, industrial (Appendix C)
Personnel: 1
Materials:
Solder, lead-tin alloy (Item 18, Appendix E)
Flux, solder, liquid rosin base (Item 19, Appendix E)
Equipment Conditions:
WARNING
1.
2.
3.
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
Disconnect air conditioner input power at source.
Open left electric plate (para 4-30):
Open right electric plate (para 4-31).
INSPECTION
1.
Check diode for cracks, evidence of overheating, and other visible damage. Replace, if damaged (see Figure 450).
2.
Check that diode is connected between terminals 3 and 10 for control relays K1- K5, and K20 (see Figure FO-3). 3.
Check that diode is connected between terminals 2 and 10 for control relays K6, K7, K18, and K19 (see Figure
FO-3).
TESTING
1.
Use multimeter to check forward-and-back resistance of diode.
·· Back resistance should be 900 to 1100 ohms.
·· Forward resistance should be 0 to 5 ohms.
2. . Replace diode, if defective.
REMOVAL
1.
Remove two screws (2) from relay.
2.
Remove diode (1).
INSTALLATION
1.
Assemble replacement diode with wire terminals and shrink tubing. Color band denotes cathode end.
2.
Place diode (1) in mounting position.
3.
Install two screws (2).
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SUPPRESSION DIODES (CR2-CR11) - Continued
FOLLOW ON PROCEDURE
1.
Close right electric plate (para 4-31).
2.
Close left electric plate (para 4-30).
3.
Install center front evaporator panel (para 4-22).
4.
Install right front evaporator panel (para 4-25).
5.
Connect air conditioner input power at source.
Figure 4-50. Suppression Diodes (CR2 - CR11)
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4-48.
INDICATOR LIGHTS (DSII-DS7, DS9).
This task consists of: Inspection
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Crimping tool (pigtail) (Item 10, Appendix B)
Personnel :1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
Disconnect air conditioner input power at source.
Open left electric plate (para 4-30).
Open right electric plate (para 4-31).
INSPECTION
1.
Check that light lenses are not cracked or broken. Replace light, if damaged (see Figure 4-51).
2.
Check that leads are properly connected (see Figure FO-3). Repair all broken leads. If wiring harness is
damaged, repair as necessary.
REMOVAL
1.
Tag and disconnect leads.
2.
Remove clip (1).
3.
Remove light assembly (2) through front of panel.
INSTALLATION
1.
Install light assembly (2) through front of panel.
2.
Install clip (1).
3.
Reconnect leads and remove tags.
FOLLOW ON PROCEDURE
1.
Close left electric plate (para 4-30).
2.
Close right electric plate (para 4-31).
3.
Install right front evaporator panel (para 4-25).
4.
Connect air conditioner unit power at source.
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INDICATOR LIGHTS (DS1-DS7, DS9).- Continued
Figure 4-51. Indicator Lights ( DS1-DS7, DS9)
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4-49.
CONTROL RELAYS ( K1-K7, K18-K20).
This task consists of:
Removal
Inspection
Testing
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
Disconnect air conditioner input power at source.
Open left electric plate (para 4-30).
Open right electric plate (para 4-31).
REMOVAL
1.
Slip wire retaining clip (1) off relay (2) (see Figure 4-52).
2.
Pull relay (2) from 11-pin socket (3).
INSPECTION
1.
Check for loose, corroded, missing or broken pins.
2.
Check relay for cracks, signs of overheating and other visible damage. Replace relay, if damaged.
TESTING
Use multimeter to check continuity between following pins. If relay condition is not correct, replace relay.
PINS
1-4
5-6
2-10
1-3
6-7
8-11
9-11
CLOSED
x
x
500 ± 50 ohms
OPEN
x
x
x
x
INSTALLATION
1.
Fungus proof replacement relay per MIL-V-173.
2.
Plug relay (2) into 11-Pin socket (3).
3.
Secure with wire retaining clip (1).
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4-49.
CONTROL RELAYS ( K1-K7, K18-K20). - Continued
FOLLOW ON PROCEDURE
1.
Close right electric plate (para 4-31).
2.
Close left electric plate (para 4-30).
3.
Install center front evaporator panel (para 4-22).
4.
Install right front evaporator panel (para 4-25).
5.
Connect air conditioner input power at source.
Figure 4-52.
Control Relays (K1 - K7, K18 - K20)
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4-50.
RELAY SOCKETS.
This task consists of: Inspection
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
Disconnect air conditioner input power at source.
Swing open control box, left and right electric plates (para 4-45).
INSPECTION/TEST
1.
Pull relay from socket (para 4-49 or 4-54).
2.
Check that relay socket and terminals are not cracked, broken, loose, or corroded (see Figure 4-53).
3.
Use multimeter to measure resistance from each socket contact to its associated terminal (see Figure FO-3).
Resistance should be 0.5 ohm or less. Replace socket, if defective.
REMOVAL
1.
Remove relay from socket (para 4-49 or 4-54).
2.
Tag and disconnect leads.
3.
For K7, K18 or K19 socket removal, remove control box brace (para 4-63).
4.
Remove suppression diode (para 4-47).
5.
For K1-K7, K18-K20, remove two screws (1), locknuts (4), flat washers (5), clip (2), and socket (3).
6.
Remove resistor (para 4-55).
7.
For K21 or K22, remove two screws (6), clips (9), locknuts (8), and four flat washers (10) and socket (7).
INSTALLATION
1.
Install K21 or K22 socket (7) with two screws (6), clips (9), four flat washers (10), and two locknuts (8).
2.
Install resistor (para 4-55).
3.
Install K1-K7, K18-K20 socket (3) with two screws (1), flat washers (5), clip (2), and two locknuts (4).
4.
Install suppression diode (para 4-47).
5.
Plug relay into socket (para 4-49 or 4-54).
6.
If sockets K7, K18 or K19 were replaced, install control box brace (para 4-63) as required.
7.
Reconnect leads and remove tags.
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RELAY SOCKETS.- Continued
FOLLOW ON PROCEDURE
1.
Close control box, left and right electric plates (para 4-45).
2.
Install center front evaporator panel (para 4-22).
3.
Install right front evaporator panel (para 4-25)
4.
Connect air conditioner input power at source.
Figure 4-53. Relay Sockets (11-Pin)
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4-51.
FAN CONTACTORS ( K8 AND K9).
This task consists of: Inspection
Testing
Removal
Repair/ Replace
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Varnish, moisture and fungus resistant (Item 16, Appendix)
Equipment Conditions:
WARNING
Disconnect Input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
Disconnect air conditioner input power at source.
Remove center front evaporator panel (para 4-22).
Open left electric plate (para 4-30).
INSPECTION
Inspect contactor for cracks, corrosion, loose electrical connections, and loose mounting hardware. Replace contactor
if cracked, broken, or badly corroded (see Figure 4-54).
TESTING
1.
Tag and disconnect wires from thermal overload.
2.
Using multimeter, test for continuity across each individual overload element. If no continuity is indicated, replace
element.
3.
Using multimeter, check continuity between input terminal of thermal overload and contactor output terminal while
pressing reset bar. If continuity is not indicated, replace contactor assembly.
4.
Using multimeter, measure continuity across contactor coil with one wire disconnected from coil terminal. If meter
does not read 60 - 10 ohms, replace contactor.
5.
Reconnect coil wire and tag wires.
REMOVAL
1.
Tag and disconnect leads.
2.
Remove four screws (4), locknuts (6), eight flat washers (5).
3.
Remove contactor assembly (3).
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FAN CONTACTORS ( K8 AND K9).- Continued
Figure 4-54 Fan Contactors (K8 and K9)
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REPAIR/REPLACE
1.
2.
3.
4.
NOTE
Repair consists of replacing thermal overload or fan contactor.
Remove two screws (1).
Remove thermal overload (2).
Place thermal overload (2) in mounting position.
Install two screws (1).
INSTALLATION
1.
Fungus proof replacement fan contactor per MIL-V-173.
2.
Place fan contactor (3) in mounting position.
3.
Install four screws (4), eight flat washers (5), and four locknuts (6).
4.
Reconnect contactor assembly leads and remove tags.
FOLLOW ON PROCEDURE
1.
Close left electric plate (para 4-30).
2.
Install center front evaporator panel (para 4-22).
3.
Install right front evaporator panel (para 4-25)
4.
Connect air conditioner input power at source.
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4-52.
COMPRESSOR CONTRACTOR ( K 10).
This task consists of:
Inspection
Testing
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
Disconnect air conditioner input power at source.
Remove center front evaporator panel (para 4 -22).
Open left electric plate (para 4-30).
INSPECTION
Inspect contactor for cracks, corrosion, loose electrical connections, and loose mounting hardware. Replace contactor
if cracked, broken, or badly corroded (see Figure 4-55).
TESTING
Using multimeter, measure continuity across contactor coil with one wire disconnected from coil terminal. If meter does
not read 60 ± 10 ohms, replace contactor.
REMOVAL
1.
Tag and disconnect leads.
2.
Remove three screws (1), locknut (4), and six flat washers (3).
3.
Remove contactor and mounting plate (2).
INSTALLATION
1.
Fungus proof replacement compressor contactor per MIL-V-173.
2.
Place contactor and mounting plate (2) in mounting position.
3.
Install three screws (1), locknuts (4), and six flat washers (3).
4.
Reconnect leads and remove tags.
FOLLOW ON PROCEDURE
1.
Close left electric plate (para 4-30).
2.
Install center front evaporator panel (para 4-22).
3.
Install right front evaporator panel (para 4-25).
4.
Connect air conditioner input power at source.
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Figure 4-55. Compressor Contractor (K10)
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4-53.
HEATER CONTRACTOR (K11).
This task consists of:
Inspection
Testing
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
Disconnect air conditioner input power at source.
Remove center front evaporator panel (para 4-22).
Open left electric-plate (para 4-30).
INSPECTION
Inspect contactor for cracks, corrosion, loose electrical connections, and loose mounting hardware. Replace contactor
if cracked, broken, or badly corroded (see Figure 4-56).
TESTING
Using multimeter, measure continuity across contactor coil with one wire disconnected from coil terminal. If meter does
not read 60 ± 10 ohms, replace contactor.
REMOVAL
1.
Tag and disconnect leads.
2.
Remove three screws (1), locknuts (3), and six flat washers (2).
3.
Remove contactor and mounting plate (4).
INSTALLATION
1.
Fungus proof replacement heater contactor per MIL-V-173.
2.
Place contactor and mounting plate (4) in mounting position.
3.
Install three screws (1), locknuts (3), and six flat washers (2).
4.
Reconnect leads and remove tags.
FOLLOW ON PROCEDURE
1.
Close right electric plate (para 4-31).
2.
Close left electric plate (para 4-30).
3.
Install center front evaporator panel (para 4-22).
4.
Install right front evaporator panel (para 4-25).
5.
Connect air conditioner input power at source.
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Figure 4-56. Heater Contactor (K11)).
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4-54. TIME DELAY (10 AND 60 SEC) RELAYS (K21 AND K22).
This task covers:
Inspection
Testing
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages used
can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove center front evaporator panel (para 4-22).
3. Open right electric plate (para 4-31).
INSPECTION
1. Check for loose wire connections (see Figure 4-57).
2. Check for cracks, signs of overheating, and other visible damage. Replace relay, if defective.
TESTING
1. Using multimeter, check continuity:
Terminal A (+)
to B (-): continuity
1
1
3
3
2.
3.
4.
to 4
to 7
to 6
to 9
:
:
:
:
no continuity
continuity
no continuity
continuity
If conditions are not shown above, replace relay.
Apply 24 volts dc across terminals A(+) and B(-) (prime power can be used).
Using multimeter, measure voltage drop between terminals 2 and 5. Voltage indicated should be 19 to 29 volts dc.
After about 10 seconds (K21) or 60 seconds (K22), voltage should drop to less than two volts with external resistor
installed.
Replace relay if it fails above tests.
REMOVAL
Pull relay (1) out of socket by spreading two holding brackets (2).
INSTALLATION
1.
Fungus proof replacement time delay relay per MIL-V-173.
2.
Plug relay (1) into socket.
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FOLLOW ON PROCEDURE
1.
2.
3.
Close right electric plate (para 4-31).
Install center front evaporator panel (para 4-22).
Connect air conditioner input power at source.
Figure 4-57. Time Delay (10 and 60 sec) Relays (K21 and K22).
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4-55. RESISTORS (RI AND R2).
This task covers:
Inspection
Testing
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Crimping tool (Item 5, Appendix B)
Heat gun (Item 2, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove center front evaporator panel (para 4-22).
3. Open right electric plate (para 4-31).
INSPECTION
1.
2.
Check for loose wire connections (see Figure 4-58).
Check for cracks, signs of overheating, and other visible damage. Replace resistor, if defective.
REMOVAL
1.
2.
Remove two screws (1).
Remove resistor (2).
TESTING
1. Using multimeter, measure resistance across R1 (terminals 2 and 5 of K21). If resistance is not 1.2 to 1.4 megohms,
replace R1.
2. Using multimeter, measure resistance across R2 (terminals 2 and 5 of K22). If resistance is not 855,000 to 945,000
ohms, replace R2.
INSTALLATION
1.
2.
3.
Install wire terminals and shrink tubing to replacement resistor.
Place resistor (2) in mounting position.
Install two screws (1).
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FOLLOW ON PROCEDURE
1.
2.
3.
Close right electric plate (para 4-31).
Install center front evaporator panel (para 4-22).
Connect air conditioner input power at source.
Figure 4-58. Resistors (R1 and R2)
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4-56. MODE SELECT SWITCH (S1).
This task covers:
Inspection
Testing
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Heat gun (Item 2, Appendix B)
Soldering iron (Item 16, Appendix B)
Screw driver, flat tip (Item 11, Appendix B)
Goggles, industrial (Appendix C)
Personnel: 1
Materials:
Solder, lead-tin alloy (Item 18, Appendix E)
Flux, solder, liquid rosin base (Item 19, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Open right electric plate (para 4-31).
INSPECTION
1.
2.
3.
Using wiring diagram (see Figure FO-3) check for loose wires or solder connections, and that leads are properly
connected (see Figure 4-59).
Check switch (1) for smoothness of operation. Replace switch, if defective.
Check switch (1) for signs of overheating or other visible damage. If wires are damaged, replace as necessary.
TESTING
NOTE
In this test, switch contacts are identified by the wire number attached to the contact. Each wire is labeled
with a wire number. See Figure FO-3 as an aid during testing.
Set switch to each position in turn. Using multimeter, check continuity as listed in Table 4-4. If conditions are abnormal
at any switch setting, replace switch.
REMOVAL
1.
2.
3.
4.
Unsolder, tag and disconnect leads.
Loosen set screw (4) and remove knob (5).
Remove nut (3) and star washer (2).
Remove switch (1).
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Table 4-4. MODE SELECT SWITCH Test
Check Continuity
Set SW to:
OFF
AUTO
COOL
HEAT
From
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
Wire
To
104 -119
104-120
104-121
1002-1062
1002-1063
104 -119
104-120
104-121
1002-1062
1002-1063
104 -119
104-120
104-121
1002-1062
1002-1063
104 -119
104-120
104-121
1003-1062
1002-1063
Figure 4-59. Mode Select Switch (S1)
4-107
Read
Open
Open
Open
Open
Open
Closed
Closed
Closed
Open
Open
Closed
Closed
Closed
Open
Closed
Open
Open
Open
Closed
Open
ARMY TM 9-4210-381-14
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AIR FORCE TO 35E9-136-31
4-56. MODE SELECT SWITCH (S1) - Continued.
INSTALLATION
1.
2.
3.
4.
Place switch (1) in mounting position.
Install star washer (2) and nut (3).
Solder leads as tagged and remove tags.
Install knob (5) and tighten set screw (4).
FOLLOW ON PROCEDURE
1.
2.
Close right electric plate (para 4-31).
Connect air conditioner input power at source.
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4-57. KNOB (MODE SELECT SWITCH (S1)).
This task covers:
Inspection
Removal
Installation
INITIAL SETUP:
Tools:
Screw driver, flat tip, 1/8" WD (Item 11, Appendix B)
Personnel: 1
INSPECTION
Check knob for cracks, and other visible damage. Replace knob, if defective (see Figure 4-60).
REMOVAL
Loosen set screw (1) and remove knob (2).
INSTALLATION
Position knob (2) in place and tighten set screw (1).
Figure 4-60. Knob (Mode Select Switch (S1))
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4-58. SERVICE LIGHT SWITCH (S2).
This task covers:
Inspection
Testing
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect Input power to the air conditioner before performing any Internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Open right electric plate (para 4-31).
INSPECTION
1.
2.
3.
4.
Check switch (1) to see that leads are properly connected (see Figure 4-61 and Figure FO-3).
Check that leads are not loose or broken. Tighten loose leads. Ifwiring is damaged, replace as necessary.
Check that switch terminals are not loose, broken, or corroded. Replace switch, if defective.
Check switch for signs of overheating or other visible damage. Replace switch, if defective.
TESTING
1.
2.
3.
4.
Tag and disconnect leads from switch.
Using multimeter, check continuity between two switch terminals and set switch to ON, then OFF.
ON - Continuity.
OFF - No continuity.
If switch fails test, replace switch.
If switch not being replaced, connect leads tagged in step 1.
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REMOVAL
1.
2.
3.
Tag and disconnect leads from switch.
Remove nut (3) and star washer (2).
Remove switch (1).
INSTALLATION
1.
2.
3.
Place switch (1) in mounting position.
Install star washer (2) and nut (3).
Reconnect leads and remove tags.
FOLLOW ON PROCEDURES
1.
2.
Close right electric plate (para 4-31).
Connect air conditioner input power at source.
Figure 4-61. Service Light Switch (S2)
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4-59. FAULT RESET SWITCH (S12).
This task covers:
Inspection
Testing
Repair/Replace
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Soldering Iron (Item 16, Appendix B)
Goggles, industrial (Appendix C)
Personnel: 1
Materials:
Solder, lead-tin alloy (Item 18, Appendix E)
Flux, soldering, liquid rosin base (Item 19, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnected unit power.
1. Disconnect air conditioner input power at source.
2. Open right electric plate (para 4-31).
INSPECTION
1.
2.
3.
4.
Check switch (4) to see that leads are properly connected (see Figure 4-62 and Figure FO-3).
Check that leads are not loose or broken. Tighten loose leads. If wiring is damaged, replace as necessary.
Check that switch (4) terminals are not loose, broken, or corroded. Replace switch, if defective.
Check switch (4) for signs of overheating or other visible damage. Replace switch, if defective.
TESTING
1.
2.
Using multimeter, check continuity between terminals and depress switch.
OUT - Continuity.
IN - No Continuity
If switch fails test, replace switch.
REPAIR/REPLACE
Repair consists of replacing splash proof seal or fault reset switch.
REMOVAL
1.
2.
3.
Unsolder, tag and disconnect leads.
Remove splash proof seal (1), nut (2), and star washer (3).
Remove switch (4).
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INSTALLATION
1.
2.
3.
Place switch (4) in mounting position.
Install star washer (3), nut (2) and cap (1).
Solder leads as tagged and remove tags.
FOLLOW ON PROCEDURES
1.
2.
Close right electric plate (para 4-31).
Connect air conditioner input power at source.
Figure 4-62. Fault Reset Switch (S12)
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4-60. TRANSFORMER (T1).
This task covers:
Inspection
Testing
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Material:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove center front evaporator panel (para 4-22).
3. Open left electric plate (para 4-30).
INSPECTION
1.
2.
3.
Check for loose, corroded, missing or broken connections.
Check for damaged wires; repair as necessary.
Check transformer (1) for cracks, evidence of overheating, and other visible damage. Replace transformer, if
defective.
TESTING
1.
2.
3.
4.
5.
Using multimeter, check for continuity between black and white input leads. If open, replace transformer.
Using multimeter, check for continuity between R and C output terminals. If open, replace transformer.
Using multimeter set on high OHMS scale, measure resistance between black or white input leads and transformer
case. If resistance is less than 500,000 ohm, replace transformer.
Using multimeter set on high OHMS scale, measure resistance between R or C output terminals and transformer
case. If resistance is less than 500,000 ohms, replace transformer.
Using multimeter set on high OHMS scale, measure resistance between R or C output terminals and black or white
input leads. If resistance is less than 500,000 ohms, replace transformer.
REMOVAL
1.
2.
3.
Tag and disconnect leads (see Figure 4-63).
Remove four screws (2), locknuts (4), and eight flat washers (3).
Remove transformer (1).
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INSTALLATION
1.
2.
3.
4.
Fungus proof replacement transformer per MIL-V-173.
Place transformer (1) in mounting position.
Install four screws (2), eight flat washers (3), and four locknuts (4).
Reconnect leads and remove tags.
FOLLOW ON PROCTDURES
1.
2.
3.
Close left electric plate (para 4-30).
Install center front evaporator panel (para 4-22).
Connect air conditioner input power at source.
Figure 4-63. Transformer (T1)
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4-61 TERMINAL BOARDS (TB1-TB3).
This task covers:
Inspection
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment ConditionsWARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used, can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
4.
Disconnect air conditioner input power at source.
Remove center front evaporator panel (para 4-22).
Open left electric plate (para 4-30).
Open right electric plate (para 4-31).
INSPECTION
1.
2.
Check terminal boards for loose or corroded terminals, cracks and obvious damage. Replace terminal board, if
cracked or broken (see Figure 4-64).
Check that wire leads are secure and properly located (see Figure FO-3).
REMOVAL
1.
2.
3.
Tag and disconnect leads.
Remove four screws (2), locknuts (1), and flat washers (4).
Remove terminal boards (3).
INSTALLATION
1.
2.
3.
Place replacement terminal boards (3) in mounting position.
Install four screws (2), flat washers (4), and locknuts (1).
Reconnect leads and remove tags.
FOLLOW ON PROCEDURES
1.
2.
3.
4.
Close left electric plate (para 4-30).
Close right electric plate (para 4-31).
Install center front evaporator panel (para 4-22).
Connect air conditioner input power at source.
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Figure 4-64. Terminal Boards (TB1-TB3).
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4-62. CIRCUIT BREAKERS (CB1 AND CB2).
This task covers:
Inspection
Testing
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove center front evaporator panel (para 4-22).
3. Open left electric plate (para 4-30).
INSPECTION
1.
2.
3.
Check that mounting hardware and circuit breakers (3) are in place and secure (see Figure 4-65).
Check that wire leads are properly connected to circuit breakers (3) and are not damaged (see Figure FO-3).
Check circuit breakers (3) for signs of overheating or other visible damage.
TESTING
Using multimeter, check continuity between circuit breaker (3) terminals. Contacts should be closed. If there is no
continuity, replace circuit breaker.
REMOVAL
1.
2.
3.
Tag and disconnect leads.
Remove two screws (1), locknuts (2), and four flat washers (4).
Remove circuit breaker (3).
INSTALLATION
1.
2.
3.
Place replacement circuit breaker (3) in mounting position.
Install two screws (1), four flat washers (4) and two locknuts (2).
Reconnect leads and remove tags.
FOLLOW ON PROCEDURES
1.
2.
3.
Close left electric plate (para 4-30).
Install center front evaporator panel (para 4-22).
Connect air conditioner input power at source.
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Figure 4-65. Circuit Breakers (CB1-CB3).
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4-63. CONTROL BOX.
This task covers:
Inspection
Testing
Removal
Repair/Replace
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Drill, electric, portable (Item 6, Appendix B)
Drill set, twist (Item 7, Appendix B)
Riveter, blind (Item 8, Appendix B)
Soldering Iron (Item 16, Appendix B)
Goggles, industrial (Appendix C)
Personnel: 1
Materials:
Solder, lead-tin alloy (Item 18, Appendix E)
Flux, soldering, liquid rosin base (Item 19, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing, any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
4.
5.
Disconnect air conditioner input power at source.
Remove center front evaporator panel (para 4-22).
Open left electric plate (para 4-30).
Open right electric plate (para 4-31).
Open control box (para 4-45).
INSPECTION
1. Check control box (13) for dents, cracks, punctures, or missing mounting hardware. Replace if damage creates a
hazard or interferes with operation (see Figure 4-66).
2. Check that hinge (4), receptacles (10), bushing (14) and locking ring (7) are in place and secure. Repair or replace
as needed.
REMOVAL
1.
2.
3.
Remove four screws (1), flat washers (2) and locknuts (3).
Remove bolt (20), locknut (18) and two flat washers (19).
Set control box (13) in evaporator compartment.
REPAIR/REPLACE
NOTE
Repair consists of replacing hinge, receptacle ,bushing and locking ring, brace, or control box.
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1.
Hinge.
a.
b.
c.
d.
e.
2.
Receptacle.
a.
b.
3.
Remove 10 rivets (15) from control box (13).
Remove 13 rivets (17) from frame bracket (16).
Position replacement hinge (4) in mounting position on control box (13).
Install 10 rivets (15) to hinge (4).
Install 13 rivets (17) to frame bracket (16).
Remove two rivets (12) and receptacle (10).
Install replacement receptacle (10) with two rivets (12).
Bushing and Locking Ring.
a.
b.
c.
d.
e.
f.
Tag and disconnect wiring harness wires (see Figure FO-3).
Remove locking ring (7).
Remove bushing (14).
Install replacement bushing (14) in mounting position.
Install replacement locking ring (7).
Connect wiring harness wires tagged in step 1.
Figure 4-66. Control Box
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4-63. CONTROL BOX - Continued.
REPAIR/REPLACE - Continued.
4.
Brace.
a.
b.
c.
d.
5.
a.
b.
c.
d.
e.
f
g.
h.
Remove six screws (9), locknuts (4), and twelve flat washers (5) and (8).
Remove control box brace (11).
Place replacement brace (11) in mounting position.
Install six screws (9), twelve flat washers (5) and (8), and six locknuts (4).
Control Box.
Tag and disconnect wiring harness wires (see Figure FO-3).
Remove 10 rivets (15) securing hinge (4) to control box (13).
Remove control box (13).
Remove control box components listed in paragraph 4-45.
Install replacement control box components listed in paragraph 4-45.
Install replacement control box (13) to hinge (4) with 10 rivets (15).
Install left and right electric plates (para 4-30 and 4-31).
Connect wiring harness wires tagged in step a (see Figure FO-3).
INSTALLATION
1.
2.
3.
4.
5.
6.
Position control box (13) in mounting position.
Install four screws (1), flat washers (2), and locknuts (3).
Install bolt (20), two flat washers (19), and locknut (18).
Close control box (para 4-45).
Close left electric plate (para 4-30).
Close right electric plate (para 4-31).
FOLLOW ON ,PROCEDURES
1.
2.
Install center front evaporator panel (para 4-22).
Connect air conditioner input power at source.
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4-64. TERMINAL BOARD (TB4).
This task covers:
Inspection
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages used can
KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
4.
Disconnect air conditioner input power at source.
Remove center front evaporator panel (para 4-22).
Remove left front evaporator panel (para 4-23).
Remove control wire J-box cover (para 4-33).
INSPECTION
1.
2.
Check terminal board (4) for loose or corroded terminals, cracks and obvious damage. Replace terminal board, if
defective (see Figure 4-67).
Check that wire leads are secure and properly located (see Figure FO-3).
REMOVAL
1.
2.
3.
Tag and disconnect leads.
Remove four screws (3), flat washers (1), and lockwashers (2).
Remove terminal board (4).
INSTALLATION
1.
2.
3.
Position terminal board (4) in mounting position.
Install four screws (3), lockwashers (2), and flat washers (1).
Reconnect leads and remove tags.
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4-64. TERMINAL BOARD (TB4) - Continued.
FOLLOW ON PROCEDURES
1.
2.
3.
4.
Install Control wire J-box cover (para 4-33).
Install left front evaporator panel (para 4-23).
Install center front evaporator panel (para 4-22).
Connect air conditioner input power at source.
Figure 4-67. Terminal Board (TB4)
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4-65. SERVICE LIGHT (DS8).
This task covers:
Inspection
Testing Removal
Repair/Replace Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input Power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
3. Remove circulating air out RFI filter access cover (para 4-41).
INSPECTION
1.
2.
3.
Check lamp guard (8) for bent or broken prongs (see Figure 4-68).
Check for missing or loose mounting hardware.
Check light bulb (9) for signs of burnout, cracks, or breaks. Replace light bulb, if defective.
TESTING
NOTE
Power must be applied for testing.
1.
2.
If service light switch (S2) fails to turn service bulb (9) on, unscrew service bulb (9) from lamp holder (5).
Using multimeter, check that service bulb (9) filaments are not burned out. Replace service bulb, if defective.
REMOVAL
1.
2.
3.
4.
Unscrew bulb (9).
Loosen two screws and remove lamp guard (8).
Remove two screws (7), flat washers (6), and lamp holder (5).
Tag and disconnect leads.
NOTE
When mounting hardware for box is removed, the mounting bracket for sensing bulb will
come loose also.
5.
Remove two screws (1), locknuts (3), four flat washers (4), and box (2).
REPAIR/REPLACE
Repair consists of replacing service bulb (9), lamp guard (8), lamp holder (5), insulator bushing or service light.
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4-65. SERVICE LIGHT (DS8) - Continued.
INSTALLATION
1.
2.
3.
4.
5.
Install box (2) with two screws (1), four flat washers (4), and two locknuts (3).
Reconnect leads and remove tags.
Install lamp holder (5) with two screws (7) and flat washers (6).
Install lamp guard (8) and tighten two screws.
Install bulb (9).
FOLLOW ON PROCEDURES
1.
2.
3.
Install circulating air out RFI filter access cover (para 4-41).
Install right front condenser panel (para 4-28).
Connect air conditioner input power at source.
Figure 4-68. Service Light (DS8)
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4-66. FRESH AIR DAMPER SOLENOID (L3).
This task covers:
Inspection
Testing Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Material:
Varnish, moisture and fungus resistant (Item 16, Appendix B)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Open left front evaporator panel (para 4-23).
INSPECTION
1.
2.
3.
Check for loose, corroded, missing or broken connections (see Figure 4-69).
Check for damaged wires; repair as necessary.
Check solenoid (4) for cracks, evidence of overheating, and other visible damage. Replace solenoid, if defective.
TESTING
1.
2.
Using wiring diagram (see Figure FO-3), check 120 V ac input power.
Using wiring diagram (see Figure FO-3), check for 120 V ac output power. Replace solenoid, If defective.
REMOVAL
1.
2.
3.
4.
Tag and disconnect leads.
Remove screw (6), locknut (9), two flat washers (5), spacers (7), and control rod (8).
Remove four screws (1), lockwashers (2), and flat washers (3).
Remove solenoid (4) and shield (10).
INSTALLATON
1.
2.
3.
4.
5.
Fungus proof replacement solenoid per M;L-V-173.
Place solenoid (4) and shield (10) in mounting position.
Install four screws (1), lockwashers (2), and flat washers (3).
Install control rod (8) with screw (6), two flat washers (5), spacers (7), and locknut (9).
Reconnect leads and remove tags.
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4-66. FRESH AIR DAMPER SOLENOID (L3) - Continued.
FOLLOW ON PROCEDURES
1.
2.
Close left front evaporator panel (para 4-23).
Connect air conditioner input power at source.
Figure 4-69. Fresh Air Damper Solenoid (L3)
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4-67. WIRE HARNESS.
This task covers:
Inspection
Testing
Repair
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Heat gun (Item 2, Appendix B)
Crimping tool (Item 5, Appendix B)
Crimping tool (pig tail) (Item 10, Appendix B)
Soldering iron (Item 16, Appendix B)
Goggles, industrial (Appendix C)
Personnel: 2
Materials:
Solder, lead-tin alloy (Item 18, Appendix E)
Flux, solder, liquid rosin base (Item 19, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1.
2.
3.
4.
5.
6.
7.
8.
Disconnect air conditioner input power at source.
Open left front evaporator panel (para 4-23).
Remove right front evaporator panel (para 4-25).
Open left electric plate (para 4-30).
Open right electric plate (para 4-31).
Open control box (para 4-45).
Remove left front condenser panel (para 4-27).
Remove right front condenser panel (para 4-28).
INSPECTION
Check wiring, terminals and connections for corrosion, frayed or broken wires, and signs of overheating. Replace wiring
or connections as necessary.
TESTING
Using wiring diagram (see Figure FO-3), check continuity on suspected bad wiring.
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4-67. WIRE HARNESS - Continued.
REPAIR
1.
General. Preferred repair methods consist of replacing wires, terminals, connectors, etc, rather than splicing wires,
bending ends to form terminals, and other makeshift procedures, although the latter may be appropriate for
emergency field repairs. Determine the proper size and length of wire, or terminal, or connector to be used for
replacement.
2.
Soldering Connections. Wire connections must be made mechanically sound before they are soldered. Solder
alone does not provide sufficient strength to prevent breakage. Joining surfaces of connections to be soldered must
be clean and bright. If a separate flux is used, it should conform to Specification MIL-F-14256 rosin base flux, and
should be brushed onto the joint before soldering. Wires should always be heated to the point at which the solder
will melt completely and flow into all parts of the joint. Excessive build up of solder "gobs" on the joint should be
avoided or removed.
3.
Insulating Joints. The preferred method of insulating electrical joints is by the use of heat-shrink tubing. To apply,
cut a piece of heat-shrink tubing of suitable diameter to a one inch length for covering joints at terminals or
connectors, or to a length about 1/2 inch (1. 3cm) longer than the joint to be insulated, and slide the tubing over the
wire before making the joint. After the joint is made, slide the tubing so that it covers the joint, and shrink in place
with moderate heat.
4.
Splicing Wires. To repair broken or cut wires that are otherwise sound, the mating ends can be stripped and
spliced. A commercial butt splice can be crimped onto the ends to join them, or a "Western Union" wire splice can
be made. The latter is made by stripping 1/4 1/2 inch (0. 6 1. 3cm) of insulation from the wire ends, holding the
ends parallel and facing opposite directions, then twisting each end around the other wire at least three turns.
Solder and apply insulation as described above.
5.
Crimping Terminals. To install a terminal on the end of a wire, strip 1/4 1/2 inch (0. 6 1. 3cm) of insulation from
the end of wire, apply a one inch piece of heat-shrink tubing (if the terminals are of the uninsulated type), and insert
wire end into the shank of the terminal. Crimp the shank, and install heatshrink tubing, if necessary.
FOLLOW ON PROCEDURES
Install any panels that were removed.
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4-68. EVAPORATOR (CIRCULATOR) MOTOR AND HOUSING SUPPLY.
This task covers:
Inspection
Testing
Repair
Replacement
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front evaporator panel (para 4-25).
3. Swing open control box (para 4-45).
INSPECTION, TESTING, REPAIR, AND REPLACEMENT
Inspection, testing, repair, and replacement of the evaporator (circulator) motor and housing assembly components is
covered in the following referenced paragraphs.
1.
2.
3.
4.
5.
Fan belt (para 4-69).
Evaporator motor (para 4-70).
Circulator fan (para 4-71).
Pulleys 60 Hz (evaporator motor and circulator fan) (para 4-72).
Pulleys 50 Hz (evaporator motor and circulator fan) (para 4-73).
FOLLOW ON PROCEDURES
1.
Close control box (para 4-45).
2.
Close right front evaporator panel (para 4-25).
3.
Connect air conditioner input power at source.
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4-69. FAN BELT (EVAPORATOR MOTOR AND HOUSING ASSEMBLY).
This task covers:
Inspection
Adjust
Removal
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Swing open control box (para 4-45).
INSPECTION
1. Check that belt is not cut, worn, frayed, or cracked. If belt is damaged, replace belt (see Figure 4-70).
2. At a point halfway between the motor pulley and fan pulley, press the belt with hand. Belt should not depress more
than 1/2 inch (1.3 cm). If belt is too loose, adjust belt tension.
ADJUST
1.
Loosen four locknuts (1).
2.
Reposition motor in appropriate direction to obtain proper tension.
3.
Tighten four locknuts (1).
4.
Check belt tension (INSPECTION step 2), above.
5.
Repeat steps 1 thru 4 until proper tension is obtained.
REMOVAL
1.
Loosen four locknuts (1).
2.
Move motor in proper direction to obtain sufficient slack in fan belt.
3.
Remove belt (3) from pulleys (2).
INSTALLATION
1.
Slip belt (3) onto pulleys (2).
2.
Perform steps 2 thru 5 in ADJUST procedure.
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FOLLOW ON PROCEDURES
1.
Close control box (para 4-45).
2.
Install right front evaporator panel (para 4-25).
3.
Install center front evaporator panel (para 4-22).
4.
Connect air conditioner input power at source.
Figure 4-70. Fan Belt (Evaporator Motor And Housing Assembly)
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4-70. EVAPORATOR MOTOR (B1).
This task covers:
Inspection
Service
Removal
Testing
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Crimping tool (pigtail) (Item 10, Appendix B)
Lubricating gun (Item 15, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Grease aeroshell 22 (Item 2, Appendix E)
Rags (Item 12, Appendix E)
Equipment Conditions:
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove fan belt (para 4-69).
INSPECTION
1. Check motor (4) for rotational freedom by spinning shaft. If there is any stiffness or binding, contact Direct
Support Maintenance (see Figure 4-71).
2. Check motor bearings for shaft end play. If there is excessive end play, contact Direct Support Maintenance.
SERVICE
1. Lubrication. Lubricate motor (para 4-1).
2. Cleaning. Use clean dry cloth to remove dirt and grease from motor (4).
REMOVAL
1. Remove four screws (2) and J-box cover (3).
2. Tag and disconnect leads.
3. Loosen four locknuts (5) until bolt threads are even with nut.
When handling motor, wear gloves to avoid injury to personnel and to reduce fin
damage on the coil.
4. Slide motor (4) towards coil and remove.
5. Remove pulley (para 4-68).
6. Remove four locknuts (5), flat washers (6), and two brackets (1).
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TESTING
1. Using multimeter, check continuity between wires 1 and 2, 1 and 3, and 2 and 3. Replace motor if there is no
continuity between any pair of wires. Motor winding is open.
2. Using multimeter set on high OHMS scale, test stator insulation between each wire (1, 2, and 3) and motor
housing.
A reading of less than 500,000 ohms indicates insulation failure. Replace motor.
Figure 4-71. Evaporator Motor (B1)
INSTALLATION
1. Install two brackets (1) loosely with four flat washers (6) and locknuts (5).
2. Install pulley (para 4-68).
When handling motor, wear gloves to avoid Injury to personnel and to reduce fin
damage on the coil.
3. Place motor (4) onto slide rails (7) and slide into mounting position.
4. Reconnect leads and remove tags.
5. Install J-box cover (3) with four screws (2).
FOLLOW ON PROCEDURES
1. Install and adjust fan belt (para 4-69).
2. Connect air conditioner input power at source.
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4-71. CIRCULATOR FAN (EVAPORATOR).
This task covers:
Inspection
Service
Removal
Repair/Replace
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Corrosion preventative (Item 17, Appendix E)
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (Item 13, Appendix E)
Equipment Conditions:
1.
2.
3.
4.
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
Disconnect air conditioner input power at source.
Remove fan belt (para 4-69).
Remove evaporator motor (para 4-70).
Remove circulator fan pulley (para 4-68).
INSPECTION
1. Inspect for noise or missing mounting hardware (see Figure 4-72).
2. Check fan shaft for rotational freedom by spinning shaft. If there is any stiffness or binding, replace bearings and
bearing collar.
3. Check motor for shaft end play and defects. Replace shaft, if defective.
SERVICE
Service consists of applying corrosion preventative compound to shaft before installation.
REMOVAL
1. Remove 10 screws (1), flat washers (3), and lockwashers (2) securing top brackets (4).
2. Remove 6 screws (10), flat washers (12), and lockwashers (11) securing blower (14) to housing (13).
3. Tilt blower (14) towards coil and remove.
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Figure 4-72. Circulator Fan (Evaporator)
REPAIR/REPLACE
NOTE
Repair consists of replacing bearing, bearing cups, bearing collar, shaft or fan assembly.
Dress high metal defects in shaft with a file. If shaft is damaged beyond repair, replace
shaft. Replacement shaft must be cut to length.
1.
2.
3.
4.
Measure length of shaft (15) from bearing (8) on pulley side of shaft.
Loosen two set screws (6).
Unlock two bearings collars (7) from shaft (15) by turning bearing quarter turn.
Loosen two set screws (5) securing squirrel cage to shaft (15).
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4-71. CIRCULATOR FAN (EVAPORATOR) - Continued.
REPAIR/REPLACE - Continued.
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be
explosive. Repeated or prolonged skin contact or Inhalation of vapors can be toxic.
Use a well ventilated area, wear gloves, and keep away from sparks or flame.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Clean exposed ends of shaft (15).
Dress high metal defects on shaft (15) with file.
Remove shaft (15).
Slide one end of shaft (15) into each bearing (8) and remove both bearings individually.
Remove two bearing cups (9).
Install shaft (15). Extend shaft on pulley side to length measured in step 1.
Install two bearing cups (9) and bearings (8).
Install two replacement bearing collars (7) by turning quarter turn, locking bearings in place.
Tighten set screw (6).
Apply corrosion preventative compound to exposed ends of shaft (15).
INSTALLATION
1. Install blower (14) by tilting away from coil.
2. Secure blower to brackets (4) with 10 screws (1), lockwashers (2), and flat washers (3).
3. Secure blower to housing (13) with 6 screws (10), lockwashers (11), and flat washers (12).
FOLLOW ON PROCEDURES
1. Install circulator fan pulley (para 4-68)
2. Install evaporator motor (para 4-70).
3. Install and adjust fan belt (para 4-69).
4. Close control box (para 4-45).
5. Connect air conditioner input power at source.
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4-72. PULLEYS 60 HZ, GREEN (EVAPORATOR MOTOR AND CIRCULATOR FAN).
This task covers
Inspection
Removal
Adjust
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
Disconnect Input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front evaporator panel (para 4-25).
3. Swing open control box (para 4-45).
INSPECTION
1. Check evaporator motor and circulator fan pulleys diameter measures 4 7/8 inches (12.4 cm). If pulley measurements are not correct, install correct pulley. (See Figure 4-73)
2. Check pulleys for dents, burrs or any damage that would cause interference with fan operation. Replace pulley,
if damaged.
REMOVAL
NOTE
To remove pulleys mounted on inside of cabinet, remove nut, lockwasher, small flat
washer, large flat washer, and pulley.
1. Circulator Fan Pulley (Evaporator).
a. Remove fan belt (para 4-69).
NOTE
Bolts are used as pulley remover devices.
b. Match mark position of pulley on shaft (4).
c. Remove two bolts (6) and screw into two threaded holes (5).
d. Tighten two bolts (6) and remove pulley (7).
2. Evaporator Motor Pulley.
a. Match mark position of pulley on shaft (3).
b. Loosen three set screws (2) (two on front and one on rear).
c. Remove pulley (1).
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4-72. PULLEYS 60 HZ, GREEN (EVAPORATOR MOTOR AND CIRCULATOR FAN) - Continued.
Figure 4-73. Pulleys 60 Hz, Green (Evaporator Motor And Circulator Fan)
ADJUST
1. Close pulley gap.
2. Line up notches.
3. Open pulley gap four 1/2 turns.
4. To adjust 50 Hz pulleys (red) for 60 Hz operation perform steps 1, 2 , and 5
5. Open pulley gap four turns.
INSTALLATION
NOTE
To install pulley inside of cabinet, place pulley on mounting screw and secure with
large flat washer, small flat washer, lockwasher, and nut.
1. Circulator Fan Pulley (Evaporator).
a.
Install pulley (7) and align with match mark on shaft (4).
b.
Tighten two bolts (6) in unthreaded holes.
2. Evaporator Motor Pulley.
a.
Install pulley (1) and align with match mark on shaft (3).
b.
Tighten three set screws (2) (two on front and one on rear).
FOLLOW ON PROCEDURES
Install and adjust fan belt (para 4-69).
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4-73. PULLEYS 50 HZ, RED (EVAPORATOR MOTOR AND CIRCULATOR FAN).
This task covers:
Inspection
Removal
Adjust
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front evaporator panel (para 4-25).
3. Swing open control box (para 4-45).
INSPECTION
1. Check evaporator motor and circulator fan pulleys diameter measures 4 3/4 inches (12.1 cm). If pulleys
measurement are not correct, install correct pulley. (See Figure 4-74)
2. Check pulleys for dents, burrs or any damage that would cause interference with fan operation. Replace pulley,
if damaged.
REMOVAL
NOTE
To remove pulleys mounted on inside of cabinet, remove nut, lockwasher, small flat
washer, large flat washer, and pulley.
1. Circulator Fan Pulley (Evaporator)
a. Remove fan belt (para 4-69).
NOTE
Bolts are used as pulley remover devices.
b. Match mark position of pulley on shaft (4).
c. Remove two bolts (6) and screw into threaded holes (5).
d. Tighten two bolts (6) and remove pulley (7).
2. Evaporator Motor Pulley.
a. Match mark position of pulley on shaft (3).
b. Loosen three set screws (2) (two on front and one on rear).
c. Remove pulley (1).
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4-73. PULLEYS 50 HZ, RED (EVAPORATOR MOTOR AND CIRCULATOR FAN) - Continued
4-73. PULLEYS 50 HZ, RED (EVAPORATOR MOTOR AND CIRCULATOR FAN) - Continued.
ADJUST
1. Close pulley gap.
2. Line up notches.
3. Open pulley gap two turns.
4. To adjust 60 Hz pulleys (green) for 50 Hz operation perform steps 1, 2, and 5.
5. Open pulley gap five turns.
INSTALLATION
NOTE
To install pulley inside of cabinet, place pulley on mounting screw and secure with large
flat washer, small flat washer, lockwasher, and nut.
1. Circulator Fan Pulley (Evaporator).
a. Install pulley (7) and align with match mark on shaft (4).
b. Install two bolts (6) in unthreaded holes.
2. Evaporator Motor Pulley.
a. Install pulley (1) and align with mark on shaft (3).
b. Tighten three set screws (2) (two on front and one on rear).
FOLLOW ON PROCEDURES
Install and adjust fan belt (para 4-69).
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4-74. CONDENSER MOTOR AND HOUSING ASSEMBLY.
This task covers:
Inspection
Testing
Repair
Replacement
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front condenser panel (para 4-27).
INSPECITON, TESTING, REPAIR, AND REPLACEMENT
NOTE
Applicable inspection, testing, repair, and replacement of the condenser motor and
housing assembly components is covered in the following referenced paragraphs.
1.
2.
3.
4.
5.
Fan belt (para 4-75).
Condenser motor (para 4-76).
Circulator fan (para 4-77).
Pulleys 60 Hz (condenser motor and circulator fan) (para 4-78).
Pulleys 50 Hz (condenser motor and circulator fan) (para 4-79).
FOLLOW ON PROCEDURES
1. Install left front condenser panel (para 4-27).
2. Connect air conditioner input power at source.
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4-75. FAN BELT (CONDENSER MOTOR AND HOUSING ASSEMBLY).
This task covers:
Inspection
Adjust
Removal
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
Disconnect input power to the air conditioner before performing any Internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front condenser panel (para 4-27).
INSPECTION
1. Check that belt is not cut, worn, frayed, or cracked. If belt is damaged, replace belt (see Figure 4-75).
2. At a point halfway between the motor pulley and fan pulley, press the belt with hand. Belt should not depress
more than 1/2 inch (1.3 cm). If belt is too loose, adjust belt tension. ADJUST
1. Loosen four locknuts (1).
2. Reposition motor in appropriate direction to obtain proper tension (see INSPECTION).
3. Tighten four locknuts (1).
4. Check belt tension (inspection step 2), above.
5. Repeat steps 1 thru 4 until proper tension is obtained.
REMOVAL
1. Loosen four locknuts (1).
2. Move motor in proper direction to obtain sufficient slack in fan belt.
3. Remove belt (3) from pulleys (2).
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INSTALLATION
1. Slip belt (3) onto pulleys (2).
2. Perform steps 2 thru 4 in ADJUST procedure.
FOLLOW ON PROCEDURES
1. Install left front condenser panel (para 4-27).
2. Connect air conditioner input power at source.
Figure 4-75. Fan Belt (Condenser Motor And Housing Assembly)
4-145
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4-76. CONDENSER MOTOR (B3).
This task covers:
Inspection
Service
Removal
Testing
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Crimping tool (pigtail) (Item 10, Appendix B)
Lubricating gun (Item 15, Appendix B)
Personnel: 1
Materials:
Grease aeroshell 22 (Item 2, Appendix E)
Rags (Item 12, Appendix E)
Equipment Conditions:
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove fan belt (para 4-75).
INSPECTION
1. Check motor (5) for rotational freedom by spinning shaft. If there is any stiffness or binding, contact Direct
Support Maintenance (see Figure 4-76).
2. Check motor bearings for shaft end play. If there is excessive end play, contact Direct Support Maintenance.
SERVICE
1. Lubrication. Lubricate motor (para 4-1).
2. Cleaning. Use clean dry cloth to remove dirt and grease from motor (5).
REMOVAL
1. Remove four screws (3) and J-box cover (4).
2. Tag and disconnect leads.
3. Support motor (5) and remove four locknuts (2) and flat washers (1).
4. Remove motor (5).
5. Remove pulley (para 4-78 or 4-79).
TESTING
1. Using multimeter, check continuity between wires 1 and 2, 1 and 3, and 2 and 3. Replace motor if there is no
continuity between any pair of wires.
2.Using multimeter set on high OHMS scale, test stator insulation between each wire (1, 2, and 3) and motor
housing. A reading of less than 500,000 ohms indicates insulation failure. Replace motor.
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Figure 4-76. Condenser Motor (B3)
INSTALLATION
1. Install pulley (60 Hz para 4-78 or 50 Hz para 4-79).
2. Place motor (5) in mounting position.
3. Install four flat washers (1) and locknuts (2).
4. Reconnect leads and remove tags.
5. Install J-box cover (4) with four screws (3).
FOLLOW ON PROCEDURES
Install and adjust fan belt (para 4-75).
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4-77. CIRCULATOR FAN (CONDENSER).
This task covers:
Inspection
Service
Removal
Repair/Replace
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Personnel: 1
Materials:
Corrosion preventative (Item 17, Appendix E)
Rags (Item 12, Appendix E)
Methyl-Ethyl Ketone (MEK) (Item 13, Appendix E)
Equipment Conditions:
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove condenser motor (para 4-76).
INSPECTION
1. Inspect for noise or missing mounting hardware (see Figure 4-77).
2. Check fan shaft for rotational freedom by spinning shaft. If there is any stiffness or binding, replace bearings and
bearing collar.
3. Check motor for shaft end play and defects. Replace shaft, if defective.
SERVICE
Service consists of applying corrosion preventative compound to shaft before installation.
REMOVAL
Use great care to avoid contact with refrigerant gas being discharged under pressure. Sudden and irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face protector or goggles In any situation where skineye-contact is possible.
1.
2.
3.
4.
5.
Front seat (clockwise) actuator service valve (see Figure 5-20).
Slowly loosen flare nut (9) on actuator to release gas.
Remove two bolts (7), lockwashers (6), and flat washers (5). (1/2 inch socket top rear bracket)
Remove three screws (3), lockwashers (2), flat washers (1), and top bracket (4).
Remove screw (15), lockwasher (16), flat washer (17), and clamp (18).
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6. Position flare nut (9) and tubing out of way.
NOTE
Rubber grommets will fly in different directions when removing circulator fan housing
from bracket.
7. Remove four bolts (22), locknuts (19), eight grommets (21) and flat washers (20).
8. Remove circulator fan housing (23).
9. If fan housing is being replaced, remove condenser fan connecting link assembly (para 4-89) and contact Direct
Support Maintenance to remove actuator.
Figure 4-77. Circulator Fan (Condenser)
REPAIR/REPLACE
NOTE
Repair consists of replacing bearing, bearing collar, bearing cups, shaft, or fan assembly.
Dress high metal defects in shaft with a file. If shaft is damaged beyond repair, replace
shaft. Replacement shaft must be cut to length.
1. Measure length of shaft from bearing (13) on pulley side of shaft.
2. Loosen two set screws (11).
3. Unlock two bearing collars (12) from shaft (10) by turning collars quarter turn.
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4-77. CIRCULATOR FAN (CONDENSER) - Continued.
4. Loosen two set screws (8) secure squirrel cage to shaft (10)
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be
explosive. Repeated or prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area, wear gloves, and keep away from sparks or flame.
5.
6.
7.
8.
9.
10.
11.
12.
Clean exposed ends of shaft (10).
Dress high metal defects on shaft (10) with file.
Remove shaft (10).
Slide one end of shaft (10) into each bearing (13) and remove both bearings (13) individually.
Remove two bearing cups (14).
Install shaft (10). Extend shaft on pulley side to length measured in step 1.
Install two bearings cups (14) and replacement bearings (13).
Install two replacement bearing collars (12) by turning quarter turn, locking bearings in place, then tighten two set
screws (11) in bearing collars (12).
13. Apply corrosion preventative compound to exposed ends of shaft (10).
INSTALLATION
1. If fan housing was replaced, install condenser fan connecting link assembly (para 4-89) and contact Direct
Support Maintenance to install actuator.
2. Position circulator fan (23) in mounting position.
3. Install four bolts (22), grommets (21), eight flat washers (20), and four locknuts (19) .
4. Install top brackets (4) with three screws (3), lockwashers (2) and flat washers (1).
5. Install two bolts (7), lockwashers (6), and flat washers (5).
6. Install clamp (18) with screw (15), lockwasher (16), and flat washer (17).
7. Install actuator line with flare nut (9) loose, but do not tighten at this time.
8. To back seat (counterclockwise) actuator service valve contact Direct Support Maintenance. Let gas escape for
three seconds and tighten flare nut (9).
9. Leak test all newly connected joints and those in the repair area (contact Direct Support Maintenance).
FOLLOW ON PROCEDURES
Install condenser motor (para 4-76).
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4-78. PULLEYS 60 HZ, GREEN (CONDENSER MOTOR AND CIRCULATOR FAN).
This task covers:
Inspection
Removal
Adjust
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
Disconnect Input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front condenser panel (para 4-27).
INSPECTION
1. Check condenser motor pulley diameter measures 4 1/2 inches (11.4 cm) and circulator fan pulley diameter
measures 6 3/4 inches (17.1 cm). If measurements are not correct, install correct pulley (see Figure 4-78).
2. Check pulleys for dents, burrs or any damage that would cause interference with fan operation. Replace pulley,
if damaged.
REMOVAL
NOTE
To remove pulleys mounted on inside of cabinet, remove nut, lockwasher, small flat
washer, large flat washer, and pulley.
1. Circulator Fan Pulley (Condenser).
a. Remove fan belt (para 4-75).
NOTE
Bolts are used as pulley remover device.
b. Match mark position of pulley on shaft (4).
c. Remove two bolts (6) and screw into threaded holes (7).
d. Tighten two bolts (6) and remove pulley (5).
2. Condenser Motor Pulley.
a. Match mark position of pulley on shaft (3).
b. Loosen three set screws (1) (two in front one in rear).
c. Remove pulley (2).
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4-78. PULLEYS 60 HZ, GREEN (CONDENSER MOTOR AND CIRCULATOR FAN) - Continued.
Figure 4-78. Pulleys 60 Hz, Green (Condenser Motor and Circulator Fan)
ADJUST
1.
2.
3.
4.
5.
Close pulley gap.
Line up notches.
Open pulley gap 3 turns.
To adjust 50 Hz pulleys (red) for 60 Hz operation perform steps 1, 2, and 5.
Open pulley gap 4 turns.
INSTALLATION
NOTE
To install pulley inside of cabinet, place pulley on mounting screw and secure with large
flat washer, small flat washer, lockwasher, and nut.
1. Circulator Fan Pulley (Condenser).
a. Install pulley (5) and align with match mark on shaft (4).
b. Install two bolts (6) in unthreaded holes.
2. Condenser Motor Pulley.
a. Install pulley (2) and align with match mark on shaft (3).
b. Tighten three set screws (1) (two in front and one in rear).
FOLLOW ON PROCEDURES
Install and adjust fan belt (para 4-75).
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4-79. PULLEYS 50 HZ, RED (CONDENSER MOTOR AND CIRCULATOR FAN).
This task covers:
Inspection
Removal
Adjust
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
Disconnect input power to the air conditioner before performing any Internal
maintenance. Voltages used can KILL Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front condenser motor (para 4-27).
INSPECTION
1. Check condenser fan pulley diameter measures 5 1/4 inches (13.3 cm) and circulator fan pulley diameter
measures 6 1/2 inches (16.5 cm). If pulley measurement are not correct, install correct pulley (see Figure 4-79).
2. Check pulleys for dents, burrs or any damage that would cause interference with fan operation. Replace pulley,
if damaged.
REMOVAL
NOTE
To remove pulleys mounted on inside of cabinet, remove nut, lockwasher, small flat
washer, large flat washer, and pulley.
1. Circulator Fan Pulley (Condenser).
a. Remove fan belt (para 4-75).
NOTE
Bolts are used as pulley remover devices.
b. Match mark position of pulley on shaft (4).
c. Remove two bolts (6) and screw into threaded holes (7).
d. Tighten two bolts (6) and remove pulley (5).
2. Condenser Motor Pulley.
a. Match mark position of pulley on shaft (3).
b. Loosen three set screws (1) (two in front and one in rear).
c. Remove pulley (2).
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4-79. PULLEYS 50 HZ, RED (CONDENSER MOTOR AND CIRCULATOR FAN) - Continued.
Figure 4-79. Pulleys 50 Hz, Red (Condenser Motor and Circulator Fan)
ADJUST
1. Close pulley gap.
2. Line up notches.
3. Open pulley gap three 1/2 turns.
4. To adjust 60 Hz pulleys (green) for 50 Hz operation perform steps 1, 2, and 5.
5. Open pulley gap five turns.
INSTALLATION
NOTE
To install pulley inside of cabinet, place pulley on mounting screw and secure with large
flat washer, small flat washer, lockwasher, and nut.
1. Circulator Fan Pulley (Condenser).
a. Install pulley (5) and align with match mark on shaft (4).
b. Install two bolts (6) in unthreaded holes.
2. Condenser Motor Pulley.
a. Install pulley (2) and align with match mark on shaft (3).
b. Tighten three set screws (1) (two in front and one in rear).
FOLLOW ON PROCEDURES
Install and adjust fan belt (para 4-75).
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4-80. ELECTRIC HEATER (EH).
This task covers:
Inspection
Removal
Adjust
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel; 1
Equipment Conditions:
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front evaporator panel (para 4-23).
INSPECTION
Check heater elements for deformation, damaged terminals, threads, cracked or broken parts. Replace if damaged.
TESTING
1. Tag and disconnect leads on heater element under test.
2. Using multimeter, check for continuity between two terminal studs of each element. If no continuity is indicated,
replace element.
REMOVAL
CAUTION
Use two wrenches to ensure that terminal stud does not turn, preventing ceramic
breakage.
1. Remove three screws (3), flat washers (1), and lockwashers (2) (see Figure 4-80).
2. Remove plastic cover (4).
3. Remove two locknuts (5), lockwashers (6), and four flat washers (7).
4. Tag and disconnect leads.
5. Remove two nuts (8).
6. Remove screw (14), flat washer (12), and lockwasher (13).
7. Remove element (10) and clamp (11).
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4-80. ELECTRIC HEATER (EH) - Continued.
Figure 4-80. Electric Heater
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INSTALLATION
1. Place clamp (11) on heater element (10).
2. Place element (10) and clamp (11) in mounting position.
3. Install screw (14), lockwasher (13), and flat washer (12).
CAUTION
Use two wrenches to ensure that terminal stud does not turn, preventing ceramic
breakage.
4. Install two nuts (8).
5. Reconnect wire leads tagged in removal onto terminal stud (9)
6. Install four flat washers (7), lockwashers (6), and locknut (5).
7. Place plastic cover (4) in mounting position.
8. Install three screws (3), lockwashers (2), and flat washers (1).
FOLLOW ON PROCEDURES
1. Install left front evaporator panel (para 4-23).
2. Connect air conditioner power at source.
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4-81. COMPRESSOR CRANKCASE HEATER (CCH).
This task covers:
Inspection
Removal
Adjust
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel:1
Equipment Conditions:
Disconnect input power to the air conditioner before performing any Internal
maintenance. Voltages used can KILL Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
INSPECTION
1. Remove two screws (2) and J-box cover (3) (see Figure 4-81).
2. Check crankcase heater wires in J-box for corrosion or loose electrical connections.
3. Check for signs of overheating or other visible damage. Replace heater, if defective.
TESTING
The following testing procedure Is performed with power on. Proceed with extreme caution. Death or serious Injury can result.
1. Connect air conditioner input power and verify CB2 is dosed.
2. Using a clamp-on ammeter, verify current flow through compressor crankcase heater wires (red) located in J-box
is less than 10 amps.
3. If no current flow is indicated or current is greater than 10 amps, replace crankcase heater.
REMOVAL
1. Disconnect air conditioner input power at source.
2. Tag and disconnect red wire leads.
3. Loosen two screws (1) and remove flex conduit (4).
Allow crankcase heater to cool before touching crankcase heater. Surfaces are
extremely hot. Serious Injury can result.
4. Allow heater to cool.
5. Remove crankcase heater (5).
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Figure 4-81. Compressor Crankcase Heater
INSTALLATION
NOTE
When replacing crankcase heater, cut conduit to 10 1/2 inches, cut wires to 18 inches,
and strip wire ends to 1/2 inch maximum.
1. Install crankcase heater (5).
2. Install flex conduit (4) and tighten two screws (1) .
3. Connect red wire leads and remove tags.
4. Install J-box cover (3) with two screws (2).
FOLLOW ON PROCEDURES
1. Install right front condenser panel (para 4-28).
2. Connect air conditioner input power at source.
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4-82. DIRTY FILTER SWITCH (S3).
This task covers:
Inspection
Removal
Adjust
Installation
INITIAL SET-UP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Manometer (Item 3, Appendix B)
Riveter, blind (Item 8, Appendix B)
Personnel: 1
Material:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front evaporator panel (para 4-23).
INSPECTION
Check dirty filter switch for corrosion, loose electrical connections or missing mounting hardware. If damaged, replace
switch (see Figure 4-82).
TESTING
1. Remove screw (6) and cover (4).
2. Using multimeter, check continuity between common and open electrical terminals.
3. Turn adjustment screw back and forth slightly and check that switch contacts open and close.
4. If dirty filter switch fails above tests, replace switch.
ADJUST
1. Attach tube (1) from manometer to switch (3).
2. Connect multimeter to common and normally open terminals of switch.
3. While blowing into tube, gently adjust switch to close when indication reaches 1.15 ± 0.05 inches wc on
manometer.
REMOVAL
1. Tag and disconnect leads.
2. Remove two rivets (2).
3. Remove dirty filter switch (3).
4. Remove tubing (5) and (7).
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Figure 4-82. Dirty Filter Switch (S3)
INSTALLATION
1 Fungus proof replacement dirty filter switch per MIL-V-173.
2 Place dirty filter switch (3) in mounting position.
3 Install two rivets (2).
4 Install tubing (5) and (7).
5 Reconnect leads and remove tags.
6 Install cover (4) with screw (6).
FOLLOW ON PROCEDURES
1 Install left front evaporator panel (para 4-23).
2 Connect air conditioner input power at source.
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4-83. HIGH TEMPERATURE SWITCH (S6).
This task covers:
a. Inspection
d. Installation
b. Removal
c. Testing
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Material:
Heat gun (Item 2, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front evaporator panel (para 4-23).
INSPECTION
Check high temperature switch (3) for corrosion, loose electrical connections or missing mounting hardware. If damaged,
replace switch (see Figure 4-83).
REMOVAL
1 Tag and disconnect leads.
2 Remove two screws (4), locknuts (2), and four flat washers (1).
3 Remove switch (3).
TESTING
NOTE
For full operational test of switch, an external heat source is required. Switch should open (no continuity
across contacts) at 130 degrees F (54.4°C).
With switch at room temperature, using multimeter, check for continuity between switch terminals. If continuity is not
indicated, replace switch.
INSTALLATION
1. Place switch (3) in mounting position.
2. Install two screws (4), four flat washers (1), and two locknuts (2).
3. Reconnect leads and remove tags.
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FOLLOW ON PROCEDURES
1 Install left front evaporator panel (para 4-23).
2 Connect air conditioner input power at source.
Figure 4-83. High Temperature Switch (S6)
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4-84. AIR FLOW SWITCH (S8).
This task covers:
a. Inspection
d. Installation
b. Testing
c. Removal
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Goggles, industrial (Appendix C)
Personnel: 1
Material:
Solder, lead-tin alloy (Item 18, Appendix E)
Flux, solder, liquid rosin base (item 19, Appendix E)
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front evaporator panel (para 4-25).
INSPECTION
1. Check for missing mounting hardware (see Figure 4-84).
2. Check that leads are properly connected to terminals.
TESTING
1. Slide cover (1) off air flow switch (5).
2. Using multimeter, check continuity between two wired terminal.
· Move flow sensor down - no continuity.
· Move flow sensor up - continuity.
3. If air flow switch fails test, replace switch.
REMOVAL
1. Tag, unsolder and disconnect leads.
2. Remove screw (2), lockwasher (3), and flat washer (4).
3. Remove air flow switch (5).
4. Check that air flow sensor arm (6) is not bent or broken.
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Figure 4-84. Air Flow Switch (S8)
INSTALLATION
1. Fungus proof replacement air flow switch per MIL-V-173.
2. Place air flow switch (5) in mounting position.
3. Install screw (2), lockwasher (3), and flat washer (4).
4. Solder leads and remove tags.
5. Slide cover (1) on switch (5).
FOLLOW ON PROCEDURES
1. Install right front evaporator panel (para 4-25).
2. Connect air conditioner input power at source.
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4-85. HEAT CONTROL THERMOSTAT (S9).
This task covers:
a. Inspection
d. Removal
b. Testing
e. Installation
c. Adjust
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Material:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front evaporator panel (para 4-23).
INSPECTION
1. Check that leads are properly connected (see Figure 4-85 and Figure FO-3).
2. Check that capillary line is not damaged.
3. Check thermostat (5) for signs of overheating or other obvious damage. Replace if damaged.
TESTING
1. Using multimeter, check continuity. Place probes on red and blue terminals.
2. Slowly turn dial counterclockwise until continuity is indicated. Turn dial back and forth slightly to check that
switch contacts open and close on a very narrow band.
3. If thermostat fails test, replace thermostat.
ADJUST
Set thermostat to 72°F (22°C).
REMOVAL
1.
Remove screw (6) and cover (7).
2.
Remove four screws (1), lockwashers (2), and flat washers (3).
3.
Gently pull thermostat (5) away from bracket (4) as far as harness will allow.
4.
Tag and disconnect leads.
5.
Remove thermostat (5).
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Figure 4-85. Heat Control Thermostat (S9)
INSTALLATION
NOTE
On replacement thermostat install insulator bushing.
1. Fungus proof replacement thermostat per MIL-V-173.
2. Reconnect leads and remove tags.
3. Place thermostat (5) in mounting position.
4. Install four screws (1) lockwashers (2), and flat washers (3).
5. Install cover (7) with screw (6).
6. Adjust thermostat (see ADJUST).
FOLLOW ON PROCEDURES
1. Install left front evaporator panel (para 4-23).
2. Connect air conditioner input power at source.
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4-86. LOW AMBIENT TEMPERATURE THERMOSTAT (S13).
This task covers:
a. Inspection
b. Testing
d. Removal
e. Removal
c. Adjust
f. Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Material:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
INSPECTION
1.
Check that leads are properly connected before (see Figure 4-86 and Figure FO-3).
2.
Check that capillary line and sensing bulb are not damaged.
3.
Check thermostat (10) for signs of overheating or other obvious damage. Replace if damaged.
TESTING
1. Using multimeter, check continuity. Place probes on red and blue terminals.
2. Slowly turn dial counterclockwise until continuity is indicated. Turn dial back and forth slightly to check that
switch contacts open and close on a very narrow band.
3. If thermostat fails test, replace thermostat.
ADJUST
Set thermostat to 0°F (-18°C).
REMOVAL
1. Remove screw (9) and cover (8).
2. Tag and disconnect leads.
3. Remove screw (2), locknut (4), two flat washers (1), and clamp (3).
4. Remove four locknuts (6), eight flat washers (5), and four screws (7).
5. Remove thermostat (10).
6. Install cover (8) and screw (9)
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Figure 4-86. Low Ambient Temperature Thermostat (S13)
INSPECTION
1. Fungus proof replacement thermostat per MIL-V-173.
2. Place thermostat (10) in mounting position.
3. Install four screws (7), eight flat washers (5), and four locknuts (6).
4. Install sensing bulb with clamp (3), screw (2), two flat washers (1), and locknut (4).
5. Reconnect leads and remove tags.
FOLLOW ON PROCEDURES
1. Install right front condenser panel (para 4-28).
2. Connect air conditioner input power at source.
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4-87. COOL CONTROL THERMOSTAT (S14).
This task covers:
a. Inspection
d. Removal
b. Testing
e. Installation
c. Adjust
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Material:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages used can
KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front evaporator panel (para 4-23).
INSPECTION
1. Remove two screws (9), flat washers (7), lockwashers (8), and cover (6). (See Figure 4-87).
2. Check that leads are properly connected (see Figure FO-3).
3. Check that capillary line (18) and sensing bulb (5) are not damaged.
4. Check thermostat for signs of overheating or other obvious damage. Replace if damaged.
TESTING
1. Using multimeter, check continuity. Place probes on each set of red and blue terminals, in turn.
2. At each set, slowly turn dial back and forth slightly to check that switch opens and closes on a very narrow range.
3. Place probes on each set of red and yellow terminals in turn. Repeat step 2.
4. Replace thermostat if it fails any of above tests.
ADJUST
NOTE
This temperature adjustment is for single mode of operation.
Set temperature to desired room temperature between 68° and 95°F (20° and 35°C).
REMOVAL
1. Remove screw (1), flat washer (3), lockwasher (2), and sensing bulb (5).
2. Remove sensing bulb clamp (4).
3. Remove screw (16), flat washer (15), lockwasher (17), and clamp (14).
4. Tag and disconnect leads.
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5. Remove thermostat housing grommet (13).
6. Remove six screws (10).
7. Remove thermostat (11) and sensing bulb (5).
INSTALLATION
1. Fungus proof thermostat per MIL-V-173.
2. Position thermostat (11) and sensing bulb (5) in mounting position.
3. Install thermostat (11) with six screws (10) to housing (12).
4. Install sensing bulb (5), and grommet (13).
5. Install clamp (14) with screw (16), lockwasher (17), and flat washer (15).
6. Install sensing bulb (5) with clamp (4), screw (1), lockwasher (2), and flat washer (3).
7. Reconnect leads and remove tags.
8. Set thermostat to appropriate operating temperature (see ADJUST).
FOLLOW ON PROCEDURES
1. Install cover (6) with two screws (9), lockwashers (8), and flat washers (7).
2. Install left front evaporator panel (para 4-23).
3. Connect air conditioner input power at source.
Figure 4-87. Cool Control Thermostat (S14)
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4-88. SOLENOID VALVES (L1 AND L2) COIL REMOVAL.
This task covers:
a. Inspection
b. Testing
c. Replace
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Crimping tool (pigtail) (Item 10, Appendix B)
Personnel: 1
Material:
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front evaporator panel (para 4-25).
INSPECTION
1. Check that leads are properly connected (see Figure 4-88 and Figure FO-3).
2. Check coil for signs of overheating or other obvious damage. Replace coil, if damaged.
TESTING
1. Check to be sure power has been disconnected.
2. Tag and disconnect wires from coil.
3. Use multimeter set on lowest OHMS scale to check for continuity between the coil wires. If continuity is not
found, coil is open and not be replaced.
4. Use multimeter to check for continuity between each wire and coil casing. If continuity is found between either
wire and case, the coil is grounded and should be replaced.
5. If continuity checks are satisfactory, apply 120 V ac from an external power supply across coil wires, and listen
for a sharp click when the valve changes position. If a click is not heard, internal valve problems are indicated
and entire valve should be replaced. Contact Direct Support Maintenance for further action.
REPLACE
NOTE
Replacement consists of replacing defective coil. Refer all other solenoid repair replacement to Direct
Support Maintenance.
1.
2.
3.
4.
Remove screw (6) and coil cover (5).
Tag and disconnect leads.
Remove coil retainer (2) and nameplate (1).
Remove coil (3).
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Figure 4-88. Solenoid Valve (L1 and L2) Coil Removal
5. Fungus proof replacement coil per MIL-V-173.
NOTE
On replacement coil, remove one knockout, install bushing, strip and dead end wires, and install crimp
pigtails to wires.
6.
7.
8.
9.
Install coil (3) on valve plunger (4).
Connect wire leads tagged in step 2.
Install coil cover (5) with screw (6).
Install nameplate (1) and coil retainer (2).
FOLLOW ON PROCEDURES
1. Install right front evaporator panel (para 4-25).
2. Connect air conditioner input power at source.
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4-89. CONDENSER FAN CONNECTING LINK ASSEMBLY.
This task covers:
a. Inspection
d. Installation
b. Adjust
c. Removal
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages used
can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front condenser panel (para 4-27).
INSPECTION
1. Check that control rod (7) is not bent or damaged. Replace if damaged (see Figure 4-89).
2. Check that connector swivels (5) and (9) are not damaged. Replace if damaged.
3. Check for damaged, loose, or missing mounting hardware.
ADJUST
1. Loosen screw (8) on actuator connector swivel (9) and close damper.
2. Match mark control rod (7) next to connector swivel (9).
3. Open damper with 1/2 inch (1.3 cm) clearance and match mark control rod (7).
4. Measure damper rod marks for one inch (2.54 cm) between steps 2 and 3.
5. If measurement between steps 2 and 3 is less than one inch (2.54 cm), repeat steps 1 thru 4.
6. To test linkage operation contact Direct Support Maintenance.
REMOVAL
1. Loosen screw (8) on actuator connector swivel (9).
2. Loosen screw (6) on control lever connector swivel (5).
3. Remove control rod (7).
4. Remove locknut (10) and actuator connector swivel (9).
5. Remove locknut (1) and control lever connector swivel (5).
6. Remove bolt (3), locknut (4), and control lever (2).
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INSPECTION
1. If control rod is replaced, cut replacement control rod (7) to 13 inches (33 cm).
2. Install control lever (2) with bolt (3) and locknut (4).
3. Install control lever connector swivel (5) with locknut (1).
4. Install actuator connector swivel (9) with locknut (10).
5. Install control rod (7).
6. Tighten screw (6) on control lever connector swivel (5).
7. Tighten screw (8) on actuator connector swivel (9)
8. Adjust linkage.
FOLLOW ON PROCEDURES
1. Install left front condenser panel (para 4-27).
2. Connect conditioner input power at source.
Figure 4-89. Condenser Fan Connecting Link Assembly
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4-90. CONDENSER COIL.
This task covers:
a. Inspection
b. Service
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Fin comb (Item 12, Appendix B)
Vacuum cleaner (item 13, Appendix B)
Goggles, industrial (Appendix C)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages used
can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front condenser panel (para 4-27).
3. Remove right front condenser panel (para 4-28).
INSPECTION
1. Check for accumulated dirt. Clean if dirt is evident (see Figure 4-90).
2. Check fins for dents, bent edges, or any condition that would block or distort air flow. Straighten all damaged fins
with a plastic fin comb. If a leak or major damage is evident, refer to Direct Support Maintenance.
SERVICE
WARNING
Compressed air used for cleaning purposes shall not exceed 30 psi (2.1 kg/cm2). Do not direct
compressed air against the skin. When using compressed air, wear safety glasses or goggles to prevent
dirt from being blown into your eyes.
CAUTION
Do not use steam to clean coil. Pressure can build up in system causing damage to components.
Clean coil with a soft bristle brush, vacuum cleaner and brush attachment, or use compressed air at 30 psi (2.1 kg/cm2)
or less from inside of unit to blow the dirt out. Take care to avoid fin damage. When using compressed air, wear safety
glasses or goggles to prevent dirt from being blown into your eyes.
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FOLLOW ON PROCEDURES
1. Install left front condenser panel (para 4-27).
2. Install right front condenser panel (para 4-28).
3. Connect air conditioner input power at source.
Figure 4-90. Condenser Coil Cleaning
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4-91. EVAPORATOR COIL.
This task covers:
a. Inspection
b. Service
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Fin comb (Item 12, Appendix B)
Vacuum cleaner (item 13, Appendix B)
Goggles, industrial (Appendix C)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
4.
Disconnect air conditioner input power at source.
Remove left front evaporator panel (para 4-23).
Remove right front evaporator panel (para 4-25).
Open control box (para 4-45).
INSPECTION
1. Check for accumulated dirt. Clean if dirt is evident (see Figure 4-91).
2. Check fins for dents, bent edges, or any condition that would block or distort air flow. Straighten all damaged fins
with a plastic fin comb. If a leak or major damage is evident, refer to Direct Support Maintenance.
SERVICE
WARNING
Compressed air used for cleaning purposes shall not exceed 30 psi (2.1 kg/cm2). Do not direct
compressed air against the skin. When using compressed air, wear safety glasses or goggles to
prevent dirt from being blown into your eyes.
CAUTION
Do not use steam to clean coil. Pressure can build up in system causing damage to components.
Clean coil with a soft bristle brush, vacuum cleaner and brush attachment, or use compressed air at 30 psi (2.1 kg/cm2)
or less from inside of unit to blow the dirt out. Take care to avoid fin damage. When using compressed air, wear safety
glasses or goggles. Dirt can be blown into your eyes.
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FOLLOW ON PROCEDURES
1. Install left front evaporator panel (para 4-23).
2. Install right front evaporator panel (para 4-25).
3. Close control box (para 4-45).
4. Connect air conditioner input power at source.
Figure 4-91. Evaporator Coil Cleaning
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4-92. DRAIN AREAS.
This task covers:
a. Inspection
b. Service
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Corrosion preventative (Item 5, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air. conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
4.
5.
Disconnect air conditioner input power at source.
Remove left front evaporator panel (para 4-23).
Remove right front evaporator panel (para 4-25).
Remove left front condenser panel (para 4-27).
Remove right front condenser panel (para 4-28).
INSPECTION
1. Check that drain areas are clean (see Figure 4-92).
2. Check that drain areas do not contain water.
3. Check drain pan for rust and corrosion. Apply corrosion preventative as required.
SERVICE
1. Pour some clean fresh water into drain areas.
2. If water does not freely flow out of drain tubes or has muddy appearance, insert flexible wire in drain tube.
Agitate until clog and accumulated debris are loose.
3. Pour additional water in drain area until unrestricted flow of water pours from drain tubes.
4. If water does not freely flow out of drain tube area, disconnect drain tubes from tee fitting, insert flexible wire in
drain line. Agitate until clog and accumulated debris are loose.
5. Pour some clean fresh water into drain tube at tee fitting until unrestricted flow of clean water pours from drain
tube.
6. Connect drain tubes.
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FOLLOW ON PROCEDURES
1.
2.
3.
4.
5.
Install left front evaporator panel (para 4-23).
Install right front evaporator panel (para 4-25).
Install left front condenser panel (para 4-27).
Install right front condenser panel (para 4-28).
Connect air conditioner input power at source.
Figure 4-92. Drain Areas
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Section VII. PREPARATION FOR STORAGE OR SHIPMENT
4-93. PREPARATION FOR STORAGE OR SHIPMENT.
a. Administrative storage of equipment.
(1) Placement of equipment in administrative storage should be for short periods of time when a shortage of
maintenance effort exists. Items should be in mission readiness within 24 hours or within the time factors
determined by the directing authority. During the storage period appropriate maintenance records will be kept.
(2) Before placing equipment in administrative storage, current maintenance services and equipment serviceable
criteria (ESC) evaluations should be completed, shortcomings and deficiencies should be corrected, and all
modification work orders (MWO's) should be applied.
(3) Storage site selection. Inside storage is preferred for items selected for administrative storage. If inside storage
is not available, trucks, vans, conex containers and other containers may be used.
b. Intermediate storage - 46 to 180 days. Repeat administrative storage procedures. No additional special handling is
required other than protection from damage and the elements. Place the air conditioner in a dry, covered area.
c. Long term or flyable storage - over 180 days. Repeat administrative storage procedures and the following:
(1)
(2)
(3)
(4)
Bolt the unit to a skid base; preferably the original used to ship the unit if it has been preserved.
Wrap the unit with two layers of heavy plastic sheet or barrier paper.
Tape and strap the wrapping in place.
Mark the air conditioner per standard Army, Navy, or Air Force procedures.
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CHAPTER 5
DIRECT SUPPORT MAINTENANCE
Section I. REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
5-1. COMMON TOOLS AND EQUIPMENT. For authorized common tools and equipment, refer to the Modified Table
of Organization and Equipment (MTOE) applicable to your unit.
5-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT . No special tools are required for Direct Support
Maintenance of the air conditioner.
5-3. REPAIR PARTS. Repair parts are listed and illustrated in the Repair and Special Tools List (RPSTL), TM 9-4120381-24P, covering Unit, Direct Support, and General Support Maintenance for this equipment.
Section II. DIRECT SUPPORT TROUBLESHOOTING
5-4. GENERAL. This section contains direct support troubleshooting information for locating and correcting most of the
operating troubles which may develop in the air conditioner.
NOTE
Before you use the table, be sure you have performed all applicable PMCS (Table 4-1).
5-5. TROUBLESHOOTING. Each malfunction for the compressor is listed in Table 5-1. The malfunction is followed by
a list of tests or inspections which help to determine probable causes and corrective actions to take. All malfunctions that
may occur and all tests or inspections and corrective actions may not be listed. If a malfunction is not listed or is not
corrected by corrective action, notify your supervisor.
WARNING
· HIGH VOLTAGE
Is used in the operation of this equipment.
DEATH ON CONTACT
may result if personnel fail to observe safety precautions.
· Never work on electrical equipment unless there is another person nearby who is familiar with the operation
and hazards of the equipment and who is competent in administering first aid. When the technician is aided
by operators, he must warn them about dangerous areas.
· Whenever possible, the Input power supply to equipment must be shut off before beginning work on the
equipment. Take particular care to ground every capacitor likely to hold a dangerous potential. When
working inside the equipment, after the power has been turned off, always ground every part before touching
it.
· Be careful not to contact high-voltage connections of 208 V ac input when installing or operating this
equipment.
· Whenever the nature of the operation permits, keep one hand away from the equipment to reduce the
hazard of current flowing through vital organs of the body.
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· Do not operate the equipment without all panels and covers In place and tightly secured.
· Do not be misled by the term "low voltage." Potentials as low as 50 volts may cause death under adverse
conditions.
Table 5-1. Direct Support Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. COMPRESSOR WILL NOT START.
Step 1. Power off.
a. Check to see if circuit breaker CB1 is tripped (para 4-62) and reset circuit breaker.
b. Check main fuses and wiring (para.4-42), repair or replace as necessary.
Step 2. Current overload open.
a. Check K23 and K24 current overloads (para 5-52) in compressor (B2) electrical box for open (see Figure
FO-3.)
b. Replace current overload if K23 or K24 are open (para 5-52).
Step 3. Oil safety switch open.
Reset low oil pressure switch (S7) manually (para 5-25).
Step 4. Check for loose electrical connections or faulty wiring (para 5-50)..
Tighten connections. Check wiring and rewire if necessary.
Step 5. Compressor motor burned out.
Check and replace compressor if defective (para 5-46).
2. LOW COMPRESSOR CAPACITY OR INABILITY TO PULL DOWN SYSTEM.
Step 1. Blown valve plate or cylinder head gasket.
See malfunction 3.
Step 2. Leaky valve plates or worn valve seats.
Replace valve plate assembly (para 5-47).
Step 3. Leaky suction valves.
Replace suction valves (para 5-47).
Step 4. Broken connecting rods or pistons.
a. Replace connecting rods and pistons (para 5-49), replace if necessary.
b. Check rods, pistons, and cylinder tolerances (para 5-49).
c. Replace compressor (para 5-46) if any cylinder bore is out of tolerance.
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Table 5-1. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. BLOWN VALVE PLATE OR CYLINDER HEAD GASKETS.
Step 1. Cylinder head bolts not properly torqued.
a. Replace cylinder head gasket (para 5-47).
b. Retorque cylinder head bolts to 30-35 lb-ft.
Step 2. Liquid refrigerant floodback or flooded start. See malfunction 7.
4. COMPRESSOR CYCLES ON LOW-PRESSURE CONTROL.
Step 1. Low refrigerant pressure switch erratic in operation.
a. Check tubing to switch to see if clogged or crimped (para 5-24).
b. Check switch setting (para 5-24).
Step 2. Insufficient refrigerant in system.
Add refrigerant (para 5-17).
Step 3. Suction service valve closed.
Backseat (counterclockwise) suction service valve (para 5-34).
Step 4. Restricted air flow through condenser.
Clean condenser (para 4-90).
Step 5. Discharge service valve not fully open.
Backseat (counterclockwise) discharge service valve (para 5-33).
Step 6. Air in system.
Purge refrigerant system (para 5-13).
5. COMPRESSOR CONTINUALLY CYCLES.
Step 1. Faulty high refrigerant pressure switch.
Adjust or replace switch (para 5-23).
Step 2. Faulty low refrigerant pressure switch.
Adjust or replace switch (para 5-24).
Step 3. Faulty low oil pressure switch.
Adjust or replace switch (para 5-25).
Step 4. Condenser capacity reduced by refrigerant overcharge accompanied by high discharge pressure.
Remove overcharge (para 5-17).
Step 5. Plugged drier filter.
Replace drier filter (para 5-26).
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Table 5-1. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
6. LOW DISCHARGE PRESSURE.
Step 1. Suction service valve partially closed.
Backseat (counterclockwise) suction service valve (para 5-34).
Step 2. Leaky compressor suction valves.
Remove cylinder head, examine valves and valve seats (para 5-47), replace if necessary.
Step 3. Worn piston rings.
a. Check connecting rods pistons, and rings (para 5-49), replace if necessary.
b. Check rods, pistons, and cylinder tolerances (para 5-49).
c. If any cylinder bore is out of tolerance (para 5-49), replace compressor (para 5-46).
7. FLOODING.
Step 1. Improperly set primary expansion valve.
Adjust primary expansion valve (para 5-38).
Step 2. Improperly set liquid quench expansion valve.
Adjust liquid quench expansion valve (para 5-36).
Step 3. Improperly set hot gas bypass valve
Adjust hot gas bypass valve (para 5-37).
Step 4. Evaporator circulator fan failure.
a. Check fan belt tension (para 4-69).
b. Check evaporator motor (para 4-70).
c. Check evaporator motor fan pulleys (para 4-72 and 4-73).
d. Check evaporator circulator fan (para 4-71).
8. LOW SUCTION PRESSURE.
Step 1. Insufficient refrigerant in system.
Add refrigerant (para 5-17).
Step 2. Evaporator circulator fan failure.
a. Check fan belt tension (para 4-69).
b. Check evaporator motor (para 4-70).
c. Check evaporator motor and fan pulleys (para 4-72 and 4-73).
d. Check evaporator circulator fan (para 4-71).
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Table 5-1. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8. LOW SUCTION PRESSURE - Continued.
Step 3. Plugged drier filter.
Replace drier filter (para 5-26).
9. COMPRESSOR NOISY.
Step 1. Slugging due to floodback of refrigerant.
See malfunction 6.
Step 2. Hydraulic knock due to excess oil in circulation.
a. Remove excess compressor oil (para 5-46).
b. Recheck oil level (para 5-46).
Step 3. Bearings wiped because of loss of oil.
a. Add compressor oil (para 5-46).
b. Recheck oil level (para 5-46).
c. Check pipes for rattles and vibration (see malfunction 10).
Step 4. Compressor not firmly mounted.
Check for loose mounting hardware (para 5-46).
Step 5. Broken connecting rods or pistons.
a. Check connecting rods pistons, and rings (para 5-49), replace if necessary.
b. Check rods, pistons, and cylinder tolerances (para 5-49).
c. If any cylinder bore is out of tolerance (para 5-49), replace compressor (para 5-46).
Step 6. Broken discharge or suction valves.
Check discharge and suction valves (para 5-33 and 5-34), replace if necessary.
10. PIPE RATTLE.
Inadequately supported piping or loose pipe connections.
Support pipes or check pipe connections.
11. OIL PRESSURE LOWER THAN NORMAL OR NO OIL PRESSURE.
Step 1. Low oil charge.
a. Check compressor oil level (para 5-46).
b. Add compressor oil and recheck compressor oil level (para 5-46).
Step 2. Faulty oil pump end bearing assembly.
Replace oil pump end bearing assembly (para 5-48).
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Table 5-1. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
11. OIL PRESSURE LOWER THAN NORMAL OR NO OIL PRESSURE - Continued.
Step 3. Worn oil pump.
Replace oil pump assembly (para 5-48).
12. COMPRESSOR MOTOR PROTECTORS TRIPPING OR CYCLING
Step 1. High discharge pressure.
Check operation of condenser fan (para 4-77) and clogged condenser coil, contact General Support
Maintenance.
Step 2. Defective overload K23 or K24 relay.
Replace defective relay (para 5-52).
Step 3. High suction temperature.
Improperly set liquid quench valve (para 5-36) or hot gas bypass valve (para 5-37), adjust valves.
Step 4. Loose power or control circuit wiring connections.
Check all power and control circuit connections (Figure FO-3).
Step 5. Defective compressor motor.
Check motor windings for short to ground (see malfunction 14).
13. COMPRESSOR CYCLES ON LOCKED ROTOR.
Step 1. Low line voltage.
Check line voltage and determine location of voltage drop (para 4-13).
Step 2. Seized compressor. Remove pump end bearing assembly and attempt to rotate eccentric shaft (para 548).
Replace compressor (para 5-46) if eccentric shaft does not turn.
Step 3. Defective compressor motor.
Check motor windings for short to ground. (See malfunction 14.)
Step 4. Single phasing.
a. Check voltage across all three legs at compressor contactor K10 (para 4-51 and Figure FO-3). If incorrect,
correct source of problem.
b. Check input voltage to RFI box (para 4-42).
Step 5. Liquid refrigerant condensing in cylinder.
Check and replace valve plates (para 5-47).
5-6
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Table 5-1. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
14. MOTOR BURNOUT.
Check control box for welded starter contacts, welded overload contacts or burned out heater elements.
a. Replace crankcase heater (para 4-81), if defective.
b. Replace terminal plate (para 5-51), if defective.
c. Replace current overloads K23 and K24 (para 5-52), if defective.
NOTE
For steps d, e, and f, tag and remove all wires from terminal plate.
d. Check thermal overload (S15) for continuity. Using multimeter, measure across terminals 8 and 9 for
continuity. Replace compressor (para 5-46) if continuity is not indicated.
e. Check motor windings for short to ground. Using multimeter, measure from each terminal (1, 2, and 3) on
terminal plate (para 5-51) to ground. Replace compressor (para 5-46) if any measurement has continuity.
f. Check motor windings resistance. Using multimeter, measure across terminalsl-2, 2-3, and 1-3 (para 5-51)
for less than 10 ohms. If any measurement is greater than 10 ohms, replace compressor (para 5-46).
15. COMPRESSOR RUNNING HOT.
Step 1. Blown valve plate head gasket.
Replace gasket (para 5-47), if defective.
Step 2. Broken suction or discharge valve.
Replace valves and valve plate (para 5-47), if defective.
Step 3. Compression ratio too high.
a. Check setting of high (para 5-23) and low (para 5-24) pressure switches.
b. Clean condenser coil (para 4-90).
c. Check that evaporator motor (para 4-70) and condenser motor (para 4-76) are operating properly.
5-7
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section III. DIRECT SUPPORT MAINTENANCE PROCEDURES
Para
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
5-16
5-17
5-18
5-19
5-20
5-21
5-22
5-23
5-24
5-25
5-26
5-27
5-28
5-29
5-30
5-31
5-32
5-33
5-34
5-35
5-36
5-37
5-38
5-39
5-40
5-41
5-42
5-43
5-44
Title
Page
General ................................ ................................ ................................ ..............................
5-9
Panels and Information Plates................................ ................................ .............................
5-9
Evaporator Motor (B1) ................................ ................................ ................................ ...............5-11
Condenser Motor (B3)................................ ................................ ................................ .........
5-14
Refrigeration System, General Repairs ................................ ................................ ..............
5-17
Service Manifold Installation ................................ ................................ ..............................
5-18
Discharging Refrigeration System ................................ ................................ ......................
5-20
Purging Refrigerant System ................................ ................................ ...............................
5-22
Brazing/Debrazing Procedures ................................ ................................ ...........................
5-24
Leak Testing Refrigerant System ................................ ................................ ........................
5-26
Evacuating Refrigerant System ................................ ................................ ..........................
5-28
Charging Refrigerant System ................................ ................................ .............................
5-31
Refrigerant Pressure Check ................................ ................................ ...............................
5-34
Discharging Compressor................................ ................................ ................................ .....
5-37
Purging Compressor ................................ ................................ ................................ ..........
5-39
Pump Down ................................ ................................ ................................ .......................
5-41
Start Up After Repairs ................................ ................................ ................................ ........
5-43
High Refrigerant Pressure Switch (S4) ................................ ................................ ...............
5-45
Low Refrigerant Pressure Switch (S5) ................................ ................................ ................
5-48
Low Oil Pressure Switch (S7) ................................ ................................ .............................
5-51
Drier Filter (Dehydrator) ................................ ................................ ................................ .....
5-54
Refrigerant Strainer ................................ ................................ ................................ ............
5-57
Sight Refrigerant Glass ................................ ................................ ................................ ......
5-59
Service Valves (Head and Hot Gas Bypass) ................................ ................................ .......
5-61
Service Valve (Expansion) ................................ ................................ ................................ .
5-63
Service Valve (Actuator) ................................ ................................ ................................ ....
5-65
Service Valves (Schrader) ................................ ................................ ................................ .
5-67
Discharge Valve (Compressor) ................................ ................................ ...........................
5-69
Suction Valve (Compressor) ................................ ................................ ...............................
5-71
Solenoid Valves (L1 and L2) ................................ ................................ ..............................
5-73
Thermostatic Expansion Valve (Liquid Quench) ................................ ................................ .
5-75
Hot Gas Bypass Valve ................................ ................................ ................................ .......
5-79
Thermostatic Expansion Valve (Primary) ................................ ................................ ...........
5-83
Manual Valve (Bypass) ................................ ................................ ................................ ......
5-86
Vibration Eliminators ................................ ................................ ................................ ..........
5-88
Condenser Fan Damper Actuator................................ ................................ ........................
5-90
Receiver ................................ ................................ ................................ ............................
5-93
Distributor ................................ ................................ ................................ ..........................
5-95
Pressure Regulator Valve ................................ ................................ ................................ ...
5-96
5-8
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Para
5-45
5-46
5-47
5-48
5-49
5-50
5-51
5-52
5-53
5-54
Title
Tubing and Fittings ................................ ................................ ................................ ....
Compressor ................................ ................................ ................................ ..............
Valve Plate Assembly ................................ ................................ ...............................
Pump End Bearing Assembly ................................ ................................ ....................
Crankshaft, Pistons and Rods ................................ ................................ ...................
Electrical Box Assembly ................................ ................................ ............................
Terminal Plate ................................ ................................ ................................ ...........
Current Overloads (K23 and K24) ................................ ................................ .............
Condenser Coil ................................ ................................ ................................ .........
Evaporator Coil ................................ ................................ ................................ .........
Page
5-100
5-101
5-109
5-111
5-113
5-118
5-120
5-123
5-125
5-127
5-6.
GENERAL. This section contains maintenance procedures which are authorized to Direct Support Maintenance
(F) by the Maintenance Allocation Chart (MAC) Appendix B and Source, Maintenance and Recoverability (SMR) coded
items. Each paragraph covers a complete maintenance procedure but may require other tasks to be included (i.e. initial
setups, references and follow on procedures). Perform procedures/tasks in designated order.
5-7.
PANELS AND INFORMATION PLATES.
following paragraphs:
For removal, inspection, cleaning, and installation, refer to the
a. Center Front Evaporator Panel. Refer to paragraph 4-22.
b. Left Front Evaporator Panel. Refer to paragraph 4-23.
c. Right Front Evaporator Panel. Refer to paragraph 4-25.
d. Information Plates. Refer to paragraph 4-26.
e. Left Front Condenser Panel. Refer to paragraph 4-27.
f. Right Front Condenser Panel. Refer to paragraph 4-28.
g. Front Service Valve Panel. Refer to paragraph 4-29.
h. Left Electric Plate. Refer to paragraph 4-30.
i. Right Electric Plate. Refer to paragraph 4-31.
j. Repair. Repairs are limited to straightening of minor dents, rewelding of broken welds, installation of loose or
missing rivets and rivnuts, replacement of quarter turn receptacles, replacement of loose or missing bushing,
grommets, gaskets and insulation, paint touch up, and replacement of damaged or missing information plates.
(1) Minor Dents. Repair minor dents using standard sheet metal repair practices.
(2) Broken Welds. Repair broken welds using standard weld repair practices.
(3) Rivets. To replace loose or missing rivets, drill old rivet out using a drill bit slightly smaller than the
diameter of old rivet body, and install replacement rivet.
(4) Rivnuts. To replace loose or missing rivnuts, drill old rivnut out using a drill bit slightly smaller than the
diameter of the old rivnut body, and install replacement rivnut.
(5) Quarter Turn Receptacles. To replace or repair quarter turn receptacles, drill old rivet out using a drill bit
slightly smaller than the diameter of old rivet body, and install replacement receptacle.
5-9
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
(6) Bushing arid Grommets. Replace or repair damaged bushings or grommets using standard electricians
repair practices.
(7) Gasket/Insulation. To replace or repair gasket or insulation:
(a) Remove as much old gasket or insulation material as possible by pulling or scraping it away from the
metal surface.
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be
explosive. Repeated or prolonged skin contact or inhalation of vapors can be toxic.
Use a well ventilated area, wear gloves, and keep away from sparks or flame.
(b) Soften and remove old adhesive, gasket and insulation residue, using acetone or MEK and a stiff
brush.
(c) Starting with an end, carefully attach the gasket to the metal. Press into firm contact all over.
(8) Touch Up. Should touch up or refinishing be necessary, refer to TM 43-0139, Painting Instructions for
Field Use.
(9) Information Plates. To replace damaged or missing information plates, drill rivets out using a drill bit
slightly smaller than the diameter of the rivet body, and secure new information plate with replacement
rivets.
5-10
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-8.
EVAPORATOR MOTOR (B1).
This task covers:
Disassembly
Repair
Reassembly
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
File, hand (Item 22, Appendix B)
Personnel: 1
Materials:
Grease aeroshell 22 (Item 2, Appendix E)
Rags (Item 12, Appendix E)
Equipment Conditions:
Remove evaporator motor (para 4-70).
DISASSEMBLY
1.
2.
3.
Remove three screws (17) (see Figure 5-1).
Remove fan shield (1) from end cap (5).
Loosen fan clamp screw (16).
CAUTION
Plastic fan is very fragile. Be careful not to break fan when prying clamp open and prying fan off
the shaft.
4.
5.
6.
7.
Pry open clamp (3).
Remove plastic fan (2) by prying off shaft.
Match-mark motor frame (8) and end caps (5) and (13).
Remove four end cap nuts (12) and through bolts (4).
CAUTION
When removing end caps, rotor will be freed. Damage to rotor could occur if rotor is dropped while
removing end caps from motor.
8.
9.
10.
11.
12.
13.
Remove end caps (5) and (13).
Carefully pull rotor (15) from the motor frame (8).
Identify location of two wavy spring washers (7) and bearing spacer washer (6).
Carefully remove small bearing (10) from fan end of shaft (9).
Carefully remove large bearing (11) from shaft end (14).
Examine rotor (15), stator and housing (8), and shafts for nicks, gouges, deformations, or evidence of
overheating.
REPAIR
Dress high metal defects in shaft with a file. If rotor or stator are beyond repair, replace motor.
5-11
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-8.
EVAPORATOR MOTOR (B1) - Continued.
Figure 5-1. Evaporator Motor (B1)
5-12
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
REASSEMBLY
1.
2.
3.
4.
Coat the bearing cavity of end caps (5) and (13) with grease.
Install small bearing (10) to fan end of shaft (9).
Install large bearing (11) to shaft end (14).
Insert bearing washer (6) and two wavy spring washers (7).
CAUTION
Damage to rotor could occur if rotor is dropped.
5.
6.
7.
8.
9.
10.
11.
Carefully insert rotor (15) with small bearing (10) and large bearing (11) into motor frame (8).
Carefully work end caps (5) and (13) onto shaft ends keeping the match-marks in alignment.
Install four through bolts (4) through end caps (5) and (13).
Partially tighten four through bolts (4) with end cap nuts (12).
Before final tightening, check freedom of rotation by turning shaft by hand. There should be no drag or binding.
Alternately tighten nuts (12) and adjust as necessary.
Check for binding and drag.
CAUTION
Plastic fan is very fragile. Be careful not to break fan when installing fan onto shaft.
12.
13.
Install plastic fan (2) onto shaft.
Tighten clamping screw (16).
NOTE
Align the large hole on fan shield with grease fitting.
14.
Install fan shield (1) and secure with three screws (17).
FOLLOW ON PROCEDURE
Install evaporator motor (para 4-70).
5-13
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-9.
CONDENSER MOTOR (B3).
This task covers:
Disassembly
Repair
Reassembly
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
File, hand (Item 22, Appendix B)
Personnel: 1
Materials:
Grease aeroshell 22 (Item 2, Appendix E)
Rags (item 12, Appendix E)
Equipment Conditions:
Remove condenser motor (para 4-76).
DISASSEMBLY
1. Remove three screws (16) (see Figure 5-2).
2. Remove fan shield (1) from end cap (5).
3. Loosen clamping screw (15) .
CAUTION
Plastic fan is very fragile. Be careful not to break fan when prying clamp open and prying fan off the shaft.
4.
5.
6.
7.
Pry open clamp (3)
Remove plastic fan (2) by prying off shaft.
Match-mark motor frame (7) and end caps (5) and (12).
Remove four end cap nuts (11) and through bolts (4).
CAUTION
When removing end caps, rotor will be freed. Damage to rotor could occur if rotor is dropped while
removing end caps from motor.
8.
9.
10.
11.
12.
13.
Remove end caps (5) and (12).
Carefully pull rotor (14) from the motor frame (7).
Identify location of two wavy spring washers (6).
Carefully remove small bearing (9) from fan end of shaft (8).
Carefully remove large bearing (10) from shaft end (13).
Examine rotor (14), stator and housing assembly (7), and shafts for nicks, gouges, deformations, or evidence of
overheating.
REPAIR
Dress high metal defects in shaft with a file. If rotor or stator are beyond repair, replace motor.
5-14
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure 5-2. Condenser Motor (B3)
5-15
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-9.
CONDENSER MOTOR (B3)-Continued.
REASSEMBLY
1.
2.
3.
4.
Coat the bearing cavity of end caps (5) and (12) with grease.
Install small bearing (9) on fan end of shaft (8).
Install large bearing (10) on shaft end (13).
Insert two wavy spring washers (6) into end cap (5).
CAUTION
Damage to rotor could occur if rotor is dropped.
5.
6.
7.
8.
9.
10.
11.
Carefully insert rotor (14) with small bearing (9) and large bearing (10) into motor frame (7).
Carefully work end caps (5) and (12) onto shaft ends keeping the match-marks in alignment.
Install four through bolts (4) through end caps (5) and (12).
Partially tighten four through bolts (4) with end cap nuts (11).
Before final tightening, check freedom of rotation by turning shaft by hand. There should be no drag or binding.
Alternately tighten nuts (11) and adjust as necessary.
Check for binding and drag.
CAUTION
Plastic fan is very fragile. Be careful not to break fan when installing fan onto
shaft.
12. Install plastic fan (2) onto shaft.
13. Tighten fan clamping screw (15).
NOTE
Align the large hole on fan shield with grease fitting.
14. Install fan shield (1) and secure with three screws (16).
FOLLOW ON PROCEDURE
Install condenser motor (para 4-76).
5-16
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-10.
EVAPORATOR MOTOR (B1).
This task covers: Service
INITIAL SETUP
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Personnel: 1
WARNING
DANGEROUS CHEMICAL (R-22) is used in this equipment.
DEATH
or severe damage may result if personnel fail to observe safety precautions. Use great care to avoid
contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break down and form
carbonyl chloride (phosgene), a highly poisonous and corrosive gas.
REFRIGERANT UNDER PRESSURE
is used in the operation of this equipment.
DEATH
or severe Injury may result if you fall to observe safety precautions. Never use a heating torch on
any part that contains R-22 refrigerant. Do not let liquid refrigerant touch you, and do not Inhale
refrigerant gas.
REPAIR
1. The refrigeration system must be totally discharged before performing any maintenance action that requires
opening of the pressurized system (para 5-12).
2. The drier filter replacement and leak testing are required after any system component has been removed and replaced (para 5-26 and para 5-15).
3. The system must be evacuated before it is charged (para 5-16).
4. The system must be properly charged to function properly (para 5-17).
5-17
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-11.
SERVICE MANIFOLD INSTALLATION
This task covers:
Service
INITIAL SETUP
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal
maintenance. Voltages used can KILL. Shutting the unit off at the control panel
does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
SERVICE
WARNING
Death or serious injury may result if personnel fail to observe safety precautions.
Use great care to avoid contact with liquid refrigerant or refrigerant gas being
discharged under pressure. Sudden and irreversible tissue damage can result from
freezing. Wear thermal protective gloves and a face protector or goggles in any
situation where skin-eye-contact is possible.
Prevent contact of refrigerant gas with flame or hot surfaces. Heat causes the
refrigerant to break down and form carbonyl chloride (phosgene), a highly poisonous
and corrosive gas.
1.
2.
3.
4.
5.
6.
7.
8.
Remove protective caps (Figure 5-3) from high and low pressure service valve stems.
Insure service valves for manifold are closed, then remove caps from service ports.
Remove blue and red hoses from service manifold hose rack.
Connect blue hose to low pressure service valve and red hose to high pressure service valve.
Open high and low pressure service valves.
Loosen blue hose at compound gauge port and allow refrigerant to purge for 3-5 seconds, then tighten.
Loosen red hose at pressuregauge port and allow refrigerant to purge for 3-5 seconds, then tighten.
The service manifold is now installed, purged and ready for test or maintenance operations.
FOLLOW ON PROCEDURE
1. When all testing is complete, install right front condenser panel (para 4-28).
2. Connect air conditioner input power at source.
5-18
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure 5-3. Service Manifold Installation
5-19
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-12.
DISCHARGING REFRIGERATION SYSTEM.
This task covers:
Service
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Recovery and Recycling Unit, Refrigeration (Item 26, Appendix B)
Pail, utility (Appendix C)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Equipment Condition:
Service manifold installed (para 5-11)
NOTE
In accordance with Environmental Protection Agency regulations, refrigerants cannot be
discharged into the atmosphere. A refrigerant recovery and recycling unit must be used
whenever discharging the refrigerant system. Operation of the recovery/recycling unit
must be by AUTHORIZED PERSONNEL ONLY.
SERVICE
WARNING
Death or serious injury may result if personnel fail to observe safety precautions.
Use great care to avoid contact with liquid refrigerant or refrigerant gas being
discharged under pressure. Sudden and irreversible tissue damage can result from
freezing. Wear thermal protective gloves and a face protector or goggles in any
situation where skin-eye-contact is possible.
Prevent contact of refrigerant gas with flame or hot surfaces. Heat causes the
refrigerant to break down and form carbonyl chloride (phosgene), a highly poisonous
and corrosive gas.
CAUTION
•
Do not permit the oil to escape from the unit. If oil is escaping, close the valve(s)
slightly to prevent possible oil loss.
•
Do not permit the refrigerant to escape fast enough to form ice or frost on either the
lines or the valve(s) to prevent possible damage to system.
5-20
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Connect and operate recovery/recycling unit in accordance with the manufacturer’s instructions.
Figure 5-4. Discharging Refrigeration System
5-21
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-13.
PURGING REFRIGERANT SYSTEM.
This task covers: Service
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Goggles, industrial (Appendix C)
Nitrogen regulator (Item 25, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Material:
Nitrogen (Item 14, Appendix E)
Equipment Conditions:
1. Install service manifold (para 5-11 steps 1 thru 5.)
2. Discharge system (para 5-12).
SERVICE
WARNING
Death or serious injury may result if personnel fail to observe safety precautions. Use great care to
avoid contact with liquid refrigerant or refrigerant gas-being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break down and form
carbonyl chloride (phosgene), a highly poisonous and corrosive gas.
CAUTION
Nitrogen cylinders are pressurized containers. The pressure in the cylinder can exceed 2000 psi. A
nitrogen pressure regulator should be used at all times when nitrogen is used for leak check or purge
operations. Do not allow nitrogen pressure regulator setting to exceed 200 psig during purging.
Nitrogen is an inert gas. However, it also presents danger as a suffocant and, therefore, must also
be discharged in a ventilated location.
NOTE
The refrigeration system must be purged with dry nitrogen before any brazing or debrazing is performed
on any component.
5-22
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
1. If system was pumped down, connect manifold red hose to expansion service valve (para 5-30).
2. Connect yellow 1/4 inch (0.64 cm) charging hose (Figure 5-5) from charge port to nitrogen regulator and dry
nitrogen cylinder.
3. Loosen low pressure hose (blue) at compound gauge port of service manifold.
4. Open pressure gauge valve (PGV) on service manifold.
5. Open charging valve (CV) on service manifold.
6. Open the nitrogen cylinder valve and adjust the regulator so that less than 1-2 cfm (0.028-0.057 m3/minute) of
nitrogen flow rate is established.
7. Check to insure that nitrogen is flowing from loosened hose at compound gauge port of service manifold.
8. Allow nitrogen to sweep through the system for a minimum of 5 minutes before brazing or debrazing operations
are started; continue sweep during the operation and for 5 minutes after completion.
9. Close nitrogen cylinder valve, service manifold valves and high and low pressure service valves on the unit.
10. Disconnect hose from nitrogen regulator and return it to hose rack.
11. Assuming that all repairs are completed, go to Leak Testing the Refrigerant System (para 5-15).
Figure 5-5.
Purging Refrigerant System
5-23
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-14.
BRAZING, DEBRAZING PROCEDURES.
This task covers: Service
INITIAL SETUP
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Goggles, industrial (Appendix C)
Nitrogen regulator (Item 25, Appendix B)
Personnel: 1
Materials:
Rags (Item 12, Appendix E)
Nitrogen (Item 14, Appendix E)
Brazing alloy, silver (Item 21, Appendix E)
Brazing flux (Item 19, Appendix E)
Abrasive cloth (part of Item 1, Appendix B)
Equipment Conditions:
1. Discharge refrigerant system (para 5-12).
2. Purge system with nitrogen (para 5-13).
SERVICE
WARNING
All refrigerant-22 must be discharged from the system and the entire system must be purged with dry
nitrogen before beginning any debrazing operation. The polyurethane foam used as insulation in the
air conditioner will break down to form toxic gases if exposed to the flame of a torch at brazing
temperature.
NOTE
Grade IV or VI brazing alloy and Type B flux, as specified in MIL-B-7883, must be used for all copper to brass joints.
Grade III brazing alloy may be substituted for Grade IV or VI for copper to copper joints; flux is not required for copper to
copper joints.
All tubing in the refrigeration system is seamless copper with a bright internal finish that permits thorough cleaning and
prevents entrapment of moisture and other impurities. Rigid grade copper is used for straight sections and soft grade for
sections that must be bent. All interconnecting fittings, such as elbows, tees, etc., are also copper. The bodies of all
valves and all connections on other components are brass. All joints, except those provided with flare fittings, are made
by brazing in accordance with MIL-B-7883, except that radiographic examination is not required.
5-24
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1. Debrazing. Debraze joints for removal of refrigeration system components as follows:
a. Determine which joints are to be debrazed. Due to the limited work space inside the air conditioner, it may
be more convenient to remove a part of the interconnecting tubing with the component rather than
debrazing the joint on the component itself.
b. Before debrazing a joint on a valve, disassemble the valve to the extent possible, then wrap all but the
joint with a wet rag to act as a heat sink.
c. Protect insulation, wiring harnesses, cabinet, and other surrounding components with appropriate shields.
d. Be sure the work area is well ventilated and that dry nitrogen is flowing through the refrigeration system at
a rate of less than 1-2 cfm (0.028-0.057 m3/minute) (para 5-13).
e. Apply sufficient heat uniformly around the joint to quickly melt the filler alloy. If heat is applied slowly, or
only on one side, the entire component or length of tubing will be heated and filler alloy in adjacent joints
may also be melted. Remove heat as soon as the joint separates.
2. Cleaning Debrazed Joints. All filler alloy must be cleaned from debrazed joints before reassembly. Heat each
piece of the joint until the filler alloy is melted and then wipe it away with a damp cloth. Be sure no filler alloy or
other debris is left inside any tubing, fitting, or component.
3. Reassembly. If tubing sections or fittings were removed with a component, debraze them from the component,
clean the joints, and braze them to the new component before reinstallation.
4. Brazing. Braze joints within the air conditioner as follows:
a. Position the component to be installed.
b. To prepare a joint on a valve for brazing, disassemble the valve to the extent possible, then wrap all but
the joint with a wet rag to act as a heat sink.
c. Protect insulation, wiring harnesses, and surrounding comments with appropriate shields.
d. Be sure the work area is well ventilated and that dry nitrogen is flowing through the refrigeration system at
a rate of less than 1-2 cfm (0.028-0.057 m3/minute).
e. Apply sufficient heat uniformly around the joint to quickly raise it to a temperature that will melt the filler
alloy. Remove the heat as soon as brazing is completed.
f. Allow to cool. Reassemble the valve.
5. Leak test the repair and surrounding area (para 5-15).
5-25
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-15.
LEAK TESTING REFRIGERANT SYSTEM.
This task covers: Service
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Personnel: 1
Materials:
Nitrogen, technical (Item 14, Appendix E)
Rags (Item 12, Appendix E)
Refrigerant-22 (Item 11, Appendix E)
Equipment Conditions:
1. Install service manifold (para 5-11 steps 1 thru 5).
2. Purge refrigerant system (para 5-13).
SERVICE
WARNING
Death or serious injury may result if personnel fail to observe safety precautions. Use great care to
avoid contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible. Prevent contact of
refrigerant gas with flame or heat surfaces. Heat causes the refrigerant to break down and form
carbonyl chloride (phosgene), a highly poisonous and corrosive gas.
CAUTION
Nitrogen cylinders are pressurized containers. The pressure in the cylinder can exceed 2000 psi. A
nitrogen pressure regulator should be used at all times when nitrogen is used for leak check or purge
operations. Do not allow nitrogen pressure regulator setting to exceed 200 psig during purging.
Nitrogen is an inert gas. However, it also presents danger as a suffocant and, therefore, must also
be discharged in a ventilated location.
5-26
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AIR FORCE TO 35E9-136-31
NOTE
The entire repaired area should be thoroughly leak tested after repair or replacement of
any component before it is recharged with refrigerant-22. Leak testing is also the
method for troubleshooting when a system has lost all or part of its refrigerant charge
through an undetermined cause.
1. Open compound and pressure gauges. If system pressure is 50 psig or higher, proceed to step 6; if not,
continue with step 2.
2. Disconnect nitrogen cylinder and connect yellow hose to R-22 cylinder.
3. Open R-22 cylinder valve and let purge for 3-5 seconds.
4. Open CV and PGV and allow refrigerant to enter system until compound and pressure gauges indicate a
minimum pressure of 50 psig, then close CV.
5. Close R-22 refrigerant cylinder valve and remove yellow manifold hose.
6. Install yellow hose to nitrogen cylinder (para 5-13).
7. Open nitrogen cylinder valve and adjust regulator to a pressure 10 psi greater than system pressure.
8. Loosen 1/4 inch (0.64 cm) yellow hose at charge port and purge for 3-5 seconds, then tighten.
9. Open charge valve and adjust nitrogen regulator to slowly raise command and pressure gauge reading to 300
psig.
10. Using a halon leak detector, check all fittings, connections and components in surrounding area for leaks. Insure
pressure remains at 300 psig by adding more nitrogen if necessary.
11. Close CV and nitrogen cylinder valve.
12. Open VPV and bleed pressure out of lines.
13. Remove yellow hose from nitrogen regulator and connect to service manifold hose rack.
14. Always perform a final leak test before the air conditioner is reassembled and the refrigeration system is
evacuated and charged.
5-27
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-16.
EVACUATING REFRIGERANT SYSTEM.
This task covers: Service
INITIAL SETUP:
Tools:
Tool, kit, service, refrigeration unit (Item 1, Appendix B)
Pump, vacuum (part of Item 1, Appendix B)
Gloves, chemical (Appendix C) Goggles, industrial (Appendix C)
Personnel: 1
Materials:
R-22 Refrigerant cylinder (Item 11, Appendix E)
Rags (Item 12, Appendix E)
Equipment Conditions :
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltage
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Install service manifold (para 5-11).
SERVICE
WARNING
Death or serious injury may result if personnel fail to observe safety precautions. Use great care to
avoid contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break down and form
carbonyl chloride (phosgene), a highly poisonous and corrosive gas.
CAUTION
Do not evacuate a leaking system. The vacuum created can cause air, moisture, and dirt to enter
system.
NOTE
•
The refrigeration system must be evacuated to remove all moisture before it is charged with R-22
refrigerant.
•
•
Check that system was leak tested and has no leaks (para 5-15).
If compressor was replaced as result of a burn out, check that compressor burn out procedures were
followed (para 5-46).
5-28
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-16.
EVACUATING REFRIGERANT SYSTEM.
Figure 5-6. Evacuating Refrigerant System
5-29
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Check that new drier filter was installed. If not, install one (para 5-26).
Check that both charging manifold valves are closed.
Remove yellow 3/8 inch (0.95 cm) hose from hose rack and connect to vacuum pump.
Remove 1/4 inch (0.64 cm) yellow hose from hose rack and connect to R-22 refrigerant cylinder positioned for
dispensing gas.
Open R-22 refrigerant cylinder and loosen 1/4 inch (0.64 cm) yellow hose at charge port and purge for 3-5
seconds, then tighten.
Open VPV, CGV, and PGV.
Start vacuum pump and open ballast valve (on vacuum pump) one turn.
Observe gauge reading on vacuum pump for reading of 29-30 Hg vacuum.
Close VPV and open CV and add refrigerant until compound and pressure gauges read approximately 2 psig
(4.41 kg), then close CV.
Stop vacuum pump and close ballast valve.
Allow refrigerant to remain in system for one hour.
NOTE
Refrigerant will act as a blotter for moisture. One hour is recommended time for maximum moisture
removal. Shorter blotting period could be used if it is known that system is relatively dry.
12.
13.
14.
15.
16.
17.
18.
19.
Open VPV.
Repeat steps 7 thru 11.
Open VPV.
Repeat steps7 thru 11.
Close VPV and OGV.
Stop vacuum pump and close ballast valve.
Disconnect hose from vacuum pump and return it to rack.
Charge refrigeration system (para 5-17).
5-30
ARMY TM 9-4120-381-14
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5-17.
CHARGING REFRIGERANTSYSTEM.
This task covers: Service
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Recovery and Recycling Unit, Refrigeration (Item 26, Appendix B)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Personnel: 1
Materials:
R-22 Refrigerant cylinder (Item 11, Appendix E)
Rags (Item 12, Appendix E )
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance.Voltage
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front evaporator panel (para 4-25).
SERVICE
WARNING
Death or serious injury may result if personnel fail to observe safety precautions. Use great care to
avoid contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible.
Prevent contact of refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly poisonous and corrosive gas.
1. After system has been satisfactorily evacuated, it must be fully charged with R22 refrigerant.
CAUTION
Never introduce liquid refrigerant Into the low pressure (suction, service) valve. Compressor damage
may result.
NOTE
The system must be evacuated before charging. Use only R-22 refrigerant to charge unit. Whenever
available, use recycled refrigerant for charging the refrigeration system.
2. Check that service manifold is connected (para 5-11).
3. Check that 1/4 (0.64 cm) inch yellow hose is connected to R-22 refrigerant cylinder.
5-31
ARMY TM 9-4120-381-14
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5-17.
CHARGING REFRIGERANT SYSTEM-Continued.
SERVICE-Continued.
4. Position R-22 refrigerant cylinder so that liquid will be dispensed.
5. Place cylinder on accurate scale, measure and record weight of cylinder.
6. Open CV, VPV, and OGV. Allow liquid refrigerant to enter system until the drum weight has decreased by 22
pounds (9.99 kg) or until system pressure has equalized with cylinder pressure.
7. Close CGV. NOTE If system pressure equalized prior to admitting a complete charge, proceed to step 8.
NOTE
If system pressure equalized prior to admitting a complete charge proceed to step 8.
8. Position refrigerant cylinder so that gas only will be dispensed.
9. If air conditioner is set up for single mode of operation, proceed to steps 10 and 11. If air conditioner is set up for
remote operation proceed to step 13.
10. Set cool control thermostat (para 4-87) to lowest temperature setting.
11. Connect air conditioner input power at source.
12. Turn MODE SELECT SWITCH to COOL mode.
Figure 5-7.
Charging Refrigerant System
5-32
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13. Open CGV and monitor weight of refrigerant cylinder as compressor draws additional refrigerant into system.
14. Close CGV when complete charge weight has been admitted.
15. Perform pressure check and repeat steps 14 and 15, if necessary (para 5-18)
16. After 15 minutes, observe sight glass (para 5-28).
a. Milky white or bubbly liquid means system has a low charge.
NOTE
Bubbles may be visible at temperatures less than 70°F (21°C) or greater than 100°F (38°C).
b. Clear bubble-free liquid means system is fully charged.
17. If charge is low add gas refrigerant.
a. Be sure that drum is switched to gas position.
b. Open CGV
c. Continue to charge until sight glass is clear and bubble free.
d. Close CGV.
18. Check air conditioner for proper cooling.
evaporator discharge air and inlet air.
There should be at least a 15° temperature difference between
19. Disconnect air conditioner input power at source.
20. Turn mode selector switch to OFF.
21. Close all manifold valves.
22. Disconnect manifold hoses from service valves, R-22 cylinder, and attach them to hose rack.
FOLLOW ON PROCEDURE
1. Install right front condenser panel (para 4-28).
2. Install right front evaporator panel (para 4-25).
3. Connect air conditioner input power at source.
4. Set MODE SELECT SWITCH to system configuration. (AUTO or REMOTE).
5-33
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
5-18.
REFRIGERANT PRESSURE CHECK..
This task covers: Service
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Goggle, industrial (Appendix C)
Personnel: 1
SERVICE
WARNING
Death or serious injury may result if personnel fail to observe safety precautions. Use great care to
avoid contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break down and form
carbonyl chloride (phosgene), a highly poisonous and corrosive gas.
1. Except in cases where it is obvious that the refrigerant charge has been lost, the first step in troubleshooting
problems in the refrigeration system should be to check discharge and suction pressures under operating
conditions.
2. Check pressures as follows:
a. Turn mode selector switch to OFF.
b. Connect service manifold (para 5-11).
c. Both gauges should read the same. Check the reading with the appropriate column in Table 5-2. If the
system is even partially charged, the pressure should be approximately equal to that shown in the table for
the appropriate ambient temperature. If the pressure is considerably less than shown in the table, the
system does not contain enough refrigerant to continue the pressure check; go to leak testing (para 5-15).
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance or adjusting
thermostat. Voltages used can KILL. Shutting the unit off at the control panel does not disconnect unit
power.
d. Disconnect air conditioner input power at source.
e. Open left electric plate (para 4-30).
NOTE
If air conditioner is configured for dual operation, jumper wires need to be installed for single mode
operation refrigerant testing.
f. Install jumper wires to TB2 (para 4-61) for single mode operation. (See Figure FO-3)
5-34
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Table 5-2.
Pressure-Temperature Relationship of Saturated R-22 Refrigerant
5-35
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5-18.
REFRIGERANT PRESSURE CHECK-Continued.
SERVICE-Continued
g.
h.
i.
j.
k.
Open manual service valve (para 5-39).
Adjust cool control thermostat (para 4-87) to lowest temperature setting.
Connect air conditioner input power at source.
Turn MODE SELECT SWITCH to COOL mode.
With unit operating, allow gauges to stabilize. Take readings of the two gauges.
(1) If discharge and suction pressures are at, or near, same value, a pressure equalizer solenoid valve malfunction
or an internal compressor failure is indicated.
(2) If discharge pressure is low and suction pressure is normal, (refer to Table 5-3), a low refrigerant charge is
indicated.
(3) If discharge pressure is normal and suction pressure is either high or low, failure or maladjustment of the
pressure regulator valve or expansion valve is indicated.
(4) If discharge pressure is high and suction pressure is normal, a malfunction of the condenser fan, refrigerant
overcharge, or clogged filter drier is indicated.
I.
m.
n.
o.
When pressure tests are completed, proceed with maintenance action indicated.
Turn mode switch to OFF.
Disconnect air conditioner input power at source.
Remove jumper wires installed in step f.
FOLLOW ON PROCEDURE
1. Reset cool control thermostat (para 4-87).
2. Close left electric plate (para 4-30).
3. Remove service manifold hoses from service valves.
4. Install protective caps (para 5-11) to high and low pressure service valve stems.
5. Connect air conditioner input power at source.
Table 5-3.
Normal Operating Pressures (In Full Cooling Mode)
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5-19.
DISCHARGING COMPRESSOR.
This task covers: Service
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Personnel: 1
Equipment Conditions :
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
SERVICE
WARNING
Death or serious injury may result if personnel fail to observe safety precautions. Use great care to
avoid contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible. Prevent contact of
refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break down and form
carbonyl chloride (phosgene), a highly poisonous and corrosive gas.
1. Remove discharge and suction gauge caps.
2. Connect service manifold high pressure hose (red) to compressor discharge valve.
3. Connect service manifold low pressure hose (blue) to compressor suction valve.
4. Frontseat (clockwise) compressor suction service valve.
5. Frontseat (clockwise) compressor discharge service valve.
6. Discharge compressor (para 5-20, steps 2-6).
7. Remove service manifold hoses from compressor.
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AIR FORCE TO 35E9-136-31
5-19.
DISCHARGING COMPRESSOR - Continued.
Figure 5-8. Discharging Compressor
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-20.
PURGING COMPRESSOR.
This task covers:
Service
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
SERVICE
WARNING
Death or serious injury may result if personnel fail to observe safety precautions. Use great care to
avoid contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible.
Prevent contact of refrigerant gas with flame or hot surfaces. Heat causes the refrigerant to break
down and form carbonyl chloride (phosgene), a highly poisonous and corrosive gas.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Check that discharge and suction valves are frontseated (clockwise).
Remove discharge and suction gauge port caps.
Connect service manifold low pressure hose (blue) to compressor suction valve gauge port.
Connect service manifold high pressure hose (red) to compressor discharge valve gauge port.
Connect yellow 1/4 inch (0.64 cm) hose to R-22 refrigerant cylinder.
Open CV, CGV, and VPV. Let refrigerant flow out into container port for 30 seconds.
Turn CV slowly to reduce pressure of escaping refrigerant.
Close CGV while refrigerant is escaping.
Backseat (counterclockwise) suction and discharge service valves.
Close R-22 refrigerant valve.
Remove all service manifold hoses and return to manifold rack.
Install discharge and suction valve protective caps.
5-39
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-20.
PURGING COMPRESSOR - Continued.
Figure 5-9. Purging Compressor
5-40
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
5-21.
PUMP DOWN.
This task covers:
Service
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Goggles, industrial (Appendix C)
Gloves, chemical (Appendix C)
Personnel: 1
Equipment Condition:
Remove right front condenser panel (para 4-28).
SERVICE
1. Turn mode switch to OFF.
2. Remove suction, discharge, head, and hot gas bypass protective caps.
3. Backseat (counterclockwise) suction and discharge valves (paras 5-33 and 5-34).
WARNING
Death or serious injury may result if personnel fail to observe safety precautions. Use great care to
avoid contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible.
4. Connect service manifold to compressor suction and discharge valve (para 5-19, steps 3 and 4).
5. Crack suction valve so gauge will function .(see Figure 5-10).
6. Frontseat (clockwise) head and hot gas bypass service valves (see Figure 5-18).
CAUTION
Never pump the system down below 1 to 2 lbs gauge pressure. A slight positive pressure should always
be left in the system. This prevents air and system damaging moisture from being drawn in thru very
small leaks.
Never pump the system down to a vacuum and then open to atmosphere. A vacuum in the lines, when
opened, would fill the system with air carrying undesirable amounts of moisture into the system.
WARNING
High voltage Is used In operation of this equipment. DEATH ON CONTACT may result if personnel fail to
observe safety precautions.
7.
8.
9.
10.
Connect air conditioner input power at source.
Turn mode switch to COOL mode.
The compressor will operate until the low pressure cutout shuts off the compressor.
The compressor will stand idle for a few minutes. During this time, pressure may build up again in the system due to
refrigerant remaining in the crankcase oil. If the pressure builds up, let the compressor run to low pressure cutout.
Allow the compressor to pump down until the pressure no longer builds up.
5-41
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5-21.
PUMP DOWN - Continued.
11. Frontseat (clockwise) compressor discharge valve.
12. Turn mode switch to OFF.
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance or
adjusting thermostat. Voltages used can KILL. Shutting the unit off at the control panel does not
disconnect unit power.
13. Disconnect air conditioner input power at source.
14. Open manifold VPV and let remaining refrigerant escape.
15. Purge low side of system (para 5-13).
Figure 5-10. Pump Down
5-42
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
INSERT SUBTITLE HERE!
This task covers:
Service
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Personnel: 1
Equipment Conditions:
1. Replacement part has been leak tested per paragraph 5-15.
2. Remove right front evaporator panel (para 4-25).
3. Replace drier filter if required (para 5-26).
SERVICE
WARNING
Death or serious injury may result if personnel fail to observe safety precautions. Use great care to
avoid contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Remove discharge and suction gauge caps.
Connect high pressure hose (red) to compressor discharge valve.
Connect low pressure hose (blue) to compressor suction valve.
Remove yellow 3/8 inch hose end from hose rack and place in container.
Open CGV and PGV.
Check compressor discharge service valve is frontseated (clockwise).
Backseat (counterclockwise) compressor suction valve.
Open head service valve slowly to allow liquid refrigerant to enter system.
Slowly open CV and allow refrigerant to flow out into container (30 seconds to one minute) until system is purged.
Backseat (counterclockwise) hot gas bypass service valve (see Figure 5-18).
Backseat (counterclockwise) compressor discharge valve.
Close CGV, PGV and CV service manifold valves.
Remove all service manifold hoses and return to manifold rack.
Install discharge, suction, head, and hot gas bypass protective caps.
5-43
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5-22.
START UP AFTER REPAIRS - Continued.
FOLLOW ON PROCEDURE
WARNING
Personnel injury and/or equipment damage may result if compressor is started when service valves
are not in a backseated (counterclockwise) position.
1.
2.
3.
4.
5.
Connect air conditioner input power at source.
Check supply of refrigerant in system (para 5-17).
Install right front evaporator panel (para 4-25).
Install right front condenser panel (para 4-28).
Return air conditioner to normal operation.
Figure 5-11. Start Up After Repairs
5-44
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5-23
HIGH REFRIGERANT PRESSURE SWITCH (S4).
This task covers:
Inspection
Removal
Testing/Adjustment
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Rags (Item 12, Appendix E)
Nitrogen, technical (Item 14, Appendix E)
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
3. Purge compressor (para 5-20).
INSPECTION
1. Check that switch and cover are not dented, broken or cracked, replace switch and cover, if defective (see Figure 512).
2. Check bracket is not dented, broken or cracked. Replace bracket, if defective.
3. Check that wire leads are properly connected (see Figure FO-3).
REMOVAL
1. Remove cover (2).
2. Tag and disconnect leads.
3. Remove pressure line (6) from valve head of compressor (5/8" wrench).
4. Remove two screws (4), four flat washers (5) and (7), two locknuts (8), and clamps (9).
5. Remove screw and clamp from compressor electric box.
6. Remove two screws (12), flat washers (10), and lockwashers (11).
7. Remove switch (3).
TESTING/ADJUSTMENT
1. Using multimeter, check continuity between two lead terminals. If continuity is indicated (switch closed), switch is
defective. Replace switch.
2. Connect manifold blue hose to nitrogen cylinder.
3. Connect yellow 1/4 inch (0.64 cm) hose to pressure line (6).
4. Using multimeter, switch should close at 425 to 475 psig (30 to 33 kg/cm2) and open at 335 to 385 psig (24 to 27
kg/cm2).
5. If switch can not be adjusted to ranges in step 4, replace switch.
5-45
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-23.
HIGH REFRIGERANT PRESSURE SWITCH (S4) - Continued
Figure 5-12. High Refrigerant Pressure Switch (S4)
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ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
INSTALLATION
1. Drill 5/32 inch holes through three terminals (1) on replacement switch.
2. Fungus proof replacement switch per MIL-V-173.
3. Place switch (3) in mounting position.
4. Install two screws (12), lockwashers (11), and flat washers (10).
5. Install two clamps (9) with two screws (4), four flat washers (5) and (7), and two locknuts (8).
6. Install clamp to compressor electric box with screw.
7. Install high refrigerant pressure line (6) to valve head of compressor (5/8" wrench).
8. Reconnect leads tagged in removal and remove tags.
9. Install cover (2).
10. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
1. Replace drier filter (para 5-26).
2. Connect air conditioner input power at source.
3. Check refrigerant level (para 5-17) and charge if necessary.
4. Install right front condenser panel (para 4-28).
5-47
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-24
LOW REFRIGERANT PRESSURE SWITCH (S5).
This task covers:
Inspection
Removal
Testing/Adjustment
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Ap pendix B)
Personnel: 1
Materials:
Rags (Item 12, Appendix E)
Nitrogen (Item 14, Appendix E)
Varnish, moisture and fungus resistant (Item 16, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
3. Purge compressor (para 5-20).
INSPECTION
1. Check that switch and cover are not dented, broken or cracked. Replace switch and cover, if defective (see Figure
5-13).
2. Check bracket is not broken or cracked or dented. Replace bracket, if defective.
3. Check that wire leads are properly connected (see Figure FO-3).
REMOVAL
1. Remove cover (2).
2. Tag and disconnect leads.
3. Remove pressure line (6) from top of compressor (5/8" wrench).
4. Remove two screws (4), four flat washers (5) and (9), two locknuts and clamp (7).
5. Remove screw and clamp from compressor electric box.
6. Remove two screws (12), flat washers (10), and lockwashers (11).
7. Remove switch (3).
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AIR FORCE TO 35E9-136-31
Figure 5-13. Low Refrigerant Pressure Switch (S5)
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ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
5-24.
LOW REFRIGERANT PRESSURE SWITCH (S5) - Continued.
TESTING/ADJUSTMENT
1. Using multimeter, check continuity between two lead terminals. If continuity is indicated (switch closed), switch is
defective. Replace switch.
2. Connect manifold blue hose to nitrogen cylinder.
3. Connect yellow 1/4 inch (0.64 cm) hose to pressure line (6).
4. Using multimeter, switch should close at 1 5 to 25 psig (1 to 1.8 kg/cm2) and open at 35 to 45 psig (2.5 to 3.2
kg/cm2).
5. If switch can not be adjusted to ranges in step 4, replace switch.
INSTALLATION
1. Drill 5/32 inch holes through three terminals (1) on replacement switch.
2. Fungus proof replacement switch per MIL-V-173.
3. Place switch (3) in mounting position.
4. Install two screws (12), lockwashers (11), and flat washers (10).
5. Install two clamps (7) with two screws (4), four flat washers (5) and (9), and two locknuts (8).
6. install clamp to compressor electric box with screw.
7. Install high refrigerant pressure line (6) to top of compressor (use 5/8" wrench).
8. Reconnect leads-tagged in removal and remove tags.
9. Install cover (2).
10. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
1. Replace drier filter (para 5-26).
2. Connect air conditioner input power at source.
3. Check refrigerant level (para 5-17) and charge if necessary.
4. Install right front condenser panel (para 4-28).
5-50
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-25
LOW OIL PRESSURE SWITCH (S7).
This task covers:
Inspection
Removal
Testing/Adjustment
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Rags (Item 12, Appendix E)
Nitrogen, technical (Item 14, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
3. Purge compressor (para 5-20).
INSPECTION
1. Check that switch and cover are not dented, broken or cracked. Replace switch or cover, if defective (see Figure 514).
2. Check bracket is not broken or cracked or dented. Replace bracket, if defective.
3. Check that wire leads are properly connected. (see Figure FO-3).
REMOVAL
1. Remove cover (1).
2. Tag and disconnect leads.
3. Remove pressure lines (4) from rear of compressor (5/8" wrench).
4. Remove five screws (2), ten flat washers (3) and (6), five locknuts (7) and clamps (5).
5. Remove two screws (8), four flat washers (9) and (11), and two locknuts (12).
6. Remove switch (10).
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ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
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5-25.
LOW OIL PRESSURE SWITCH (S7) - Continued.
Figure 5-14. Low Oil Pressure Switch (S7)
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TESTING/ADJUSTMENT
1. Using multimeter, check continuity between two lead terminals. If continuity is indicated (switch closed), switch is
defective. Replace switch.
2. Connect manifold blue hose to nitrogen cylinder.
3. Connect yellow 1/4 inch (0.64 cm) hose to pressure line (4).
4. Using multimeter, switch should close at 4 to 6 psig (0.29 to 0.43 kg/cm2) and open at 9 to 12 psig (0.65 to 0.86 kg/
cm2)
5. If switch can not be adjusted to ranges in step 4, replace switch.
INSTALLATION
1. Place switch (10) in mounting position.
2. Install two screws (8), four flat washers (9) and (11), and two locknuts (12).
3. Install five clamp (5) with five screws (2), ten flat washers (3) and (6), and five locknuts (7).
4. Install pressure lines (4) to rear of compressor (5/8" wrench).
5. Reconnect leads tagged in removal and remove tags.
6. Install cover (1).
7. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
1. Connect air conditioner input power at source.
2. Check refrigerant level (para 5-17) and charge if necessary.
3. Install right front condenser panel (para 4-28).
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AIR FORCE TO 35E9-136-31
5-26.
DRIER FILTER (DEHYDRATOR).
This task covers:
Inspection
Reassembly
Removal
Installation
Service
Disassembly
Repair/Replace
INITIAL SETUP:
Tools;
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
1. Pump down refrigerant system (para 5-21).
WARNING
Disconnect Input to the air conditioner before performing any internal maintenance. Voltages used
can KILL Shutting the unit off at the control panel does not disconnect unit power.
2. Disconnect air conditioner input power at source.
3. Remove right front evaporator panel (para 4-25).
INSPECTION
1. Inspect for evidence of leaks, damaged lines, and loose or missing mounting hardware (see Figure 5-15).
2. If a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1. If drier body (8) is to be removed, disassemble drier before debrazing. (Perform disassembly).
2. If drier body (8) is to be removed, debraze tubing (7) and (9) at joints (para 5-14).
3. Remove screw (10), nut (12), and bracket (11).
SERVICE
1. Replace drier filter cartridge (5) upon compressor burn-out or whenever refrigerant system is opened for purging or
evacuation.
2. Clean filter strainer (6) upon compressor bum-out or when refrigerant system is opened for purging or evacuation.
DISASSEMBLY
1. Remove eight bolts (1) and backplate (2).
2. Remove gasket (15).
3. Remove wingnut (3), end cap (4), filter cartridge (5), and strainer (6).
4. Remove filter/strainer end cap (14) and felt gasket (13).
REPAIR/REPLACE
Repair consists of replacing backplate (2), gasket (15), wingnut (3), end cap (4), filter cartridge (5), filter strainer (6),
filter/strainer end cap (14), felt gasket (13), or drier body (8).
5-54
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
Figure 5-15. Drier Filter
5-55
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-26.
DRIER FILTER (DEHYDRATOR) - Continued.
REASSEMBLY
1. Install felt gasket (13) and filter/strainer end cap (14).
2. Install filter strainer (6), filter cartridge (5), and end cap (4) with wingnut (3).
3. Install gasket (15).
4. Install backplate (2) with eight bolts (1).
INSTALLATION
1. If drier body (8) was removed, disassemble replacement drier filter before brazing.
2. Install replacement drier body (8) with bracket (11), screw (10), and nut (12).
3. Braze tubing (7) and (9) at joints (para 5-14).
4. Reassemble drier.
5. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
1. Perform start up after repairs (para 5-22).
2. Install right front evaporator panel (para 4-25).
3. Connect air conditioner input power at source.
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5-27.
REFRIGERANT STRAINER.
This task covers:
Inspection
Reassembly
Removal
Installation
Service
Disassembly
Repair/Replace
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
1. Pump down refrigerant system (para 5-21).
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
2. Disconnect air conditioner input power at source.
INSPECTION
1. Inspect for evidence of leaks, damaged lines, and loose or missing mounting hardware (see Figure 5-16).
2. If a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1. If strainer body (4) is to be removed, disassemble strainer.
2. If strainer body (4) is to be removed, debraze tubing at coupling joints (5) (para 5-14).
SERVICE
Service consists of replacing the strainer cartridge (3).
DISASSEMBLY
1. Remove eight bolts (6) (six on replacement item) and end cap (1). (A 17 inch extension is required for removing
bolts.)
2. Remove gasket (2).
3. Remove strainer cartridge (3).
REPAIR/REPLACE
Repair consists of replacing strainer cartridge (3), gasket (2), end cap (1), strainer body (4) or refrigerant strainer.
REASSEMBLY
1. Install replacement strainer cartridge (3).
2. Install gasket (2).
3. Install end cap (1) with eight bolts (6) (six bolts on replacement item).
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5-27.
REFRIGERANT STRAINER - Continued.
Figure 5-16. Refrigerant Strainer
INSTALLATION
1. If strainer body was removed, disassemble replacement strainer.
2. If strainer body (4) was removed braze tubing at joints (5) (para 5-14).
3. Reassemble strainer.
4. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
1. Perform start up after repairs (para 5-22).
2. Connect air conditioner input power at source.
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ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-28. SIGHT REFRIGERANT GLASS.
This task covers:
Inspection
Repair
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front evaporator panel (para 4-25).
3. Swing control box out (para 4-45).
INSPECTION
1. Inspect for evidence of leaks, damaged lines, and loose or missing mounting hardware (see Figure 5-17).
2. If a leak is suspected or indicated, test per paragraph 5-15.
REPAIR
Repair of the sight refrigerant glass consists of tightening the sight glass.
REMOVAL
1. Pump down refrigerant system (para 5-21).
2. Remove plastic cover (3).
3. Remove clamps in work area.
4. Debraze tubing (1) at joints (para 5-14).
5. Remove sight refrigerant glass (2).
INSTALLATION
1. Remove plastic cover (3).
2. Position sight refrigerant glass (2) in unit.
3. Braze tubing (1) at joints (para 5-14).
4. Leak test all newly connect joints and those in the repair area (para 5-15).
5. Install clamps that were removed in work area.
6. Install plastic cover (3).
5-59
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-28.
SIGHT REFRIGERANT GLASS - Continued.
FOLLOW ON PROCEDURE
1. Swing control box in and secure in place (para 4-45).
2. Perform start up after repairs (para 5-22).
Figure 5-17. Sight Glass
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ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
5-29. SERVICE VALVES (HEAD AND HOT GAS BYPASS).
This task covers:
Inspection
Removal
INITIAL SETUP:
Installation
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
INSPECTION
1. Check that caps are in place and that threaded connection ends are not damaged. Replace if missing or damaged
(see Figure 5-18).
2. If a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1. Discharge refrigerant-system (para 5-12).
2. Receive protective caps (3).
3. Debraze tubing (1) at joints (para 5-14).
4. Remove valve (2).
INSTALLATION
1. Place valve (2) into mounting position.
2. Braze tubing (1) at joints (para 5-14).
3. Install protective caps (3).
4. Leak test all newly connected joints and those in the repair area (para 5-15).
5. Backseat (counterclockwise) both service valves (head and hotgass bypass).
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5-29.
SERVICE VALVES (HEAD AND HOT GAS BYPASS) - Continued.
FOLLOW ON PROCEDURE
1. Replace drier filter (para 5-26).
2. Charge refrigerant system (para 5-17).
Figure 5-18. Service Valves (Head and Hot Gas Bypass)
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ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
5-30. SERVICE VALVE (EXPANSION).
This task covers:
Inspection
INITIAL SETUP:
Removal
Installation
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front evaporator panel (para 4-25).
3. Swing control box out (para 4-45).
INSPECTION
1. Check that caps are in place and that threaded connection ends are not damaged. Replace if missing or damaged
(see Figure 5-19).
2. If a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1. Pump down refrigerant system (para 5-21).
2. Remove two screws (4), locknuts (1), and four washers (2) and (3).
3. Remove valve caps (5).
4. Debraze tubing at joints (7) (para 5-14).
5. Debraze valve (6) from bracket (8) (para 5-14).
INSTALLATION
NOTE
Check to see if valve caps have been removed before brazing.
1.
2.
3.
4.
5.
6.
Braze valve (6) onto bracket (8) (para 5-14).
Place valve (6) into mounting position.
Install two screws (4), four washers (2) and (3), and two locknuts (1).
Braze tubing (7) at joints (para 5-14).
Install valve caps (5).
Leak test all newly connected joints and those in the repair area (para 5-15).
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5-30.
SERVICE VALVE (EXPANSION) - Continued.
FOLLOW ON PROCEDURE
1. Replace drier filter (para 5-26).
2. Close control box (para 4-45).
3. Start up after repairs (para 5-22).
Figure 5-19. Service Valve (Expansion)
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5-31. SERVICE VALVE (ACTUATOR).
This task covers:
Inspection
INITIAL SETUP:
Removal
Installation
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front condenser panel (para 4-27).
INSPECTION
1. Check that caps are in place and that threaded connection ends are not damaged. Replace if missing or damaged
(see Figure 5-20).
2. If a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1. Discharge refrigerant system (para 5-12).
2. Disconnect air conditioner input power at source.
3. Remove valve caps (2).
4. Debraze tubing at joints (3) and (5) (para 5-14).
5. Remove screw (1), flat washer (6), and valve (4).
INSTALLATION
1. Install valve ( 4) with screw (1) and flat washer (6).
NOTE
Check to see if valve caps have been removed before brazing.
2. Braze tubing at joints (3) and (5) (para 5-14).
3. Install valve caps (2).
4. Leak test all newly connected joints and those in the repair area (para 5-15).
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5-31.
SERVICE VALVE (ACTUATOR) - Continued.
FOLLOW ON PROCEDURE
1. Install drier filter (para 5-26).
2. Install left front condenser panel (para 4-27).
3. Charge refrigerant system (para 5-17).
Figure 5-20. Service Valve (Actuator)
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5-32. SERVICE VALVES (SCHRADER).
This task covers:
Inspection
INITIAL SETUP:
Removal
Installation
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
INSPECTION
1. Check that caps are in place and that threaded connection ends are not damaged. Replace if missing or damaged
(see Figure 5-21).
2. If a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1. Discharge refrigerant system (para 5-12).
2. Remove valve cap (1) .
3. Debraze tubing (8) at joints (2) (para 5-14).
4. Remove screw (7), flat washer (6), locknut (4), and valve plate (5).
5. Debraze valve (3) from valve plate (5) (para 5-14).
INSTALLATION
NOTE
Check to see if valve caps have been removed before brazing.
1.
2.
3.
4.
5.
6.
7.
Remove schrader valve stem on replacement valve.
Braze valve (3) onto valve plate (5) (para 5-14).
Install valve plate (5) with screw (7), flat washer (6), and locknut (4).
Braze tubing (8) at joints (2) (para 5-14).
Install schrader valve stem.
Install valve cap (1).
Leak test all newly connected joints and those in the repaired area (para 5-15).
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5-32.
SERVICE VALVES (SCHRADER) - Continued.
FOLLOW ON PROCEDURE
1. Install right front condenser panel (para 4-28).
2. Charge refrigerant system (para 5-17).
Figure 5-21. Service Valves (Schrader)
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5-33.
DISCHARGE VALVE (COMPRESSOR).
This task covers:
Inspection
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Material:
Lubricating oil #Zerol 150 (Item 9, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
3. Discharge compressor (para 5-19).
INSPECTION
1. Check that caps are in place and that threaded connection ends are not damaged. Replace if missing or
damaged (see Figure 5-22).
2. If a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1. Remove valve caps (2).
2. Remove two bolts (3) and move valve (1) away from compressor. (1/2 inch wrench.)
3. If valve is to be replaced, debraze tubing (4) at joint (para 5-14).
4. If valve is good, remove gasket (5) and clean gasket material from valve (1).
INSTALLATION
1. If valve was replaced, braze tubing (4) at joint (para 5-14).
2. Coat replacement gasket (5) with lubricating oil.
3. Install replacement gasket (5) onto valve (1).
4. Install valve (1) with two bolts (3).
5. Install valve caps (2).
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5-33.
DISCHARGE VALVE (COMPRESSOR) Continued.
FOLLOW ON PROCEDURE
1. Purge compressor (para 5-20).
2. Backseat (counterclockwise) suction and discharge valves.
3. Leak test all newly connected joints and those in the repair area (para 5-15).
4. Connect air conditioner input power at source.
5. Charge refrigerant system (para 5-17).
Figure 5-22. Discharge Valve (Compressor)
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5-34.
SUCTION VALVE (COMPRESSOR).
This task covers:
Inspection
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Material:
Lubricating oil #Zerol 150 (Item 9, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
3. Discharge compressor (para 5-19).
INSPECTION
1. Check that caps are in place and that threaded connection ends are not damaged. Replace if missing or
damaged (see Figure 5-23).
2. If a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1. Remove valve caps (3).
2. Remove four bolts (4) and valve (2).
3. If valve is to be replaced, debraze tubing (5) at joint (para 5-14).
4. If valve is good, remove gasket (1) and clean gasket material from valve (2).
INSTALLATION
1. If valve was replaced, braze tubing (5) at joint (para 5-14).
2. Coat replacement gasket (1) with lubricating oil.
3. Install replacement gasket (1) onto valve (2).
4. Install valve (2) with four bolts (4).
5. Install valve caps (3).
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5-34.
SUCTION VALVE (COMPRESSOR) - Continued.
FOLLOW ON PROCEDURE
1. Purge compressor (para 5-20).
2. Backseat (counterclockwise) suction and discharge valves.
3. Leak test all newly connected joints and those in the repair area (para 5-15).
4. Connect air conditioner input power at source.
5. Charge refrigerant system (para 5-17).
Figure 5-23. Suction Valve (Compressor)
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5-34.
SOLENOID VALVES (L1 AND L2).
This task covers:
Inspection
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Swing open control box (para 4-45).
INSPECTION
1. Check for leaks or frayed wires (see Figure 5-24).
2. if a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1. Pump down refrigerant system (para 5-21).
2. Remove retainer (2), nameplate (1), and coil (3).
3. Unscrew tube assembly (4).
4. Remove plunger assembly (9).
5. Check valve body (6) for visible damage. Normally valve body replacement is unnecessary. If valve body is not
replaced, skip steps 9 and 10.
6. If L1 is being removed, skip step 7.
7. Remove two clamps and move wiring harness away from work area.
8. Remove nut (7) at bottom of bracket (8).
9. Debraze tubing (5) at joints (para 5-14).
10. Remove valve body (6).
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5-35.
SOLENOID VALVES (L1 AND L2) - Continued.
INSTALLATIION
1. Place valve body (6) in mounting position.
2. Braze tubing (5) at joints (para 5-14).
3. Install nut (7) at bottom of bracket (8).
4. Install plunger assembly (9) into tube assembly (4).
5. Install tube assembly (4).
6. Install coil (3) with nameplate (1) and retainer (2).
7. If L2 was replaced, install wiring harness with two clamps.
8. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
1. Perform start up after repairs (para 5-22).
2. Close control box (para 4-45).
Figure 5-24. Solenoid Valve (L1 And L2)
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5-36.
THERMOSTATIC EXPANSION VALVE (LIQUID QUENCH).
This task cover:
Inspection
Reassembly
Adjust
Installation
Removal
Disassembly
Repair/Replace
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix )B
Thermometer,. digital (Item 17, Appendix B)
Thermocouple (Item 18, Appendix B)
Personnel: 1
Material: Sealant tape (Item 15, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Swing open control box (para 4-45).
INSPECTION
1. Inspect for evidence of leaks, kinked or damaged capillary line, and loose or missing mounting hardware (see
Figure 5-25).
2. Check thermal bulb to see that it is securely clamped to the suction line.
3. If a leak is suspected or indicated, test per paragraph 5-15.
ADJUST
1. Open manual valve (para 5-39).
2. Install jumper wires to TB2 (para 4-61 and Figure FO-1) for single mode operation.
3. Perform a refrigerant pressure check in accordance with para 5-18. Leave gauges attached.
4. Attach first thermocouple to an exposed surface of suction return line adjacent to sensing bulb.
5. Attach second thermocouple to suction line at compressor.
6. Install right front evaporator panel (para 4-25).
7. Install center front evaporator panel (para 4-22).
8. Note pressure indicated on gauge and temperature indicated for sensing bulb.
9. Set air conditioner temperature control thermostat to highest temperature setting.
WARNING
High voltage is used in operation of this equipment. DEATH ON CONTACT may result if personnel fail to
observe safety precautions.
10. Connect air conditioner input power at source.
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5-36.
THERMOSTATIC EXPANSION VALVE (LIQUID QUENCH) - Continued.
ADJUST - Continued
Figure 5-25. Thermostatic Expansion Valve (Liquid Quench)
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11. Start the air conditioner in COOL mode. Note that suction pressure drops to 58 ± 2 psig (4. 0 ± 0. 14 kg/cm2).
Allow the compressor to run for at least 30 minutes. If the pressure is not within the above limits, ensure proper
operation of the pressure regulator valve (para 5-44) before proceeding with quench valve test.
12. Observe that thermocouple meter temperature indicated for sensing bulb remains stable for a minimum of two
minutes, then find saturation temperature for pressure indicated on gauge, using Table 5-2. For example, the
saturation temperature for a refrigerant pressure of 69 psig (4. 85 kg/cm2) is 40°F (4.40°C).
13. Compare the saturation temperature with indicated temperature at the sensing bulb. The indicated temperature
should be 20 to 30°F (-6.7 to -1.1 °C) higher than the saturation temperature. The temperature indicated at
compressor should be 65 to 85°F (18.3 to 29.4°C).
14. If indicated temperature is not within limits shown in step 11, adjust the quench valve as follows:
a. Turn adjustment screw (9) clockwise to increase suction line pressure.
b. Turn adjustment screw (9) counterclockwise to decrease suction line pressure.
15. If indicated temperature shown in step 11 can not be stabilized by adjustment, replace quench valve.
16. Tum unit OFF.
17. Remove both thermocouples.
18. Remove service manifold from high and low service valves.
19. Install service valve protective caps.
REMOVAL
1. Pump down refrigerant system (para 5-21).
WARNING
Disconnect Input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
2.
3.
4.
5.
6.
Disconnect air conditioner input power at source.
Remove locknut (15), screw (19), and two flat washers (16) and (18).
Remove two clamps (17).
Remove two flatwashers (13), screw (11) and nut (14) on sensing bulb retaining clamp (12).
Remove sensing bulb (10) from retaining clamp (12).
NOTE
• If expansion valve body is to be replaced, disassemble before debrazing.
• If expansion valve body is not damaged and will not be removed, proceed to the disassembly
procedure.
7. Remove expansion valve body (4) by debrazing tubing (3) (para 5-14).
8. Remove bolt (2) holding valve to bracket (1).
9. Remove valve (4) from bracket (1).
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5-36.
THERMOSTATIC EXPANSION VALVE (LIQUID QUENCH) - Continued.
DISASSEMBLY
1. Remove two bolts (2), or second bolt (2) as applicable.
2. Remove powerhead (6) from valve body (4).
3. Remove cage assembly (5).
4. Examine cage assembly for damage or defects.
REPAIR/REPLACE
NOTE
Repair consists of replacing power head, cage assembly, or valve body.
REASSEMBLY
1. Examine replacement cage assembly (5) for defects or damage before reassembly.
2. Install cage assembly (5).
3. Install powerhead (6) on valve body (4).
4. Install two bolts (2), or just one bolt (2) if valve will immediately be installed in unit.
INSTALLATION
NOTE
• If expansion valve body is not being installed, proceed to step 3.
• If expansion valve body is being installed, proceed to disassembly before brazing valve body.
1. Position valve (4) in mounting position.
2. Install valve (4) to bracket (1) with one bolt (2).
3. Install sensing valve body (4) by brazing tubing (3) (para 5-14).
4. Install sensing bulb (10) in retaining damps (12).
5. Tighten two flatwashers (13), screw (11) and nut (14).
6. Install two clamp halves (17) to refrigerant lines.
7. Install two flat washers (16) and (18), one screw (19), and locknut (15).
8. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
1. Perform start up after repairs (para 5-22).
2. Close control box assembly (para 4-45).
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5-37.
HOT GAS BYPASS VALVE.
This task cover:
Inspection
Reassembly
Adjust
Installation
Removal
Disassembly
Repair/Replace
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any Internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
3. Remove right front evaporator panels (para 4-25).
INSPECTION
1. Inspect for evidence of leaks, damaged lines, and loose or missing mounting hardware (see Figure 5-26).
2. If a leak is suspected or indicated, test per paragraph 5-15.
3. Check that mounting damp is secure.
ADJUST
1. Connect compound gauge to low service valve (para 5-11).
2. Open manual valve (para 5-39).
3. Open left electrical plate (para 4-30).
4. Install jumper wires to TB2 (para 4-61) for single mode operation (see FO-3).
5. Set cool control thermostat (para 4-87) to lowest temperature setting.
WARNING
High voltage is used in operation of this equipment. DEATH ON CONTACT may result if personnel fail to
observe safety precautions.
6. Connect air conditioner input power at source.
7. Start unit in COOL mode.
NOTE
• The hot gas bypass valve is set at the factory to maintain the suction pressure above 55 to 58 psig
2
(3.9 to 4.1 kg/cm ) at the compressor.
• Allow air conditioner to run until pressure remains constant.
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HOT GAS BYPASS VALVE - Continued.
ADJUST - Continued
Figure 5-26. Hot Gas Bypass Valve
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8. If suction line pressure of 55 to 58 psig (3.9 to 4.1 kg/cm2) is not present, adjust valve.
9. Turn the adjusting stem (3) one turn to change suction by 4 psig (.28 kg/cm2). Turn the stem clockwise to
increase suction pressure or counterclockwise to decrease suction pressure.
10. If valve can not be adjusted to maintain 55 to 58 psig (3.9 to 4.1 kg/cm2) suction pressure, replace valve and
repeat steps 1 thru 4.
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltage
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
11. Disconnect air conditioner input power at source.
12. After proper setting is obtained:
a. Turn unit OFF.
b. Remove service manifold from low service valve.
c. Install service valve protective cap (2) and (4).
d. Remove wires installed to TB-2 in step 4.
e. Close left electric plate (para 4-30).
f. Close manual valve (para 5-39).
REMOVAL
1. Pump down refrigerant system (para 5-21).
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages used
can KILL. Shutting the unit off at the control panel does not disconnect unit power.
2. Disconnect air conditioner input power at source.
3. Loosen flare nut (10) and let gas escape.
4. Disconnect flare nut (10).
NOTE
• If hot gas bypass valve body is to be replaced, disassemble before debrazing.
• If hot gas bypass valve body is not damaged and will not be removed, proceed to the disassembly
procedure.
5. If valve body (12) is to be removed, debraze tubing at joints (15) (para 5-14).
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5-37.
HOT GAS BYPASS VALVE - Continued.
DISASSEMBLY
1. Remove three screws (9) and lockwashers (8) from bracket (5).
2. Remove two bolts (13).
3. Remove upper body assembly (16).
4. Remove two washers (6), locknuts (7), and u-bolt (1) from bracket (5).
5. Remove cage assembly (11).
REPAIR/REPLACE
Repair consists of replacing the upper body (16), cage assembly (11) or valve body (12).
REASSEMBLY
1. Install cage assembly (11).
2. Install upper body assembly (16).
3. Install two bolts (13).
INSTALLATION
1. Install u-bolt (1), two flat washers (6), and two locknuts (7) to bracket (5).
2. Install three screws (9) and lockwashers (8).
NOTE
• If hot gas bypass valve body is not being installed, proceed to step 2.
• If hot gas bypass valve body is being installed, proceed to disassembly before brazing valve body.
3. If valve body (12) was removed, braze tubing (15) at joints (para 5-14).
4. Connect flarenut (10).
5. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
1. Perform start up after repairs (para 5-22).
2. Install right front evaporator panel (para 4-25).
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5-38.
THERMOSTATIC EXPANSION VALVE (PRIMARY).
This task covers:
Inspection
Adjust
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Thermometer, digital (Item 17, Appendix B)
Thermocouple (Item 18, Appendix B)
Personnel: 1
Material:
Sealant tape (Item 15, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Swing open control box assembly (para 4-45).
3. Remove right front condenser panel (para 4-28).
INSPECTION
1. Inspect for evidence of leaks, kinked or damaged capillary line, and loose or missing mounting hardware (see
Figure 5-27).
2. Check thermal bulb to see that it is securely clamped to the suction line.
3. If a leak is suspected or indicated, test per paragraph 5-15.
ADJUST
NOTE
The expansion valve as supplied with unit is preset at the factory. This valve should not be adjusted
unnecessarily.
1. Open manual valve (para 5-39).
2. Open left electric plate (para 4-30).
3. Install jumper wires to TB2 (para 4-61) for single mode operation (see FO-3).
4. Attach thermocouple to an exposed surface of suction return line adjacent to sensing bulb.
5. Connect pressure gauge to expansion service valve port (para 5-30).
6. Set cool control thermostat (para 4-87) to lowest temperature setting.
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THERMOSTATIC EXPANSION VALVE (PRIMARY) - Continued.
ADJUST - Continued
Figure 5-27. Thermostatic Expansion Valve (Primary)
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WARNING
High voltage is used in operation of this equipment. DEATH ON CONTACT may result if personnel fail to
observe safety precautions.
7. Connect air conditioner input power at source.
8. Start air conditioner in COOL mode.
9. Allow air conditioner to run about 30 minutes.
10. Check to be sure temperature in suction line has stabilized and thermocouple meter reading remains unchanged
for at least two minutes.
11. Note pressure on manifold gauge connected to low pressure expansion (primary) service valve. Identify
saturation temperature for pressure gauge reading (see Table 5-2) and compare with thermocouple meter
reading. The thermocouple meter temperature should be 8 to 15°F (4.48 to 8.4°C) higher than saturation
temperature found in Table 5-2.
12. If the superheat setting is not within limits shown in step 11, adjust expansion valve as follows:
a. Remove service valve cap (2) from side of power assembly (1).
NOTE
Do not change more than two full turns at one time, then wait five to ten minutes for temperature to
stabilize and recheck pressure and temperature before further adjustment.
b. Turn adjusting stem two complete turns to change superheat setting by 1 °F. Turn clockwise to increase
superheat span or counterclockwise to decrease superheat span.
c. If expansion valve can not be adjusted to within limits shown in step 11, contact General Support
Maintenance.
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages used
can KILL. Shutting the unit off at the control panel does not disconnect unit power.
13. Disconnect air conditioner input power at source.
14. After proper setting is obtained:
a. Turn unit OFF.
b. Install service valve cap (2)
c. Remove thermocouple.
d. Remove service manifold from service expansion (primary) valve.
e. Remove wires installed to TB-2 in step 3.
f. Close left electric plate (para 4-30).
g. Close manual valve (para 5-39).
FOLLOW ON PROCEDURE
1. Perform start up after repairs (para 5-22).
2. Close control box (para 4-45).
3. Install right front condenser panel (para 4-28).
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5-39.
MANUAL VALVE (BYPASS).
This task covers:
Inspection
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Swing open control box assembly (para 4-45).
INSPECTION
1. Inspect for evidence of leaks, damaged lines, and loose or missing mounting hardware. Replace if inspection
fails (see Figure 5-28).
2. If a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1. Pump down refrigerant system (para 5-21).
2. Remove valve protective cap (1).
3. Debraze tubing (3) at joints (para 5-14).
4. Remove valve (2).
INSTALLATION
1. Position valve (2) in unit.
2. Braze tubing (3) at joints (para 5-14).
3. Open valve for single unit configuration or close valve for dual unit configuration.
4. Install valve protective cap (1).
5. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
1. Close control box (para 4-45).
2. Perform start up after repairs (para 5-22).
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Figure 5-28. Manual Valve (Bypass)
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5-40.
VIBRATION ELIMINATORS.
This task covers:
Inspection
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
INSPECTION
1.
Inspect for evidence of leaks or damaged lines (see Figure 5-29).
2.
If a leak is suspected or indicated, test per paragraph 5-15.
REMOVAL
1.
Pump down refrigerant system (para 5-21).
2.
Remove screw (2), locknut (6), two flat washers (3) and (5), and clamp (4).
3.
Debraze tubing (7) at joints (para 5-14).
4.
Remove vibration eliminator (1).
INSTALLATION
1. Position vibration eliminator (1) in frame.
2. Braze tubing (7) at joints (para 5-14).
3. Install clamp (4) with screw (2), two flat washers (3) and (5), and locknut (6).
4. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
Perform start up after repairs (para 5-22).
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Figure 5-29. Vibration Eliminators
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5-41.
CONDENSER FAN DAMPER ACTUATOR.
This task covers: Inspection
Testing Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Personnel: 1
Material:
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (Item 13, Appendix E)
Nitrogen, technical (Item 14, Appendix E)
Corrosion preventative (Item 17, Appendix E)
Equipment Conditions:
1. Remove condenser circulator fan (para 4-77).
2. Remove condenser fan connecting link assembly (para 4-89).
INSPECTION
1. Check for damaged or missing parts (see Figure 5-30).
2. Check for signs of leakage. Leak test if leak is suspected (para 5-15).
TESTING
1. Frontseat (clockwise) actuator service valve (para 5-31).
WARNING
Death or serious injury may result if personnel fail to observe safety precautions. Use great care to
avoid contact with liquid refrigerant or refrigerant gas being discharged under pressure. Sudden and
irreversible tissue damage can result from freezing. Wear thermal protective gloves and a face
protector or goggles in any situation where skin-eye-contact is possible.
2. Slowly loosen flare nut (4) on actuator (5) to release gas.
3. Remove screw (10), lockwasher (11), flat washer (12), and clamp (13).
4. Remove flare nut and tubing (4).
5. Install nitrogen cylinder to manifold gauge, high side.
6. install charging valve yellow 1/4 inch (0.64 cm) line to actuator (para 5-11).
7. Open high pressure gauge valve on service manifold.
2
8. Raise pressure to 200-300 psig (90.8 to 136.2 kg/cm ).
9. Actuator closes with 1/2 inch (1.27 cm) clearance between damper and squirrel cage.
10. If damper does not close, replace actuator.
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Figure 5-30. Condenser Fan Damper Actuator
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5-41.
CONDENSER FAN DAMPER ACTUATOR - Continued.
TESTING - Continued.
11. Remove service manifold from actuator.
12. Hand tighten flarenut (4) to actuator (5).
13. Backseat (counterclockwise) actuator service valve (see Figure 5-20).
14. Let gas escape from flarenut for 1 to 3 seconds and tighten flarenut (4).
REMOVAL
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive.
Repeated or prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area,
wear gloves, and keep away from sparks or flame.
1. Clean both sides of shaft (2) on squirrel cage with MEK.
2. Loosen set screws (1) on both sides of squirrel cage.
3. Move squirrel cage (3) to side.
4. Remove nut (9) and control rod swivel (6).
5. Remove two locknuts (14) and actuator (5).
6. Remove two rivets (7) and bracket (8).
INSTALLATION
1. Install actuator bracket (8) with two rivets (7).
2. Install actuator (5) with two locknuts (14).
3. Center squirrel cage (3) in housing and tighten two set screws (1).
4. Apply corrosion preventative to both sides of shaft (2).
5. Install control rod swivel (6) with nut (9).
6. Install and adjust actuator linkage (para 4-89).
7. Install flarenut and tubing (4).
8. Backseat (counterclockwise) actuator service valve (see Figure 5-20).
9. Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
Install condenser circulator fan (para 4-77).
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5-42.
RECEIVER.
This task covers: Inspection
Removal
Installation
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
4.
Disconnect air conditioner input power at source.
Swing open control box assembly (para 4-45).
Remove evaporator circulator fan (para 4-71).
Discharge refrigerant system (para 5-12).
INSPECTION
1. Inspect for evidence of leaks, damaged lines, and loose or missing mounting hardware (see Figure 5-31).
2. If a leak is suspected or indicated, test per paragraph 5-15.
3. Inspect fusible plug (13) for evidence of leaks or damage. Replace fusible plug if defective.
REMOVAL
1. Remove two screws (1), locknuts (7), four flat washers (2) and (8), and clamp (9).
2. Frontseat (clockwise) receiver service valve (6).
3. Debraze tubing (3) and (4) at joints (para 5-14).
4. Remove bolt (10), nut (12), and bracket (11).
5. Remove receiver (5).
INSTALLATION
1. Position receiver (5) in frame.
2. Install bracket (11) with bolt (10) and nut (12).
3. Crimp and braze top of tubing (4) (para 5-14).
4. Braze tubing (3) and (4) at joints (para 5-14).
5. Install clamp (9) with two screws (1), four flat washers (2) and (8), and two locknuts (7).
6. Backseat (counterclockwise) receiver service valve (6).
7. Leak test all newly connected and surrounding area joints (para 5-15).
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5-42.
RECEIVER - Continued.
FOLLOW ON PHOCEDURE
1. Install circulator fan (para 4-71).
2. Charge refrigerant system (para 5-17).
3. Close control box (para 4-45).
Figure 5-31. Receiver
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5-43.
DISTRIBUTOR.
This task covers:
Inspection
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Material:
Brazing alloy, silver, QQ-B-654, Grade III (Item 21, Appendix E)
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Swing open control box assembly (para 4-45).
INSPECTION
1. Check for signs of leakage (see Figure 5-32). Leak test if leak is suspected (para 5-15).
2. If a leak is detected at distributor joint, braze joint (para 5-14).
3. If a capillary line leak is detected, contact General Support Maintenance.
FOLLOW ON PROCEDURE
1. Close control box (para 4-45).
2. Connect air conditioner input power at source.
Figure 5-32. Distributor
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5-44.
PRESSURE REGULATOR VALVE.
This task cover:
Inspection
Adjust
Repair/Replace
Disassembly
Reassembly
INITIAL SETUP:
Tools
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Thermometer, digital (Item 17, Appendix B)
Material:
Sealant tape (Item 15, Appendix E)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Swing open control box assembly (para 4-45).
3. Remove clamp securing valve to frame.
INSPECTION
1. Inspect for evidence of leaks, kinked or damaged capillary lines, and loose or missing mounting hardware (see
Figure 5-33).
2. Check thermal bulb (13) to see that it is securely clamped in the return air compartment (para 4-41).
3. If a leak is suspected or indicated, test per paragraph 5-15.
ADJUST
1. Close manual valve (para 5-39).
2. Attach a thermocouple and thermometer to an exposed surface of capillary line adjacent to sensing bulb in
supply air compartment.
3. Set thermostat to lowest temperature setting.
WARNING
High voltage is used in operation of this equipment. DEATH ON CONTACT may result if personnel
fail to observe safety precautions.
4. Connect air conditioner input power at source.
5. Start air conditioner in COOL mode.
6. Allow air conditioner to run about 30 minutes.
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Figure 5-33. Pressure Regulator Valve
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5-44.
PRESSURE REGULATOR VALVE - Continued.
ADJUST - Continued.
7. Check to be sure temperature reading remains unchanged for two minutes.
NOTE
For this adjustment,. the return air has to be less than 88°F (31.1 °C).
8. If indicated temperature is not 52-58°F (11.1-14.4°C), adjust pressure regulator valve.
9. Turn the stem clockwise to increase temperature; counterclockwise to decrease temperature. Run air conditioner
about 30 minutes, then check thermometer and normal temperature indication above. Make additional
adjustments to temperature as necessary.
10. If temperature can not be stabilized, repair/replace pressure regulator valve.
11. Turn off air conditioner.
12. Disconnect air conditioner input power at source.
13. Remove thermocouple.
14. Reset thermostat for desired temperature.
REPAIR/REPLACE
Repair consists of replacing bonnet assembly, adapter body, caps or pressure regulator.
DISASSEMBLY
1. Backout temperature adjust screw (2).
2. Remove eight bolts (1) and bonnet body (3).
3. Remove two spring guides (4) and (6), spring.(5) and disk (7).
4. Remove diaphragm (9) and two gaskets (8) and (10).
5. Remove eight bolts (11) and pilot body (12).
6. Remove gasket (32) and O-ring (31).
7. Remove eight bolts (28), adapter body (30), and gasket (29).
8. Remove cap (23) and gasket (24).
9. Remove stuffing box nut (22).
10. Remove packing ring (25).
11. Remove packing washer (26).
12. Remove bottom cap (27).
13. Remove bottom cap seal (21).
14. Remove dirty wiper (20).
15. Remove dirty wiper retainer (19).
16. Remove closing spring (18).
17. Remove manual operating stem (17).
18. Remove throttling plug (16).
19. Remove piston (33) through top of valve body (34).
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REASSEMBLY
1.
Install piston (33) through top of valve body (34).
2.
Install throttling plug (16).
3.
Install manual operating stem (17).
4.
Install closing spring (18).
5.
Install dirty wiper retainer (19).
6.
Install dirty wiper (20).
7.
Install bottom cap seal (21).
8.
Install bottom cap (27).
9.
Install packing washer (26).
10.
Install packing ring (25).
11.
Install stuffing box nut (22).
12.
Install gasket (24) and cap (23).
13.
Install gasket (29) and adapter body (30) with eight bolts (28).
14.
Install gasket (32) and O-ring (31).
15.
Install pilot body (12) with eight bolts (11).
16.
Install diaphragm (9) and two gaskets (8) and (10).
17.
Install two spring guides (4) and (6), spring (5) and disk (7).
18.
Install bonnet body (3) with eight bolts (1).
FOLLOW ON PROCEDURE
1.
Close control box (para 4-45).
2.
Connect air conditioner power at source.
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5-45. TUBING AND FITTINGS.
This task covers:
Inspection
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove covers and panels as necessary to have access to repair area.
NOTE
The refrigeration system contains a number of pieces of copper tubing in a variety of material grades,
sizes, lengths, and shapes, and a number of elbows, tees, and adapters in several sizes.
INSPECTION
Check tubing and fitting for signs of leakage. Leak test if leak is suspected (para 5-15).
REMOVAL
1.
2.
3.
4.
Discharge refrigerant system (para 5-12).
Purge refrigerant system (para 5-13).
Debraze the tube connections (para 5-14).
Remove part.
INSTALLATION
1.
2.
3.
4.
5.
6.
7.
Place replacement part on tube end.
Braze replacement part (para 5-14).
Purge refrigerant system (para 5-13).
Replace drier filter (para 5-26).
Leak test all newly connected joints and those in the repair area (para 5-15).
Evacuate refrigerant system (para 5-16).
Charge refrigerant system (para 5-17).
FOLLOW ON PROCEDURE
1.
2.
Install all covers and panels that were removed.
Connect air conditioner input power at source.
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5-46. COMPRESSOR.
This task covers:
Service
Testing
Bum Out Procedure
Removal
Repair/Replace
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Nitrogen regulator (Item 25, Appendix B)
Wrecking bar (Item 4, Appendix B)
Kit, compressor removal (Item 14, Appendix B)
Gauge set, telescopic (Item 24, Appendix B)
Gloves, chemical (Appendix C)
Goggles, industrial (Appendix C)
Materials:
Rags (item 12, Appendix E)
Lubricating oil #Zerol 150 (Item 9, Appendix E)
Lubricating oil SS-291 (Item 10, Appendix E)
R-11 refrigerant (Item 22, Appendix E)
Personnel: 2
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove right front condenser panel (para 4-28).
SERVICE
1.
Check sight glass. Refrigerant oil should be between 1/4 min and 1/2 max (see Figure 5-34).
2.
Add or remove refrigerant oil as necessary (see step 3 for oil removal and step 4 for adding oil).
3.
Oil Removal.
a. Pump down system (para 5-21).
b. Discharge compressor (para 5-19).
c. Remove drain plug and drain excess oil into container.
d. Install drain plug.
e. Check sight glass, refrigerant oil should be between 1/4 min and 1/2 max.
f. Add refrigerant oil (step 4) as necessary.
g. If oil is not added, perform startup after repairs (para 5-22).
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5-46. COMPRESSOR - Continued.
SERVICE - Continued.
Figure 5-34. Compressor Oil Removal
4. Adding Compressor Oil (see Figure 5-35).
a. Pump down system (para 5-21).
b. Discharge compressor (para 5-19).
c. Close all manifold valves.
d. Remove yellow 3/8 inch (0.35 cm) hose from hose rack and connect to vacuum pump.
e. Remove yellow 1/4 inch (0.64 cm) hose from hose rack and connect to R-22 refrigerant cylinder positionec for
purging.
f. Open VPV, CGV, and PGV.
g. Start vacuum pump and open ballast valve (on vacuum pump) one turn.
h. Observe gauge reading on vacuum pump for reading of 29-30 Hg.
i. Stop pump and close ballast valve.
j. Close VPV, CGV, and PGV.
k. Remove hose from vacuum pump.
I. Open VPV and CV and purge air out of yellow 3/8 inch (0.35 cm) line.
m. Close VPV and CV and place yellow 3/8 inch (0.35 cm) line in oil container.
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Figure 5-35. Adding Compressor Oil
n. Open VPV and CGV to allow oil to flow into compressor until oil level shows 1/2 full on sight glass.
o. Close VPV and CGV.
p. Purge compressor (para 5-20).
q. Perform startup after repairs (para 5-22).
TESTING
Refer to Table 5-1 for compressor testing and troubleshooting.
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5-46. COMPRESSOR - Continued.
REMOVAL
1.
Remove crankcase heater (para 4-81).
2.
Discharge compressor (para 5-19).
3.
Remove high refrigerant pressure switch and lines (para 5-23).
4.
Remove low refrigerant pressure switch and lines (para 5-24).
5.
Remove low oil pressure switch and lines (para 5-25) and support to piping at bottom of compressor
compartment.
6.
Remove service light and lamp guard (para 4-65).
7.
Remove compressor discharge valve (para 5-33).
8.
Remove compressor suction valve (para 5-34).
9.
Remove two rear mounting bolts (5), lockwasher (6), and flat washer (7) (see Figure 5-36).
10.
Loosen two front mounting bolts (5).
WARNING
Compressor weighs approximately 300 lbs. Personnel injury and/or internal components can be
damaged if compressor falls off mounting bracket and shims.
11.
Raise rear of compressor (4).
12.
Between compressor and mounting frame, place 3/4 inch shims (8) on both sides.
13.
Remove two front mounting bolts (5), lockwashers (6), and flat washers (7).
14.
Carefully raise front of compressor (4).
15.
Between compressor and mounting frame, place 3/4 inch shims (8) on both sides.
16.
Insert slide track (3) beneath compressor (4). Lip on sides of slide track point up, while lip at one end of slide
track points down at rear of compressor.
17.
Insert compressor slide (2) on slide track (3).
18.
Raise compressor and remove four shims (8) allowing compressor (4) to set on compressor slide (3).
19.
Line up dolly (1) with slide track (3) and lock wheels (9).
20.
Slide compressor (4) out on dolly (1).
21.
Tag and remove remaining wires.
22.
Drain refrigerant oil from crankcase (see SERVICE).
23.
Remove compressor.
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Figure. 5-36. Compressor
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5-46. COMPRESSOR - Continued.
REPAIR/REPLACE
Repair and replacement of the compressor components are covered in the following referenced paragraphs or replace
compressor.
1.
Valve plate assembly (para 5-47).
2.
Pump end bearing assembly (para 5-48).
3.
Crankshaft, pistons and rods (para 5-49).
4.
Electrical box assembly (para 5-50).
INSTALLATION
1.
Position compressor on dolly (1).
2.
Line up dolly (1) with slide track (3) and lock wheels (9).
3.
Connect wires tagged in REMOVAL step 21 and remove tags.
4.
Slide compressor (4) into frame.
5.
Carefully raise front of compressor.
6.
Between compressor and mounting frame, place 3/4 inch shims (8) on both sides.
7.
Raise rear of compressor.
8.
Between compressor and mounting frame, place 3/4 inch shims (8) on both sides.
9.
Remove compressor slide (2).
10.
Remove slide track (3).
11.
Raise rear of compressor.
12.
Remove shims (8) on both sides and lower compressor onto mounting frame.
13.
Loosely install two rear mounting bolts (5); lockwashers (6), and flat washers (7).
14.
Raise front of compressor.
15.
Remove shims (8) on both sides and lower compressor onto mounting frame.
16.
Install two front mounting bolts (5), lockwashers (6), and flat washers (7).
17.
Tighten rear mounting bolts (5).
18.
Install compressor suction valve (para 5-34).
19.
Install compressor discharge valve (para 5-33).
20.
Install service light and lamp guard (para 4-65).
21.
Install low oil pressure switch and lines (para 5-25).
22.
Install low refrigerant pressure switch and lines (para 5-24).
23.
Install high refrigerant pressure switch and lines (para 5-23).
24.
Install crankcase heater (para 4-81).
25.
Purge compressor (para 5-20).
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BURN OUT PROCEDURE
WARNING
Avoid skin contact or inhaling fumes from any acid formed by burnout of oil and refrigerant. Wear a
gas mask if area is not thoroughly ventilated. Wear protective goggles or glasses to protect eyes.
Wear rubber gloves to protect hands.
1.
2.
3.
4.
5.
6.
7.
8.
9.
After removal of a bad compressor from the refrigerant system, drain a sample of oil into a clear glass container.
If the oil is clean and clear, and does not have a burnt acid smell, the compressor did not fail because of motor
burn out. If burnout is no, indicated, proceed to INSTALLATION of compressor.
If the oil is black, contains sludge, and has burnt acid odor, the compressor failed because of motor burn out.
You must clean the entire refrigeration system after burn out has occurred, since contaminants will have been
carried to many corners and restrictions in the piping and fittings. These contaminants will soon mix with new
refrigerant gas and compressor oil to cause repeated burn outs.
Install new drier filter (para 5-26) and clean refrigerant strainer cartridge (para 5-27).
Install replacement compressor (see INSTALLATION).
Frontseat (clockwise) compressor discharge valve (para 5-33) and suction valve (para 5-34).
Open manual valve (para 5-39) to bypass pressure regulator.
Tag and disconnect solenoid L1 and L2 coil wires (para 4-88).
WARNING
External input power is used for this procedure. Voltages used can be deadly.
10.
11.
12.
13.
14.
Connect an external 120 V ac power source to L1 and L2 and apply power to coils to open solenoid valves.
Purge refrigerant system (para 5-13) for at least 30 seconds at 50 psig (3.5 kg/cm2) pressure.
Clean system by back flushing with liquid refrigerant, R-1 1, from pressurized cylinder or circulating pump and
reservoir with pressure of at least 100 psig (7 kg/cm2).
If pump is used, connect the discharge line of the refrigerant system to the discharge side of the pump.
Connect a line containing a filter to the suction line in the unit.
NOTE
An unused dehydrator or other suitable medium may be used as a filter.
15.
16.
The other end of the temporary suction line should be connected to a small drum or suitable reservoir.
A line should be run from the bottom of the reservoir to the inlet of the pump.
WARNING
Avoid skin contact or inhaling fumes from any acid formed by burnout of oil and refrigerant. Wear a
gas mask if area is not thoroughly ventilated. Wear protective goggles or glasses to protect eyes.
Wear rubber gloves to protect hands.
17.
Fill reservoir with fluorocarbon refrigerant, R-11, and start the pump. Continue filling the reservoir with
refrigerant, R-11, until it begins to pour out of the return line. Continue flushing for a least 15 minutes.
18.
Remove the pump, reservoir and filter. Purge refrigerant system (para 5-13). Blow dry nitrogen through the
system at 50 psig (3.5 kg/cm2) for at least 30 seconds.
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5-46. COMPRESSOR - Continued.
BURN OUT PROCEDURE - Continued.
19.
Install new drier filter (para 5-26) and clean refrigerant strainer cartridge (para 5-27).
20.
Backseat (counterclockwise) compressor discharge valve (para 5-33) and suction valve (para 5-34).
21.
Disconnect external power source from L1 and L2 coils (para 4-88) and reconnect wire leads.
22.
Close manual valve (para 5-39).
23.
Evacuate refrigerant system (para 5-' 6).
24.
Charge refrigerant system (para 5-17).
25.
Allow the air conditioner to run for 48 hours, check color and odor of oil, if oil is still discolored or has an acid
odor perform the following:
a. Drain compressor oil.
b. Repeat steps 19, 23, 24, and 25 until the oil remains clean, odor free and oil color approaches that of new oil.
FOLLOW ON PROCEDURE
1.
Connect air conditioner input power at source.
2.
Charge refrigerant system (para 5-17).
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5-47. VALVE PLATE ASSEMBLY.
This task covers:
Disassembly
Inspection
Repair
Reassembly
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Wrench, torque, 1/2", 10-150 ft lbs (Item 20, Appendix B)
Material:
Rags (Item 12, Appendix E)
Personnel: 1
Equipment Conditions:
Remove compressor (para 5-46).
DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
Remove eight bolts (1).
Remove head (11).
Remove cylinder head gasket (2).
Remove valve plate gasket (10) .
Remove discharge valve screw (3) and discharge valve step (4).
Remove discharge valve (5).
Remove valve plate (9).
Remove suction valve (6) and suction valve positioning spring (7).
INSPECTION
1.
2.
Check cylinder heads for warping, cracks or damage to gasket surfaces. Replace if necessary.
Inspect components for wear or damage. Replace if necessary.
REPAIR
Repair consists of replacing head (11), valve plate (10), discharge valve (5), suction valve (6), and positioning spring (7).
REASSEMBLY
1.
2.
3.
4.
5.
Install suction valve positioning spring (7).
Install suction valve (6).
Install valve plate gasket (10).
Install discharge valve (5).
Install discharge valve stop (4) and discharge valve screw (3).
NOTE
If side head gasket is being replaced, cut replacement gasket to match gasket being replaced.
6.
Install cylinder head gasket (2).
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5-47. VALVE PLATE ASSEMBLY - Continued.
REASSEMBLY - Continued.
7.
8.
Place head (11) in mounting position.
Install eight bolts (1) and torque to 30-35 ft-lbs.
FOLLOW ON PROCEDURE
Install compressor (para 5-46).
Figure 5-37. Valve Plate Assembly
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5-48. PUMP END BEARING ASSEMBLY.
This task covers:
Disassembly
Inspection
Repair
Reassembly
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Wrench, torque, 1/2", 10-150 ft Ibs (Item 20, Appendix B)
Material:
Rags (Item 12, Appendix E)
Personnel: 1
Equipment Conditions:
Remove compressor (para 5-46).
DISASSEMBLY
1.
Remove four cap screws (1).
2.
Remove cover plate (2) and gasket (3).
3.
Remove oil feed guide vane and spring (4).
4.
Remove two cap screws (5).
5.
Remove drive segment (6).
6.
Remove pump rotor retaining ring (7).
7.
Remove pump rotor (11)
8.
Remove eight cap screws (10).
9.
Remove oil pump bearing head assembly (9).
10.
Remove oil pump gasket (8).
11.
Clean old gasket material off compressor.
INSPECTION
1.
Inspect the bearing surfaces for evidence of wear or damage.
2.
If bearing surface is worn or scored, or oil pump is defective, replace oil pump bearing head assembly.
REPAIR
Repair consists of replacing oil pump bearing head assembly.
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5-48. PUMP END BEARING ASSEMBLY - Continued.
Figure 5-38. Pump End Bearing Head Assembly
REASSEMBLY
1.
Install oil pump gasket (8).
2.
Place oil pump bearing head assembly (9) in mounting position.
3.
Install eight cap screws (10) and torque to 30-35 ft-lbs.
4.
Install pump rotor (11).
5.
Install pump rotor retaining ring (7).
6.
Install drive segment (6).
7.
Install two cap screws (5) and torque to 4-6 ft-lbs.
8.
Install oil feed guide vane and spring (4).
9.
Place gasket (3) and cover plate (2) in mounting position.
10.
Install four cap screws (1) and torque to 16-20 ft-lbs.
FOLLOW ON PROCEDURE
Install compressor (para 5-46).
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5-49. CRANKSHAFT, PISTONS AND RODS.
This task covers:
Disassembly
Inspection
Repair
Reassembly
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Wrench, torque, 1/2", 10-150 ft-lbs (Item 20, Appendix B)
Personnel: 1
Material:
Rags (Item 12, Appendix E)
Equipment Conditions:
1. Remove compressor (para 5-46).
2. Remove valve plate assembly (para 5-47).
3. Remove pump end bearing assembly (para 5-48).
DISASSEMBLY
1.
Remove 18 cap screws (15) and flat washers (16).
CAUTION
Use extreme care when removing motor end cover to prevent damage to stator.
2.
3.
4.
Remove motor end cover (14) by pulling and lifting off horizontally until it clears windings.
Remove motor end cover gasket (17).
Remove suction strainer (13).
NOTE
If shaft turns, preventing tube assembly from being loosened, block shaft with a piece of wood.
5.
6.
7.
8.
.9.
10.
11.
Remove equalizer tube assembly (18) and lockwasher (12).
Remove 22 cap screws (27) and cap screw gaskets (26).
Remove bottom plate (28) and gasket (25).
Remove oil filter screen assembly (24).
Remove tube assembly (23) and (29).
Remove thrust washer pin (10).
Remove thrust washer (9).
CAUTION
Support rotor while it is being removed to prevent stator damage.
12.
13.
14.
Insert brass plug into rotor hole to protect end of crankshaft (7) from jackbolt.
Remove rotor (11) using a jackbolt.
Remove rotor drive key (8) and retain for reassembly.
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5-49. CRANKSHAFT, PISTONS AND RODS - Continued
DISASSEMBLY - Continued
Figure. 5-39. Crankshaft, Pistons And Rods
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15.
Remove four counterweight and eccentric strap capscrews (35) and locknuts (31).
NOTE
· Motor end counterweight) will remain on eccentric shaft until shaft is removed.
· Label counter weights and eccentric shaft shields so they can be reinstalled in same position on
eccentric shaft.
16.
Remove oil pump end counterweight (1) and two eccentric strap shields (32) and (33).
NOTE
Label eccentric straps so they may be reinstalled in the same position on eccentric shaft.
17.
18.
19.
Pull eccentric shaft out thru pump end (22). Guide eccentric straps (34) from eccentric shaft during removal
process. Rotate shaft and tap it lightly to prevent straps from jamming.
Remove motor end counter weight (30).
Remove eccentric straps (34) thru bottom cover plate opening (21).
NOTE
Keep each piston assembly together for reassembly.
20.
21.
22.
Remove lockrings (2) and piston pins (3).
Remove pistons (6) from eccentric straps (34).
Remove oil ring (4) and compression rings (5).
INSPECTION
1.
2.
3.
4.
Check all removed components for damage, replace as necessary.
Check tolerance of parts removed (Table 5-4).
Replace crankshaft, pistons and rods if out of tolerance.
Check cylinder bore (20) and motor end (19) main bearing tolerances, replace compressor if either one is out of
tolerance.
REPAIR
Repair consists of replacing pistons, eccentric straps, oil and compression rings, and eccentric shaft.
REASSEMBLY
1.
Position pistons (6) on eccentric straps (34).
NOTE
When lockrings are installed on pistons, they should be tight enough so they can not be turned by hand.
2.
3.
4.
5.
6.
Install piston pins (3) and lockrings (2).
Check ring gap by inserting each ring separately in cylinder (6), approximately 3/8 inch (0.95 cm) from top. Ring
gap should be between 0.013 and 0.005 inch (0.03 and 0.013 cm) .
Install oil ring (4) in bottom groove of piston (6) with notch end on bottom.
Install compression rings (5) in top groove of piston (6) with side marked top towards piston head.
Stagger ring gaps around pistons (6).
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5-49. CRANKSHAFT, PISTONS AND RODS - Continued.
REASSEMBLY - Continued.
Table 5-4. Compressor Wear Limits (Factory Tolerances In.)
7.
8.
Measure side clearance between ring and piston (6) (Table 5-4).
Check rings (4) and (5) rotate freely.
NOTE
· Use matched pistons and eccentric straps removed in disassembly for assembly if pistons or eccentric
straps are not replaced.
· While installing eccentric shaft and straps, tap shaft lightly and rotate shaft to prevent straps from
jamming.
9.
10.
Install piston and eccentric strap (34) assemblies through bottom plate (21) into cylinder heads (20).
Guide eccentric shaft (7) thru pump end (22) and eccentric straps (34).
NOTE
Counter weights and eccentric strap shields must be reassembled in same position as labeled in disassembly.
11.
12.
Position counterweights (1, 30) and two eccentric strap shields (32, 33) in mounting position.
Install four counterweight and eccentric strap capscrews (35) and locknuts (31) and torque to 8-10 lb-ft.
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13.
Install rotor drive key (8) on eccentric shaft.
14.
Place thrust washer (9) on eccentric shaft (7) in mounting position.
15.
Install thrust pin (10).
CAUTION
Support rotor while it is being installed to prevent stator damage.
16.
Install rotor (11) on eccentric shaft (7).
NOTE
Block shaft with a piece of wood if shaft turns preventing tube assembly from being installed.
17.
Install equalizer tube assembly (18) and lockwasher (12).
18.
Install filter strainer (13).
19.
Position motor end gasket (17) and cover (14) in mounting position.
20.
Install 18 cap screws (15) and gasket (16), and torque to 25-30 ft-lb.
21.
Install tube assembly (23) and (29).
22.
Install oil filter screen assembly (24).
23.
Position bottom plate gasket (25) and plate (28) in mounting position.
24.
Install 22 cap screw gaskets (26) and screws (27), and torque to 25-30 ft-lb.
FOLLOW ON PROCEDURE
1.
Install pump end bearing assembly (para 5-48).
2.
Install valve plate assembly (para 5-47).
3.
Install compressor into air conditioner (para 5-46).
5-117
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5-50. ELECTRICAL BOX ASSEMBLY.
This task covers:
Inspection
Repair/Replace
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Wrench, torque, 1/2", 10-150 ft-lbs (Item 20, Appendix B)
Material:
Rags (Item 12, Appendix E)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any any internal maintenance.
Voltages used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
Disconnect air conditioner input power at source.
INSPECTION
1.
Check electrical box is not bent, cracked, or punctured. Replace electrical box if damaged.
2.
Check for damaged bushings, loose, or missing mounting hardware.
REPAIR/REPLACE
Repair consists of replacing bushings or electrical box.
REMOVAL
1.
Remove compressor from air conditioner (para 5-46).
2.
Remove two screws (6), star washers (7), and cover (8).
3.
Tag and disconnect leads from terminal plate (3) and current overloads (5).
4.
Remove current overload (para 5-52).
5.
Remove terminal plate (para 5-51).
6.
Pull crankcase heater wire harness through crankcase heater bushing (9).
7.
Pull wiring harness through wiring harness bushing (1).
8.
Remove two bushings (1) and (9). Retain bushings for installation.
9.
Remove two screws (2) and current overload mounting bracket (4). Retain screws and bracket for installation.
10.
Remove two screws (10) and electrical box (11).
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INSTALLATION
1.
Install electrical box (11) with two screws (10) and torque to 16-20 ft-lb.
2.
Install current overload mounting bracket (4) with two screws (2).
3.
Install two bushings (1) and (9).
4.
Pull crankcase heater wire harness through bushing (9) and secure.
5.
Pull wiring harness through wiring harness bushing(1).
6.
Install terminal plate (para 5-51).
7.
Install current overload (para 5-52).
8.
Reconnect leads to terminal plate (3) and current overloads (5), and remove tags.
9.
Install cover (8) with two screws (6) and star washers (7).
10.
Install compressor into air conditioner (para 5-46).
FOLLOW ON PROCEDURE
Connect air conditioner input power at source.
Figure 5-40. Electrical Box Assembly
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5-51. TERMINAL PLATE.
This task covers:
Inspection
Removal
Test
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Wrench, torque, 1/2", 10-150 ft-lbs (Item 20, Appendix B)
Goggles, industrial (Appendix C)
Materials:
Rags (Item 12, Appendix E)
Lubricating oil (Item 9, Appendix E)
Solder, lead-tin alloy (Item 18, Appendix E)
Flux, solder, liquid rosin base (Item 19, Appendix E)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove compressor from air conditioner (para 5-46).
3. Remove electrical box cover (para 5-50).
INSPECTION
Check terminal plate for corrosion, burned thermal barrier, and loose or missing mounting hardware. Replace plate if
defective.
REMOVAL
1.
Tag and disconnect external leads (3) from terminal plate (2).
2.
Remove four capscrews (4).
3.
Pull terminal plate (2) out from crankcase (6).
NOTE
When disconnecting internal wire leads, cut leads as close as possible to terminal plate.
4.
5.
Tag and disconnect internal leads (5) from terminal plate (2).
Remove terminal plate (2).
TEST
Using multimeter, measure each feed through terminal of terminal plate for continuity. If any feed through terminal does
not have continuity, replace terminal plate.
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Figure. 5-41. Terminal Plate
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5-51. TERMINAL PLATE - Continued.
INSTALLATION
1.
Cut and strip internal wires to 3/8 inch (0.95 cm).
2.
Twist and tin each internal wire.
3.
Trim high voltage wires (7) so they will fit i nto terminal post.
NOTE
Low voltage wires will not fit into terminal post. A larger diameter wire needs to be installed.
4.
On low voltage wires (7) install larger diameter wire and butt connector, if necessary.
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive.
Repeated or prolonged skin contact or inhalation of vapors can be toxic. Use a well ventilated area,
wear gloves, and keep away from sparks or flame.
5.
Remove and clean old gasket material from crankcase (6).
6.
Coat gasket (1) with refrigerant oil and place in mounting position.
7.
Reconnect internal leads to terminals (5) and remove tags. (Wires require soldering).
8.
Place terminal plate (2) in mounting position.
9
Install four capscrews (4) and torque to 16-20 ft-lbs.
10.
Reconnect external leads to terminals (3) and remove tags.
FOLLOW ON PROCEDURE
1.
Install electrical box cover (para 5-50).
2.
Install compressor into air conditioner (para 5-46).
3.
Connect air conditioner input power at source.
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5-52. CURRENT OVERLOADS (K23 AND K24).
This task covers:
InspectionTest
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Soldering iron (Item 16, Appendix B)
Goggles, industrial (Appendix C)
Materials:
Rags (Item 12, Appendix E)
Solder, lead-tin alloy (Item 18, Appendix E)
Flux, solder, liquid rosin base (Item 19, Appendix E)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove compressor from air conditioner (para 5-46).
3. Remove electrical box cover (para 5-50).
INSPECTION
Check current overloads for corrosion, burned insulation, and loose or missing mounting hardware. Replace current
overload if defective.
TEST
1.
2.
3.
Disconnect wire leads from overload terminals 1 and 2
Using multimeter, measure across terminals 1 and 2 for continuity. Replace overload if no continuity exists.
Connect wire leads to overload terminals 1 and 2.
REMOVAL
1.
2.
3.
Tag and disconnect leads.
Remove two screws (1).
Remove Overload (2).
INSTALLATION
1.
2.
3.
Place overload (2) in mounting position.
Install two screws (1).
Reconnect leads and remove tags.
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5-52. CURRENT OVERLOADS (K23 AND K24) - Continued.
FOLLOW ON PROCEDURE
1.
2.
3.
Install electrical box cover (para 5-50).
Install compressor into air conditioner (para 5-46).
Connect air conditioner input power at source.
Figure 5-42. Current Overloads (K23 And K24)
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5-53. CONDENSER COIL.
This task covers:
Inspection
Repair
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Material:
Rags (Item 12, Appendix E)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove left front condenser panel (para 4-27).
3. Remove right front condenser panel (para 4-28).
INSPECTION
1.
If a leak is suspected or indicated, test per paragraph 5-15.
2.
If coil is damaged beyond repair, contact General Support Maintenance.
REPAIR
1.
Repair of the condenser coil is limited to checking for leaks and brazing damaged tubing (paras 5-15 and 5-14).
2.
If condenser coil is beyond repair, contact General Support Maintenance.
FOLLOW ON PROCEDURE
1.
Install left front condenser panel (para 4-27).
2.
Install right front condenser panel (para 4-28).
3.
Check refrigerant charge (para 5-17).
4.
Connect air conditioner input power at source.
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5-53. CONDENSER COIL - Continued
Figure. 5-43. Condenser Coil
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5-54. EVAPORATOR COIL.
This task covers:
Inspection
Repair
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Material:
Rags (Item 12, Appendix E)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
4.
Disconnect air conditioner input power at source.
Remove left front evaporator panel (para 4-23).
Remove right front evaporator panel (para 4-25).
Swing open control box (para 4-45).
INSPECTION
1.
If a leak is suspected or indicated, test per paragraph 5-15.
2.
If coil is damaged beyond repair, contact General Support Maintenance.
REPAIR
1.
Repair of the evaporator coil is limited to checking for leaks and brazing damaged tubing (para 5-15 and para 514).
2.
If condenser coil is beyond repair, contact General Support Maintenance.
FOLLOW ON PROCEDURE
1.
Close control box (para 4-45).
2.
Install left front evaporator panel (para 4-23).
3.
Install right front evaporator panel (para 4-25).
4.
Check refrigerant charge (para 5-17).
5.
Connect air conditioner input power at source.
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5-54. EVAPORATOR COIL - Continued
Figure. 5-4. Evaporator Coil
5-128
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CHAPTER 6
GENERAL SUPPORT MAINTENANCE
Section I. REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
6-1.
COMMON TOOLS AND EQUIPMENT . For authorized common tools and equipment refer to the Modified
Table of Organization and Equipment (MTOE) applicable to your unit.
6-2.
SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT. No special tools are required for General Support
Maintenance of the air conditioner.
6-3.
REPAIR PARTS. Repair parts are listed and illustrated in the Repair and Special Tools List (RPSTL), TM 94120-381-24P, covering Unit, Direct Support, and General Support Maintenance for this equipment.
Section II. GENERAL SUPPORT MAINTENANCE PROCEDURES
6-4.
GENERAL. The only items restricted to General Support Maintenance level by the Maintenance Allocation
Chart (MAC) are to replace elements of the air conditioner housing. However, General Support Maintenance may be
called upon, at times, to perform any or all of the MAC items listed for Unit and Direct Support Maintenance for
rehabilitation or overhaul of an air conditioner.
6-5.
SHEET-METAL PARTS (CHASSIS).
a. Disassemble the air conditioner to the extent necessary to gain access to damaged area for repair.
b. Remove insulation from area to be repaired (para 5-7).
WARNING
Toxic fumes are emitted by burning or overheating insulation. Heated refrigeration piping can burst
with explosive force. Shield wiring and piping, and remove insulation in the area if weld repair is
necessary.
c. Repair damage using standard sheet-metal repair procedures. Rivet or weld patches to inside surface when
required.
d. Replace insulation (para 5-7) as necessary and reassemble the air conditioner.
6-1
ARMY TM 9-4210-381-14
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6-6 REAR EVAPORATOR PANEL
This task covers:
Removal
Installation
Inspection
Repair/Replace
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Blind riveter (Item 8, Appendix B)
Riveter (Rivnut) (Item 9, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive compound (Item 1, Appendix E)
Bulk gasket material
Bulk insulation material
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (MEK) (Item 13, Appendix E)
Equipment Conditions:
NOTE
For removal of the rear evaporator panel the air conditioner may have to be removed from the van or
shelter. Refer to the van or shelter technical manual for removal instructions.
REMOVAL
1.
2.
3.
Remove 10 screws (7), flat washers (9), and lockwashers (8) (see Figure 6-1).
Lift panel (6) out slightly, loosen duct clamp (2) and remove hose (1).
Rotate panel (6) counterclockwise and set on ground.
INPECTION
1.
2.
3.
Check that panel is not bent, cracked, or punctured.
Check that gaskets and insulation are not torn, loose, or missing.
Check rivets and rivnuts for missing or loose mounting hardware.
REPAIR/REPLACE
NOTE
Repair consists of replacing RFI gasket, insulation, rivnuts and rivets, or panel.
1.
For RFI gasket, insulation, or panel removal/installation remove the following components as necessary.
a.Remove/install thermostat box and cover (para 6-7).
b.Remove/install fresh air inlet box (para 6-8).
c.Remove/install fresh air damper operator bracket (para 6-9).
6-2
ARMY TM 94120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
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Figure 6-1. Rear Evaporator Panel
6-3
ARMY TM 94120-381-14
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6-6. REAR EVAPORATOR PANEL - Continued.
2.
RFI Gasket.
a. Remove damaged gasket (10) from panel (6).
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be
explosive. Repeated or prolonged skin contact or inhalation of vapors can be toxic. Use
a well ventilated area, wear gloves, and keep away from sparks or flame.
b. Clean area for new gasket, using acetone or MEK and a stiff brush.
c. Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
To fingers.
d. Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
3.
Insulation
a. Remove damaged insulation (4).
b. Clean area for new insulation, using acetone or MEK and a stiff brush.
c. Cut insulation (4) to fit.
d. Coat surfaces of metal and insulation with adhesive. Let both surfaces dry until adhesive is tacky but will not
stick to fingers.
e. Starting with an end, carefully attach insulation to metal surface. Press into firm contact all over.
f. If insulation retainer (3) and rivet (5) were removed, install new retainer (3) and rivet (5).
INSTALLATION
1. Install hose (1) and tighten clamp (2).
2. Place panel (6) into mounting position.
3. Install 10 screws (7), lockwashers (8), and flat washers (9).
FOLLOW ON PROCEDURE
If air conditioner is to be installed in a van or shelter, refer to the van or shelter technical manual for installation
procedures.
6-4
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
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6-7 THERMOSTAT BOX AND COVER
This task covers:
Inspection
Installation
Removal
Repair/Replace
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Riveter (Rivnut) (Item 9, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Methyl-ethyl ketone (MEK) (Item 13, Appendix E)
Sealant tape (Item 15, Appendix E)
Equipment Conditions:
Open rear evaporator panel (para 6-6).
INSPECTION
1.
2.
Check that box is not bent, cracked, or punctured. Replace box, if defective (see Figure 6-2).
Check for damaged, loose, or missing mounting hardware.
NOTE
For removal of the thermostat box the air conditioner must be removed from the van or shelter.
REMOVAL
1.
2.
3.
4.
Remove cool control thermostat (para 4-87).
Remove two screws (9), locknuts (7), and four flat washers (8).
Remove two screws (2), locknuts (6), and four flat washers (3) and (5).
Remove box (4).
REPARI/REPLACE
NOTE
Repair consists of replacing bushing, gaskets, rivnuts, or thermostat box and cover.
1.
2.
Remove grommet (12).
Remove damaged gasket (10) from cover (11).
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive.
Repeated or prolonged skin contact or Inhalation of vapors can be toxic. Use a well ventilated area,
wear gloves, and keep away from sparks or flame.
3.
Clean area for new gasket, using acetone or MEK and a stiff brush.
6-5
ARMY TM 9-4120-381-14
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6-7. THERMOSTAT BOX AND COVER - Continued.
Figure 6-2. Thermostat Box And Cover
REPAIR/REPLACE - Continued
4.
5.
6.
7.
8.
9.
10.
Remove insulator bushing (13).
Install insulator bushing (13).
Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick to
fingers.
Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
Install grommet (1).
Use sealant tape to seal holes between boxes, bushing, and conduit fitting.
If required, drill out and replace damaged (total of eight) rivnuts (12).
INSTALLATION
1.
2.
3.
4.
Place thermostat box (4) in mounting position.
Install two screws (9), four flat washers (8), and two locknuts (7).
Install two screws (2), four flat washers (3) and (5), and two locknuts (6).
Install cool control thermostat (para 4-87).
FOLLOW ON PROCEDURE
Close rear evaporator panel (para 6-6).
6-6
ARMY TM 9-4210-381-14
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6-8 FRESH AIR INLET BOX
This task covers:
Inspection
Installation
Removal
Repair/Replace
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Riveter (Rivnut) (Item 9, Appendix B)
Personnel: 1
Equipment Conditions:
Open rear evaporator panel (para 6-6).
INSPECTION
1.
2.
Check that box is not bent, cracked, or punctured. Replace box, if defective (see Figure 6-3).
Check for damaged, loose, or missing mounting hardware.
NOTE
For removal of the thermostat box the air conditioner must be removed from the van or shelter.
REMOVAL
1.
2.
3.
4.
5.
Remove control wire J-box (para 4-33).
Remove fresh air connecting link (para 4-34).
Remove thermostat bracket (para 4-35).
Remove six screws (8), flat washers (6), and lockwashers (7).
Remove filter (4), and filter box (3).
REPAIR/REPLACE
Repair consists of replacing rivnuts (5) or box (3).
INSTALLATION
1.
2.
3.
4.
5.
Place box (3) in mounting position.
Install six screws (8), lockwashers (7), and flat washers (6).
Install fresh air connecting link (para 4-34).
Install control wire J-box (para 4-33).
Install thermostat bracket (para 4-35).
FOLLOW ON PROCEDURE
Close rear evaporator panel (para 6-6).
6-7
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-9. FRESH AIR DAMPER OPERATOR BRACKET - Continued.
Figure 6-3. Fresh Air Box
6-8
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-9 FRESH-AIR DAMPER OPERATOR BRACKET.
This task covers:
Inspection
Installation
Removal
Repair/Replace
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (Item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Riveter (Rivnut) (Item 9, Appendix B)
Personnel: 1
Equipment Conditions:
Open rear evaporator panel (para 6-6).
INSPECTION
1.
2.
Check that bracket (5) is not bent, cracked, or punctured. Replace bracket, if defective (see Figure 6-4).
Check for damaged, loose, or missing mounting hardware.
NOTE
For removal of the thermostat box the air conditioner must be removed from the van or shelter.
REMOVAL
1.
2.
3.
Remove fresh air damper solenoid (para 4-66).
Remove three screws (1), locknuts (4), and six flat washers (2) and (3).
Remove bracket (5).
REPAIR/REPLACE
Repair consists of replacing rivnuts (6) or bracket (5).
INSTALLATION
1.
Place bracket (5) in mounting position.
2.
Install three screws (1), six flat washers (2) and (3),, and three locknuts (4).
3.
Install fresh air damper solenoid (para 4-66).
FOLLOW ON PROCEDURE
Close rear evaporator panel (para 6-6).
6-9
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-9. FRESH AIR DAMPER OPERATOR BRACKET - CONTINUED.
Figure 6-4. Fresh Air Damper Operator Bracket
6-10
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-10.
REAR CONDENSER PANEL
This task covers:
Removal
Installation
Inspection
Repair
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Electric portable drill (item 6, Appendix B)
Twist drill set (Item 7, Appendix B)
Riveter, blind set (Item 8, Appendix B)
Riveter, (Rivnut) (Item 9, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Bulk insulation material
Rags (Item 12, Appendix E)
Methyl-ethyl ketone (Item 13, Appendix E)
Equipment Conditions:
NOTE
For removal of the rear condenser panel the air conditioner may have to be removed from the van or
shelter. Refer to the van or shelter technical manual for removal or installation instructions.
1.
2.
Remove condenser air out RFI filter (para 6-12).
Remove condenser air in RFI filter (para 6-13).
REMOVAL
1.
2.
Remove 42 screws (1), lockwashers (2), and flat washers (3) (see Figure 6-5).
Remove panel (4).
INSPECTION
1.
Check that panel (4) is not bent, cracked, or punctured. Replace panel, if defective.
2.
Check that gaskets (5) are not torn, loose, or missing.
3.
Check for missing or damaged rivnuts.
REPAIR
NOTE
Repair consists of replacing RFI gasket, rivnuts or panel.
Gasket.
a. Remove damaged gasket (5) from panel (4).
WARNING
Acetone and Methyl-Ethyl Ketone (MEK) are flammable and their vapors can be explosive. Repeated or prolonged skin
contact or inhalation of vapors can be toxic. Use a well ventilated area, wear gloves, and keep away from sparks or
flame.
6-11
ARMY TM 9.4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-10. REAR CONDENSER PANEL- Continued.
REPAIR - Continued.
b. Clean area for new gasket, using acetone or MEK and a stiff brush.
c. Coat surfaces of metal and gasket with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
to fingers.
d. Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
Figure 6-5. Rear Condenser Panel
INSTALLATION
1.
2.
Place panel (4) in mounting position.
Install 42 screws (1), lockwashers (2), and flat washers (3).
FOLLOW ON PROCEDURE
1.
2.
Install condenser air out RFI filter (para 6-12).
Install condenser air in RFI filter (para 6-13).
6-12
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-11
FRESH AIR RFI FILTER
This task covers:
Removal
Replace
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Material:
Rags (Item 12, Appendix E)
Equipment Conditions:
NOTE
For removal of the fresh air RFI filter the air conditioner may have to be removed from the van or
shelter. Remove rear evaporator panel (para 6-6).
REMOVAL
1.
2.
Remove six screws (4), flat washers (2), and lockwashers (3).
Remove filter (7).
REPLACE
Replace consists of replacing filter if found to be damaged.
NOTE
If RFI panel (filter) gasket is damaged, see paragraph 6-6.
INSTALLATION
1.
2.
Place filter (7) in mounting position.
Install six screws (4), lockwashers (3), and flat washers (2).
FOLLOW ON PROCEDURE
Install rear evaporator panel (para 6-6).
6-13
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-01017053-AC
AIR FORCE TO 35E9-136-31
6-11. FRESH AIR RFI FILTER - Continued
Figure 6-6. Fresh Air RFI Filter
6-14
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-12
CONDENSER AIR OUT RFI FILTER.
This task covers:
Removal
Replace
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Rags (Item 12, Appendix E)
Equipment Conditions:
NOTE
If the condenser RFI filter screws are not accessible from outside the shelter or van, the air
conditioner may have to be removed from the van or shelter. Remove rear condenser panel (para 610).
REMOVAL
1.
2.
Remove ten screws (3), flat washers (1), and lockwashers (2) (see Figure 6-7).
Remove filter (4).
REPLACE
Replace consists of replacing condenser air out RFI filter.
INSTALLATION
1.
Coat surfaces of metal and gasket (5) with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
to fingers.
2.
Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
3.
Place filter (4) in mounting position.
4.
Install ten screws (3), lockwashers (2), and flat washers (1).
FOLLOW ON PROCEDURE
Install rear condenser panel (para 6-10).
6-15
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-12
CONDENSER AIR OUT RFI FILTER.
Figure 6-7. Condenser Air Out RFI Filter
6-16
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-13
CONDENSER AIR IN RFI FILTER
This task covers:
Removal
Replace
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Materials:
Adhesive (Item 1, Appendix E)
Bulk gasket material
Rags (Item 12, Appendix E)
Equipment Conditions:
NOTE
If the condenser RFI filter screws are not accessible from outside the shelter or van, the air
conditioner may have to be removed from the van or shelter. .Remove rear condenser panel (para 610).
REMOVAL
1.
2.
Remove ten screws (1), flat washers (3), and lockwashers (2) (see Figure 6-8).
Remove filter (4).
REPLACE
Replace consists of replacing condenser air in RFI filter (4).
INSTALLAI ION
1.
Coat surfaces of metal and gasket (5) with adhesive. Let both surfaces dry until adhesive is tacky but will not stick
to fingers.
2.
Starting with an end, carefully attach gasket to metal surface. Press into firm contact all over.
3.
Place filter (4) in mounting position.
4.
Install ten screws (1), lockwashers (2), and flat washers (3).
FOLLOW ON PROCEDURE
Install rear condenser panel (para 6-10).
6-17
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-13
CONDENSER AIR IN RFI FILTER - Continued
Figure 6-8. Condenser Air In RFI Filter
6-18
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-14.
RFI FILTER
This task covers:
Replace
Inspection
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
NOTE
If the RFI filter screws are not accessible, the air conditioner must be removed from the van or
shelter. Refer to the van or shelter technical manual for removal and installation procedures.
Remove RFI filter top and bottom covers (para 4-42).
REPLACE
Replace RFI filter, if defective (see Figure 69).
REMOVAL
1.
2.
3.
4.
Tag and disconnect RFI filter input and output leads.
If necessary remove air conditioner to gain access to side of air conditioner.
Remove four bolts (1), locknuts (4), and eight flatwashers (2) and (3).
Remove RFI filter (5).
INSTALLAION
1.
2.
3.
4.
Place RFI filter (5) in mounting position.
Install four bolts (1), eight flatwashers (2) and (3), and four locknuts (4).
If air conditioner was removed, install air condition.
Connect leads tagged in removal.
FOLLOW ON PROCEDURE
Install RFI filter top and bottom covers (para 4-42).
6-19
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-14.
RFI FILTER - Continued.
Figure 6-9. RFI Filter
6-20
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-15
FUSE HOLDER (RFI BOX)
This task covers:
Replace
Removal
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
Remove RFI filter (para 6-14).
Replace fuse holder, if defective (see Figure 6-10).
REMOVAL
1.
2:
3.
4.
Remove two screws (3), nuts (5), and lockwashers (4).
Remove varistor and fuse holder mounting assembly (1).
Remove two screws (6), flat washers (7), lockwashers (8), and nuts (9).
'Remove fuse holder (2).
INSTALLATION
1.
2.
3.
4.
Place fuse holder (2) on varistor and fuse mounting assembly (1).
Install two screws (6), lockwashers (8), flat washers (7), and nuts (9).
Place varistor and fuse holder mounting assembly (1) in mounting position.
Install two screws (3), lockwashers (4), and nuts (5).
FOLLOW ON PROCEDURE
Install RFI filter (para 6-14).
6-21
Installation
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-15. FUSE HOLDER (RFI BOX) - Continued.
Figure 6-10. Fuse Holder (RFI Box)
6-22
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-16.VARISTORS (VR-1 THRU VR-4).
This task covers:
Removal
Installation
Inspection
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
Remove RFI filter (para 6-14).
REPLACE
Replace varistor, if defective (see Figure 6-11).
REMOVAL
1.
2.
3.
4.
Remove two screws (8), nut (2), and lockwashers (1).
Remove varistor and fuse holder mounting assembly (5).
Remove two screws (3), nuts (7), and lockwashers (6).
Remove varistor (4).
INSTALLATION
1.
2.
3.
4.
Place varistor (4) in mounting position.
Install two screws (3), lockwashers (6), and nuts (7).
Place varistor and fuse holder mounting assembly (5) in mounting position.
Install two screws (8), lockwashers (1), and nuts (2).
FOLLOW ON PROCEDURE
Install RFI filter (para 6-14).
6-23
Repair/Replace
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-16.VARISTORS (VR-1 THRU VR-4) - Continued.
6-11. VARISTORS (VR-1 THRU VR-4).
6-24
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-6 REAR EVAPORATOR PANEL
This task covers:
Removal
Reassembly
Dissasembly
Installation
Repair/Replace
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
1. Remove rear evaporator panel (para 66).
2. Pump down refrigerant system (para 5-21) (see Figure 6-12).
REMOVAL
1.
Remove valve cap (8).
2.
Remove locknut (13), screw (17), and two flat washers (14) and (16).
3.
Remove two clamps (15) from refrigerant lines.
4.
Loosen two screws (10) and nuts (12) on sensing bulb retaining clamps (11).
5.
Remove sensing bulb (9) from retaining clamp (11).
NOTE
If expansion valve body is to be replaced, disassemble before debrazing.
If expansion valve body is not damaged and will not be removed, proceed to the
disassembly procedure.
6.
7.
Remove external equalizer line (18).
Remove expansion valve body (5) by debrazing tubing (4) and distributor (3) at joints (para 5-14).
DISASSEMBLY
1.
2.
3.
4.
Remove two bolts (2).
Remove powerhead (7) from valve body (5).
Remove cage assembly (6).
Examine cage assembly for damage or defects.
REPAIR/REPLACE
Repair consists of replacing powerhead (7), cage assembly (6), valve body (5), or valve.
REASSEMBLY
1.
2.
3.
4.
Examine replacement cage assembly (6) for defects or damage before reassembly.
Install cage assembly (6).
Install powerhead (7) onto valve body (5).
Install two bolts (2).
6-25
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-17. THERMOSTATIC EXPANSION VALVE (PRIMARY) - Continued
Figure 6-12. Thermostatic Expansion Valve (Primary)
6-26
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
INSTALLATION
NOTE
If expansion valve body is not being installed, proceed to step 2.
If expansion valve body is being installed, proceed to disassembly before brazing valve body.
1.
2.
3.
4.
5.
6.
7.
8.
Install expansion valve body (5) by brazing tubing (4) and distributor (3) at joints (para 5-14).
Install sensing bulb (9) in retaining clamp (11).
Tighten two screws (10) and nuts (12) on sensing bulb retaining clamp (11).
Install two clamps (15) to refrigerant lines.
Install two flat washers (14) and (16), one screw (17), and locknut (13).
Install valve cap (8).
Install external equalizer line (18).
Leak test all brazed connections in repaired area (para 5-15).
FOLLOW ON PROCEDURE
1.
2.
Install rear evaporator panel (para 6-6).
Perform start up after repairs (para 5-22).
6-27
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-18. DISTRIBUTOR.
This task covers:
Removal
Installation
Inspection
Repair/Replace
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Material:
Brazing alloy, silver, QQ-B-654, Grade III (Item 21, Appendix E)
Personnel: 1
Equipment Conditions:
1. System has been pumped down (para 5-21).
2. Remove rear evaporator panel (para 6-6).
3. Disassemble thermostatic expansion valve (para 6-17).
REMOVAL
1.
Debraze distributor (3) at valve joint (2) (para 5-14).
NOTE
Check the length of the new distributor lines before cutting lines distributor lines to coil.
2.
3.
Cut distributor lines (1) to coil (see Figure 6-13).
Remove distributor (3).
INSTALLATION
1.
2.
3.
Braze distributor lines (1) to coil lines (para 5-14).
Braze distributor (3) to valve joint (2) (para 5-14).
Leak test all newly connected joints and those in the repair area (para 5-15).
FOLLOW ON PROCEDURE
1.
2.
3.
Reassemble thermostatic expansion valve (para 6-17).
Perform start up after repairs (para 5-22).
Install rear evaporator panel (para 6-6).
6-28
ARMY TM 9-4120-381-14
NAWVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-18. DISTRIBUTOR - Continued.
Figure 6-13. Distributor
6-29
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-19. PRESSURE REGULATOR VALVE.
This task covers:
Removal
Installation
Inspection
Repair/Replace
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
1. Pump down refrigerant system (para 5-21).
2. Remove rear evaporator panel (para 6-6).
REMOVAL
1.
2.
3.
4.
5.
6.
7.
Remove two screws (1), locknuts (9), eight flat washers (2) and (10), and two clamps (3) from refrigerant lines (see
Figure 6-14).
Loosen screw (6) and locknut (8) in circulating air out RFI filter compartment (para 4-41).
Remove sensing bulb (5) from clamp (7).
Pull two grommets (4) and (11), and sensing bulb (5) up to evaporator compartment.
Remove two bolts (12), nut (16), and four clamp halves (13).
Remove four bolts (17) and nuts (14).
Remove valve body (15).
INSTALLATION
1.
2.
3.
4.
5.
6.
7.
Place valve body (15) in mounting position.
Install four bolts (17) and nuts (14).
Install clamp halves (13) with two bolts (12) and nuts (16).
Route sensing bulb to supply air out RFI filter compartment (para 4-41) and install two grommets (4) and (11).
Place sensing bulb (5) in clamp (7).
Tighten screw (6) and locknut (8).
Install two clamps (3) on refrigerant line with two screws (1), eight flatwashers (2) and (10), and two locknuts (9).
FOLLOW ON PROCEDURE
1.
2.
Install rear evaporator panel (para 6-6).
Perform start up after repairs (para 5-22).
6-30
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-19. PRESSURE REGULATOR VALVE - Continued.
Figure 6-14. Pressure Regulator Valve
6-31
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-20. TUBING AND FITTINGS
This task covers:
Inspection
Removal
Installation
INITIAL SETUP:
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages used
can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1. Disconnect air conditioner input power at source.
2. Remove covers and panels as necessary to have access to repair area.
NOTE
The refrigeration system contains a number of pieces of copper tubing in a variety of material grades,
sizes, lengths, and shapes, and a number of elbows, tees, and adapters in several sizes.
INSPECTION
Check tubing and fittings for signs of leakage. Leak test if leak is suspected (para 5-15).
REMOVAL
1.
2.
3.
4.
Discharge refrigerant system (para 5-12).
Purge refrigerant system (para 5-13).
Debraze (para 5-14) the tube connections.
Remove part.
INSTALLATION
1.
2.
3.
4.
5.
6.
Place replacement part on tube end.
Purge refrigerant system (para 5-13).
Braze replacement part (para 5-14).
Replace drier filter cartridge (para 5-26).
Clean filter strainer (para 5-26).
Leak test (para 5-15) all newly connected joints and those in the repair area.
FOLLOW ON PROCEDURE
1.
2.
3.
4.
Evacuate refrigerant system (para 5-16).
Connect air conditioner input power at source.
Charge refrigerant system (para 5-17).
Install all covers and panels that were removed.
6-32
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-21. CONDENSOR COIL REMOVAL
This task covers:
INITIAL SETUP:
Repair
Removal
Installation
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Materials:
Rags (Item 12, Appendix E)
Brazing alloy, silver, QQ-B-654, Grade III (Item 21, Appendix E)
Personnel: 1
Equipment Conditions:
WARNING
Disconnect input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL. Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
4.
5.
6.
7.
Disconnect air conditioner input power at source.
Remove left front condenser panel (para 4-27).
Remove right front condenser panel (para 4-28).
Discharge system (para 5-12).
Remove rear condenser panel (para 6-10).
Remove high/low refrigerant switches from condenser coil (para 5-23 and 5-24).
Remove low oil switch from condenser coil (para 5-25).
REPAIR
General Support Maintenance repair of the condenser coil is limited to checking for leaks and brazing damaged tubing
(para 5-15 and 5-14).
REMOVAL (See Figure 6-15)
1. Front of Coil.
a. Remove seven screws (10), locknuts (3), and fourteen flat washers (4) and (9) securing upper bracket (8)
to frame.
b. Remove upper bracket (8).
c. Remove eight screws (12), locknuts (16), and sixteen flat washers (13) and (15) securing lower bracket
(14) to frame.
d. Remove screw (20) and locknut (2),
e. Move wiring harness and clamp (1) out of way.
f. Remove four screws (22), locknuts (6), eight flat washers (5) and (21).
g. Remove two rivets (19) and captive receptacle (18).
6-33
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-21. CONDENSER COIL REMOVAL - Continued.
2. Rear of coil.
a. Remove two screws (39), locknuts (38), and four washers (24) and (28)securing thermostat bracket (37) to
coil frame.
b. Remove four screws (36), locknuts (28), and eight flat washers (29) and (35) securing refrigerant lines
support bracket (34) to coil frame.
c. Debraze headers (23) and (33) from coil (para 5-14).
d. Cut condenser damper actuator line (30).
e. Pull condenser damper actuator line (30) through coil and frame.
WARNING
When handling coil, wear gloves to avoid injury to personnel and to reduce fin damage on the coil.
f. Remove four screws (27), locknuts (32), and eight flat washers (26) and (31).
g. Remove condenser coil (7) through front of frame.
INSTALLATION
1. On replacement coil cut notch for damper actuator line.
WARNING
When handling coil, wear gloves to avoid injury to personnel and to reduce fin damage on the coil.
2. Place coil (7) in mounting position.
3. Front of Coil.
a. Install upper bracket (8) to frame with seven screws (10), and fourteen flat washers (4) and (9), and four
locknuts (3).
b. Install lower bracket (14) to frame with eight screws (12), sixteen flat washers (13) and (15).
c. Secure front of coil to frame with four screws (22), eight flat washers (5) and (21), and four locknuts (6).
d. Install wiring harness clamp with screw (20) and locknut (2).
e. Install captive receptacle (18) with two rivets (19).
4. Rear of Coil.
a.
b.
c.
d.
Insert condenser damper actuator line (30) through coil (7) and frame.
Place coupling on actuator line (30).
Secure rear of coil to frame with four screws (27), eight flat washers (26) and (31), and four locknuts (32).
Install thermostat bracket (37) to coil frame with two screws (39), four flat washers (24) and (38), and two
locknuts (25).
6-34
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
e. Install line support bracket (34) to coil frame with four screws (36), eight flat washers (29) and (35), and
four locknuts (28).
WARNING
To avoid injury to personnel and/or damage to equipment entire system must be purged with nitrogen
before beginning any brazing operation.
f.
g.
h.
i.
j.
Braze headers (23 and 33 ), and condenser damper actuator line (30) (para 5-14 ).
Install high/low refrigerant switches to condenser coil (para 5-23 and 5-24).
Install low oil pressure switch to condenser coil (para 5-25).
Leak test all newly connected and surrounding area joints (para 5-15).
Evacuate and charge the refrigerant system (para 5-16 and 5-17).
FOLLOW ON PROCEDURE
1. Install all condenser panels (para 4-27, 4-28, and 6-10).
2. Connect air conditioner input power at source.
Figure 6-15. Condenser Coil Removal (Sheet 1 of 2)
6-35
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-21. EVAPORATOR COIL REMOVAL - Continued.
Figure 6-15. Condensor Coil Removal (Sheet 2 of 2)
6-36
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-22. EVAPORATOR COIL REMOVAL
This task covers:
INITIAL SETUP:
Repair
Removal
Installation
Tools:
Tool kit, service, refrigeration unit (Item 1, Appendix B)
Gloves, chemical (Appendix C)
Personnel: 2
Material:
Rags (Item 12, Appendix E)
Equipment Conditions:
WARNING
Disconnect Input power to the air conditioner before performing any internal maintenance. Voltages
used can KILL Shutting the unit off at the control panel does not disconnect unit power.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Disconnect air conditioner input power at source.
Remove left front evaporator panel (para 4-23).
Remove right front evaporator panel (para 4-25)
Remove rear evaporator panel (para 6-6).
Discharge system (para 5-12).
Remove evaporator motor (para 4-70).
Remove evaporator circulator fan (para 4-71).
Remove plastic heater protector (para 4-80).
Remove solenoid (12) coil, power head and nut securing solenoid to bracket (para 5-35).
Remove solenoid coil (L1) from solenoid value and set aside (para 4-88).
Remove power head, cage assembly, and sensing bulb from primary expansion valve (para 5-38).
REPAIR
General Support Maintenance repair of the evaporator coil is limited to checking for leaks and brazing damaged tubing
(para 5-15 and 5-14).
REMOVAL (See Figure 6-16)
NOTE
· Two persons are required for removing control box
· Access is needed to rear of air conditioner.
1. Remove screw (24), locknut (18), and two flat washers (20) securing control box wiring harness clamp (1) (see
Figure FO-5).
2. Remove four screws (23), lockwasher (22), flat washers (21), and bracket (19).
3. Remove control box (para 4-63) from side of coil and set on top of frame.
4. Remove four bolts (6), locknuts (4), eight flat washers (3) and (5) from shock mounts.
5. Remove evaporator motor and fan mounting bracket.
6. Remove four screws (29), lockwashers (28), flat washers (40) mounting heater assembly (27) to unit frame (32).
7. Remove four rivnuts (26) from unit frame (32) and coil frame (25).
6-37
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
6-22. EVAPORATOR COIL REMOVAL - Continued.
REMOVAL - Continued.
8. Remove four screws (30), locknuts (34), and twelve flat washers (31) and (33) securing evaporator coil to frame
(32).
9. Remove two screws (44), four locknuts (41), six flat washers (42), and two damps (43) from evaporator coil
frame.
10. Remove receptacles if necessary.
WARNING
When handling coil, wear gloves to avoid injury to personnel and to reduce fin damage on the coil.
11. Protect fins of coil with metal plate.
WARNING
To avoid Injury to personnel or damage to equipment, entire system must be purged with nitrogen
before beginning any debrazing operation.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Debraze tubing and couplings six places (2), (13), (14), (15), (16), and (17) (para 5-14).
Debraze evaporator header (2).
Remove six screws (9), locknuts (7), and flat washers (8) mounting T-support to frame.
Remove receiver damp (10).
Remove sensing bulb line clamp (11).
Move plumbing assembly (12) to the right side of evaporator compartments.
Raise evaporator coil (25) and swing out and away from heating element compartment.
Remove evaporator coil (25).
Debraze distributor from primary expansion valve and coil (para 6-18).
Remove two bolts (38), locknuts (35), and four flat washers (36) and (37).
Remove expansion bracket (39).
INSTALLATION
WARNING
When handling coil, wear gloves to avoid injury to personnel and to reduce fin damage on the coil.
1.
2.
3.
4.
Braze distributor to expansion valve and coil (para 6-18).
Place expansion valve and bracket (39) in mounting position on coil (25).
Install two bolts (38), locknuts (35), and flat washers (36) and (37).
Protect fins of coil with metal plate.
6-38
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010 7053-AC
AIR FORCE TO 35E9-136-31
6-22. EVAPORATOR COIL REMOVAL - Continued.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Position evaporator coil (25) into frame.
Cut two inch lengths of 1-1/8 OD tubing.
Place coupling on evaporator header joint (2).
Install evaporator coil (25) to frame with four screws (30), eight flat washers (31) and (33), and four locknuts (34).
Install two screws (44), six flat washers (42), two damps (43), and four locknuts (41).
Install four rivnuts (26) for mounting heater assembly to frame.
Place plumbing assembly (12) in position.
Install receiver clamp (10).
Install mounting T-support with six screws (9), flatwashers (8), and locknuts (7).
If receptacles were removed, install quarter turn receptacles with four rivets.
Install heater assembly (27) to frame with four screws (29), lockwashers (28), and flat washers (40).
Position evaporator motor and fan mounting bracket in mounting position.
Install four bolts (6), eight flat washers (3) and (5), and four locknuts (4).
Braze tubing and coupling (2), (13), (14), (15), (16), and (17) (para 5-14).
Install evaporator circulator fan (para 4-71).
Install evaporator motor (para 4-70).
Install control box to coil and fame (para 4-63).
Install control box wiring harness bracket (19) with four screws (24), lock washers (22), and flat washers (21).
Install wiring harness damp (1).
FOLLOW ON PROCEDURE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Install cage assembly, power head, and sensing bulb to primary expansion valve (para 5-38).
Install solenoid coil (L1) to solenoid valve (para 4-88).
Install power head, solenoid (L2) coil, and nut securing solenoid to bracket (para 5-35).
Install high voltage plastic heater protector (para 4-80).
Leak test all newly connected joints and those in the repair area (para 5-15).
Evacuate and charge the refrigeration system (para 5-16 and 5-17).
Install rear evaporator panel (para 6-6).
Install right front evaporator panel (para 4-25).
Install left front evaporator panel (para 4-23).
6-39
;
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure 6-16. Evaporator Coil Removal (Sheet 1 of 2)
6-40
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure 6-16. Evaporator Coil Removal (Sheet 2 of 2)
6-41/(6-42 blank)
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
APPENDIX A
REFERENCES
A-1. SCOPE. This appendix lists all forms, field manuals, technical manuals and miscellaneous publications referenced
in this manual.
A-2. FORMS.
Recommended Changes to Publications On Blank Forms
Recommended Changes To Equipment Technical Publications
Quality Deficiency Report
Packaging Improvement Report
Equipment Control Record
Report of Discrepancy
Transportation Discrepancy Report
DA-2028
DA-2028-2
SF-368
DD-Form-6
DA-2408-9
SF 364
SF 361
A-3. DEPARTMENT OF THE ARMY PUBLICATION .
The Army Maintenance Management System (TAMMS)
DA PAM 738-750
A-4. TECHNICAL MANUALS.
Unit, Intermediate Direct Support and Intermediate General Support
Maintenance Repair Parts and Special Tools List, Air Conditioner, 50,000 BTU
Destruction of Equipment to Prevent Enemy Use
Painting Instructions for Field Use
Leak Detector, Refrigerant Gas
Hand Portable Fire Extinguisher
TM 9-4120-381 -24P
TM 750-244-3
TM 43-0139
TM 9-4840-435-14
TB 5-4200-200-10
A-5. MISCELLANEOUS PUBLICATIONS.
Varnish, Moisture and Fungus Resistant
The Air Force Suggestion Program (PA)
MIL-V-173C
AFR 900-4
A-1/(A-2 blank)
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
APPENDIX B
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
B-1. GENERAL.
a. This section provides a general explanation of all maintenance and repair functions authorized at various
maintenance categories.
b. The Maintenance Allocation Chart (MAC) in Section II designates overall authority and responsibility for the
performance of maintenance functions on the identified end item or component. The application of the maintenance
functions to the end item or component will be consistent with the capacities and capabilities of the designated
maintenance categories.
c. Section II lists the tools and test equipment (both special tools and common tool sets) required for each
maintenance function as referenced from Section II.
d. IV contains supplemental instructions and explanatory notes for a particular maintenance function.
B-2. MAINTENANCE FUNCTIONS . Maintenance functions will be limited to and defined as follows:
a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical and/or electrical
characteristics with established standards through examination (e.g. by sight, sound, or feel).
b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of
an item and comparing those characteristics with prescribed standards.
c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean (includes
decontaminate when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases.
d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position, or by setting
the operating characteristics to specified parameters.
e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, measuring,
and diagnostic equipment used in precision measurement. Consists of comparisons 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.
g. Remove/Install. To remove and install the same item when required to perform service or other maintenance
functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component
or assembly) in a manner to allow the proper functioning of equipment or a system.
h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place, "Replace" is
authorized by the MAC and is shown as the third position code of the SMR code.
B-1
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
i. Repair. The application of maintenance services1 including fault location/troubleshooting2, removal/installation,
and disassembly/assembly3 procedures, and maintenance actions4 to identify troubles and restore serviceability to an
item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or
assembly), end item, or system.
j. Overhaul.
That maintenance effort (service/action) prescribed to restore an item to a completely
serviceable/operational condition as required by maintenance standards in appropriate technical publications (i.e.,
DMWR). Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally
return an item to like new condition.
k. 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 (e.g., hours/miles) considered in classifying Army equipment/components.
B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II.
a. Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of which is to identify
maintenance significant components, assemblies, subassemblies, and modules with the next higher assembly. End item
group number shall be "00".
b. Column 2, Component/Assembly.
Column 2 contains the item names of components, assemblies,
subassemblies, and modules for which maintenance is authorized.
c. Column 3, Maintenance Function. Column 3 lists the functions to be performed on the item listed in Column 2.
(For detailed explanation of these functions, see paragraph B-2.)
d. Column 4, Maintenance Level. Column 4 specifies, by the listing of a work time figure in the appropriate
subcolumn(s). The level of maintenance authorized to perform the function listed in Column 3. This figure represents
the active time required to perform the maintenance function at the indicated level of maintenance. If the number or
complexity of the tasks within the listed maintenance function vary at different maintenance levels, appropriate work time
figures will be shown for each. The work time figure represents the average time required to restore an item (assembly,
subassembly, component, module, end item, or system) to a serviceable condition under typical field operating
conditions. This time includes preparation time (including any necessary assembly time), troubleshooting/fault location
time, and quality assurance/quality control time in addition to the time required to perform the specific tasks identified for
the maintenance functions authorized in the maintenance allocation chart. The designations for the various maintenance
levels are as follows:
C ...........
O ...........
F ...........
H ...........
D ...........
Operator or Crew
Unit Maintenance
Direct Support Maintenance
General Support Maintenance
Depot Maintenance
e. Column 5, Tools and Equipment. Column 5 specifies, by code, those common tool sets (not individual tools) and
special tools, TMDE, and support equipment required to perform the designated function.
f. Column 6, Remarks. This column shall, when applicable, contain a letter code, in alphabetical order, which shall
be keyed to the remarks contained in Section IV.
Services - Inspect, test, service, adjust, align, calibrate, and/or replace.
Fault location/troubleshooting - The process of investigating and detecting the cause of equipment malfunctioning; the
act of isolating a fault within a system or unit under test (UUT).
3 Disassembly/assembly - encompasses the step-by-step taking apart (or breakdown) of a spare/functional group coded
item to the level of its least componency identified as maintenance significant (i.e., assigned an SMR code) for the
category of maintenance under consideration.
4 Actions - Welding, grinding, riveting, straightening, facing, remachining, and/or resurfacing.
B-2
1
2
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
B-4. EXPLANATION OF COLUMNS IN TOOLS AND TEST EQUIPMENT REQUIREMENTS, SECTION III .
a. Column 1, Reference Code. The tool and test equipment reference code correlates with a code used in the
MAC, Section II, Column 5.
b. Column 2, Maintenance Level. The lowest category of maintenance authorized to use the tool or test equipment.
c. Column 3, Nomenclature. Name or identification of the tool or test equipment.
d. Column 4, National Stock Number. The national stock number of the tool or test equipment.
e. Column 5, Tool Number. The manufacturer's part number.
B-5. EXPLANATION OF COLUMNS IN REMARKS, SECTION IV.
a. Column 1, Reference Code. The code recorded in Column 6, Section II.
b. Column 2, Remarks. This column lists information pertinent to the maintenance function being performed as
indicated in the MAC, Section II.
REMARKS
Section II MAINTENANCE ALLOCATION CHART
(1)
(2)
(3)
(4)
MAINTENANCE LEVEL
UNIT
DS GS DEPOT
GROUP COMPONENT/ MAINTENANCE
NUMBER ASSEMBLY
FUNCTION C
01
PANELS, BOXES
AND INFORMATION PLATES
CENTER FRONT
EVAP PANEL
LEFT FRONT
EVAP
PANEL
FRESH AIR INLET
FILTER BOX
RIGHT FRONT
EVAP
PANEL
INFORMATION
PLATES
LEFT FRONT
COND
PANEL
RIGHT FRONT
COND
PANEL
FRONT SERVICE
VALVE
PANEL
LEFT ELECTRIC
PLATE
RIGHT ELECTRIC
PLATE
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
O
F
H
D
(5)
TOOLS AND
EQUIPMENT
0.1
0.5
0.5
1,6,7,8
1
0.5
0.5
0.1
0.5
0.5
1,6,7,8,9
1
0.5
0.5
0.1
0.5
1,6,7,8
0.5
1,6,7,
8.9
1
0.1
1,6,7,8,9
1
0.1
6,7.8
0.1
0.5
0.1
0.5
0.5
1,6,7,8
0.5
0.5
0.1
0.5
0.5
0.1
0.5
0.5
1,6,7,8
1,6,7,8
0.1
1
1
1
1
B-3
(6)
REMARKS
A
B,C,D,E,F,G.
A
B,C,D,E,F,G,H.Q
A
B,H,Q
A
B,C,D,E.F,G
A
B
A
B,C,D,E,F
G,H
A
B,C,D,E.F,G.I
A
B,C.D,G,H,I
A
C,L
A
C,E
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section II MAINTENANCE ALLOCATION CHART
(1)
(2)
(3)
(4)
MAINTENANCE LEVEL
UNIT
DS GS DEPOT
GROUP COMPONENT/ MAINTENANCE
NUMBER ASSEMBLY
FUNCTION C
REAR
EVAPORATOR
PANEL
INSPECT
REPAIR
O
F
0.1
REPLACE
INSPECT
REPAIR
REPLACE
CONTROL WIRE J INSPECT
BOX
REPAIR
0.1
1.0
0.5
0.1
0.5
0.5
THERMOSTAT
BOX & COVER
FRESH AIR
INLET BOX
FRESH AIR
CONNECTING
LINK
ASSEMBLY
FRESH AIR
DAMPER
OPERATOR
BRACKET
THERMOSTAT
BRACKET
REAR
CONDENSER
PANEL
02
FILTERS
RETURN AIR
FILTER
CIRCULATING
AIR IN RFI
FILTER
FRESH AIR
FILTER
FRESH AIR RFI
FILTER
CONDENSER
AIR OUT RFI
FILTER
0.1
0.5
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
ADJUST
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
0.5
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
8,9
REPLACE
0.1
0.5
0.5
INSPECT
SERVICE
REPLACE
INSPECT
SERVICE
REPLACE
INSPECT
SERVICE
REPAIR
REPLACE
INSPECT
SERVICE
REPLACE
INSPECT
SERVICE
REPLACE
H
D
(5)
TOOLS AND
EQUIPMENT
A
1,6,7,
8,9
1
1,9
1
1,6,7,
8,9
1
0.1
1.0
1.0
1,6,7,9
1
0.1
0.5
1.0
1
1
1
A
1,6,7,9
1
0.1
1.0
1,6,.7,9
1
A
1,6,7,
1.0
1
0.1
0.5
1.0
0.5
0.1
0.5
0.5
0.1
1,13
1
0.5
0.5
0.1
0.5
1.0
0.5
0.1
0.5
1,13
1
1
1
1
1.0
1,13
1
1.0
1,13
1
0.1
0.5
B-4
(6)
REMARKS
B,D,E,F.G.Q
A
J,K,L,O,BN
A
J,L,M,O,
BN,BX
A
Q,BZ
A
O
N
P
0
A
Q
B,E,G,Q
A
T
A
T
S
A
T
C
A
T
S
A
T
S
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section II MAINTENANCE ALLOCATION CHART
(1)
(2)
(3)
(4)
MAINTENANCE LEVEL
UNIT
DS GS DEPOT
GROUP COMPONENT/ MAINTENANCE
NUMBER ASSEMBLY
FUNCTION C
03
CONDENSER
AIR IN RFI
FILTER
CIRCULATING
AIR OUT RFI
FILTER
ELECTRICAL
RFI FILTER
FUSES
FUSE HOLDER
(RFI BOX)
VARISTORS
CONTROL BOX
AND
COMPONENTS
RECTIFIER
SUPPRESSION
DIODES
1N4005
INDICATOR
LIGHTS
CONTROL
RELAYS
RELAY
SOCKETS
FAN
CONTACTORS
COMPRESSOR
CONTACTOR
HEATER
CONTACTOR
O
INSPECT
SERVICE
REPLACE
INSPECT
SERVICE
REPLACE
0.1
0.5
INSPECT
TEST
REPAIR
REPLACE
INSPECT
TEST
REPLACE
REPLACE
0.5
1.0
0.5
INSPECT
TEST
REPLACE
0.5
1.0
INSPECT
TEST
REPLACE
INSPECT
TEST
REPLACE
INSPECT
REPLACE
INSPECT
TEST
REPLACE
INSPECT
TEST
REPLACE
INSPECT
TEST
REPAIR
REPLACE
INSPECT
TEST
REPLACE
INSPECT
TEST
REPLACE
0.1
1.0
0.5
0.1
1.0
0.5
A
1.0
0.1
1.0
1.0
0.1
1.0
1.0
0.1
1.0
1.0
1.0
0.1
1.0
1.0
0.1
1.0
1.0
F
H
0.1
0.1
0.5
0.5
TOOLS AND
EQUIPMENT
1,13
1
1,13
1
(6)
REMARKS
A
T
S
A
T
A
AF,AM
E
2.0
1
1
1
2.0
1
1
1
A
AM
BL
BL
2.0
1
1
A
AM
AB
0.5
1.0
0.5
0.1
D
(5)
1
1
1
1,2,16
A
AM
U
A
AM
V
1,10
1
1
1
1
1
1
1
1
1
1
1
B-5
A
AM
U
A
AM
U
A
AM
W
U
A
AM
U
A
AF
U
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section II MAINTENANCE ALLOCATION CHART-Continued
(1)
(2)
(3)
(4)
MAINTENANCE LEVEL
UNIT
DS GS DEPOT
GROUP COMPONENT/ MAINTENANCE
NUMBER ASSEMBLY
FUNCTION C
TIME DELAY
RELAYS
RESISTORS
MODE SELECT
SWITCH
KNOB
SERVICE LIGHT
SWITCH
FAULT RESET
SWITCH
TRANSFORMER
TERMINAL
BOARDS
CIRCUIT
BREAKERS
CONTROL BOX
TERMINAL
BOARD
SERVICE LIGHT
FRESH AIR
DAMPER
SOLENOID
WIRE
HARNESS
INSPECT
TEST
REPLACE
INSPECT
TEST
REPLACE
INSPECT
TEST
REPLACE
INSPECT
REPLACE
INSPECT
TEST
REPLACE
INSPECT
TEST
REPAIR
REPLACE
INSPECT
TEST
REPLACE
INSPECT
REPLACE
INSPECT
TEST
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPLACE
INSPECT
TEST
REPAIR
REPLACE
INSPECT
TEST
REPLACE
INSPECT
TEST
REPAIR
O
F
0.1
1.0
0.5
0.1
0.5
1.0
0.1
1.0
2.0
0.1
0.2
0.1
1.0
1.0
0.1
1.0
0.5
1.0
0.1
1.0
1.0
0.1
1.0
0.1
1.0
1.0
0.1
0.5
0.5
0.1
1.0
0.1
1.0
1.0
1.0
0.1
0.5
1.0
0.1
1.0
1.0
H
D
(5)
TOOLS AND
EQUIPMENT
1
1
1
1,5
1
1,2,11,16
11
1
1
1
1
1,2,16
1
1
(6)
REMARKS
A
AM
U
A
AM
BQ,BT
A
AM
A
X
A
AM
A
AM
Y
A
AF
U.Z
A
1
1
1
1,6,7,8
1
A
AM
A
B,H,I,J,R
A
1
1
1
1
1
1
1
1,2,5,10,16
B-6
A
AF
AA
AA
A
AM
U
A
AM
AB
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section II MAINTENANCE ALLOCATION CHART
(1)
(2)
(3)
(4)
MAINTENANCE LEVEL
UNIT
DS GS DEPOT
GROUP COMPONENT/ MAINTENANCE
NUMBER ASSEMBLY
FUNCTION C
04
EVAPORATOR
(CIRCULATOR)
MOTOR &
HOUSING
ASSEMBLY
FAN BELT
EVAPORATOR
MOTOR (B1)
CIRCULATOR
FAN
(EVAPORATOR)
05
PULLEYS (60HZ)
CIRC
FAN, CIRC MTR
PULLEYS (50HZ)
CIRC MTR, CIRC
FAN
CONDENSER
MOTOR &
HOUSING
ASSEMBLY
FAN BELT
CONDENSER
MOTOR (B3)
CIRCULATOR
FAN
(CONDENSER)
PULLEYS (60HZ)
COND
MTR, COND FAN
PULLEYS (50HZ)
COND
MTR, COND FAN
O
INSPECT
ADJUST
REPLACE
INSPECT
SERVICE
TEST
REPAIR
REPLACE
INSPECT
SERVICE
REPAIR
REPLACE
INSPECT
ADJUST
REPLACE
INSPECT
ADJUST
REPLACE
0.1
0.5
1.0
0.1
0.5
1.0
INSPECT
ADJUST
REPLACE
INSPECT
SERVICE
TEST
REPAIR
REPLACE
INSPECT
SERVICE
REPAIR
REPLACE
INSPECT
ADJUST
REPLACE
INSPECT
ADJUST
REPLACE
0.1
0.5
1.0
0.1
0.5
1.0
F
H
D
(5)
TOOLS AND
EQUIPMENT
1
1
1.0
1.0
0.1
0.5
1.0
2.0
0.1
0.5
1.0
0.1
0.5
1.0
15
1
1
1,10
1
1
1
1
1
1
1
1
1
1.0
1.0
0.1
0.5
1.0
1.0
0.1
0.5
1.0
0.1
0.5
1.0
15
1
1
1,10
1
1
1
1
1
1
B-7
(6)
REMARKS
AJ
AK
A
AC
AM
AD
AE
A
AH
AG
A
Al
A
Al
AJ
AK
A
AC
AM
AD
AE
A
AH
AG
A
Al
A
Al
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section II MAINTENANCE ALLOCATION CHART
(1)
(2)
(3)
(4)
MAINTENANCE LEVEL
UNIT
DS GS DEPOT
GROUP COMPONENT/ MAINTENANCE
NUMBER ASSEMBLY
FUNCTION C
06
HEATERS,
SENSORS
ELECTRIC
HEATERS
COMPRESSOR
CRANKCASE
HEATER
DIRTY FILTER
SWITCH
HIGH TEMP
SWITCH
AIR FLOW
SWITCH
HEAT
CONTROL
THERMOSTAT
LOW AMBIENT
TEMP
THERMOSTAT
COOL
CONTROL
THERMOSTAT
HIGH REFRIG
PRESSURE
SWITCH
LOW REFRIG
PRESSURE
SWITCH
LOW OIL
PRESSURE
SWITCH
INSPECT
TEST
REPLACE
INSPECT
TEST
REPLACE
INSPECT
ADJUST
TEST
REPLACE
INSPECT
TEST
REPLACE
INSPECT
TEST
REPLACE
INSPECT
ADJUST
TEST
REPLACE
INSPECT
ADJUST
TEST
REPLACE
INSPECT
ADJUST
TEST
REPLACE
INSPECT
ADJUST
TEST
REPLACE
INSPECT
ADJUST
TEST
REPLACE
INSPECT
ADJUST
TEST
REPLACE
O
F
0.1
1.0
1.0
0.1
1.0
1.0
0.5
1.0
1.0
1.0
0.1
1.0
1.0
0.1
1.0
1.0
0.1
0.5
1.0
1.0
0.1
0.5
1.0
1.0
0.1
1.0
1.0
1.0
0.1
H
D
(5)
TOOLS AND
EQUIPMENT
1
1
1
1
1,3
1
1,8
1
1,2
1
1
1
1
1
1
1
1
1
1
1
1.0
1.0
1.0
1
1
1,6,7
1.0
1.0
1.0
1
1
1,6,7
0.5
1.0
1.0
1
1
0.1
0.1
B-8
(6)
REMARKS
A
AM
AL
A
BY
AN
A
AV
AM
U
A
AM
A
AM
U
A
AS
AM
U,J
A
AU
AM
U
A
AT
AM
J,U
A
AP
AM
U,AR
A
AQ
AM
U,AR
A
AO
AM
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section II MAINTENANCE ALLOCATION CHART
(1)
(2)
(3)
(4)
MAINTENANCE LEVEL
UNIT
DS GS DEPOT
GROUP COMPONENT/ MAINTENANCE
NUMBER ASSEMBLY
FUNCTION C
07
PIPING AND
VALVES,
REFRIGERANT
DRIER FILTER
SERVICE
INSPECT
REPAIR
REPLACE
REFRIGERANT
INSPECT
STRAINER
SERVICE
REPAIR
REPLACE
SIGHT
INSPECT
REFRIGERANT
REPAIR
GLASS
REPLACE
SERVICE VALVES INSPECT
REPLACE
SOLENOID
VALVES
VALVES
INSPECT
REPLACE
COILS
INSPECT
TEST
REPLACE
THERMOSTATIC
EXPANSION
VALVE
(LIQUID QUENCH)
HOT GAS
BYPASS VALVE
THERMOSTATIC
EXPANSION
VALVE
(PRIMARY)
MANUAL VALVE
VIBRATION
ELIMINATOR
CONDENSER
FAN DAMPER
ACTUATOR
CONDENSER
FAN
CONNECTING
LINK ASSY
O
INSPECT
ADJUST
REPAIR
REPLACE
INSPECT
ADJUST
REPAIR
REPLACE
INSPECT
ADJUST
REPAIR
REPLACE
INSPECT
REPLACE
INSPECT
REPLACE
INSPECT
TEST
REPLACE
INSPECT
ADJUST
REPLACE
F
0.1
2.0
2.0
2.0
0.1
2.0
1.0
5.0
H
D
(5)
TOOLS AND
EQUIPMENT
1
1
1
1
1
0.1
0.5
5.0
0.1
5.0
0.1
5.0
0.1
1.0
1.0
1
1
B-9
REMARKS
A
AW,BG
BD
AX,AW
A
BG
AW,BI,BJ
A
BF
BE
A
1
A
1
1
1,10
0.1
0.5
2.0
2.0
0.1
0.5
2.0
2.0
0.1
0.5
2.0
5.0
0.1
2.0
0.1
5.0
0.1
1.0
2.0
0.1
1.0
1.0
1
1
(6)
1,17,18
1
1
1
1
1.17,18
1
1
A
AM
U,BA,BV,
BW
A
AY
AZ
AL
A
BB
AZ
AL
A
AY
AZ
AL
A
1
1
1
1
A
BE
A
BR
A
O
P
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section II MAINTENANCE ALLOCATION CHART
(1)
(2)
(3)
(4)
MAINTENANCE LEVEL
UNIT
DS GS DEPOT
GROUP COMPONENT/ MAINTENANCE
NUMBER ASSEMBLY
FUNCTION C
RECEIVER
DISTRIBUTOR
PRESSURE
REGULATOR
VALVE
08
TUBING AND
FITTINGS
COMPRESSOR
ASSEMBLY (B2)
O
F
H
D
(5)
TOOLS AND
EQUIPMENT
(6)
REMARKS
INSPECT
REPLACE
INSPECT
REPLACE
INSPECT
ADJUST
REPAIR
REPLACE
INSPECT
REPLACE
0.1
2.0
0.1
0.1
5.0
1
SERVICE
TEST
REPAIR
1.0
5.0
5.0
1
1
1,19,20,
CE,CF
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
REPAIR
REPLACE
INSPECT
TEST
REPLACE
INSPECT
TEST
REPLACE
5.0
0.5
2.0
2.0
0.5
2.0
2.0
0.5
2.0
2.0
0.5
2.0
2.0
0.1
0.5
2.0
0.1
0.5
2.0
1,4,14
1
BE
A
BD
BE
A
BD
BE
A
BD
BE
A
BD
BE
A
AM
1
5.0
1
5.0
1,17,18
1
1
0.1
1.0
2.0
A,CD
BH
A
A
BC
BD
AL
A
BO
BD
21
VALVE PLATE
ASSEMBLY
PUMP END
BEARING HEAD
ASSEMBLY
CRANKSHAFT,
PISTONS AND
RODS
ELECTRICAL
BOX
ASSEMBLY
TERMINAL
PLATE
CURRENT
OVERLOADS
09
COILS
CONDENSER
COIL
EVAPORATOR
COIL
INSPECT
SERVICE
REPAIR
REPLACE
INSPECT
SERVICE
REPAIR
REPLACE
1,20
1
1,19,21
1
1,19
1
1
1
1
1
1
0.5
1.0
5.0
12,13
1
1
5.0
12,13
1
1
2.0
0.5
1.0
2.0
B-10
A
AM
A
BU
BS
A
BU
BS
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section II MAINTENANCE ALLOCATION CHART
(1)
(2)
(3)
(4)
MAINTENANCE LEVEL
UNIT
DS GS DEPOT
GROUP COMPONENT/ MAINTENANCE
NUMBER ASSEMBLY
FUNCTION C
10
CHASSIS
CHASSIS
REPAIR PARTS
DRAIN AREAS
O
INSPECT
REPAIR
INSPECT
SERVICE
F
0.5
1.0
0.5
1.0
H
D
(5)
TOOLS AND
EQUIPMENT
1.6,7,
8,9
1
1
B-11
(6)
REMARKS
A
B,D,G,H,J,K
L,M,BM
,BN,BO,BP
CB
CC
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS
MAINTENENCE ALLOCATION CHART
(1)
(2)
REFERENCE MAINTENANCE
CODE
LEVEL
1
O-F-H
2
3
4
5
6
7
8
9
O-F-H
O
F-H
O-F-H
O-F-H
O-F-H
O-F-H
O-F-H
(3)
NOMENCLATURE
TOOL KIT, SERVICE,
REFRIGERATION UNIT
HEAT GUN
MANOMETER
BAR,WRECKING
CRIMPING TOOL
DRILL, ELECTRIC, PORTABLE
DRILL SET, TWIST
RIVETER, BLIND
TOOL KIT, RIVET NUT
CONSISTING OF:
INSTALLATION TOOL
NOSE PIECE
DIE, BLIND BOLT
STUD, NOSE UNIT
NOSE UNIT
PULLER ATTACHMENT
PULLER ATTACHMENT
PULLER ATTACHMENT
PULLER
10
11
O-F-H
O-F-H
12
13
O-F-H
O-F-H
14
F-H
15
O-F-H
CRIMPING TOOL (PIGTAIL)
SCREW DRIVER, FLAT TIP,
1/8" WD
FIN COMB
VACUUM CLEANER
KIT, COMPRESSOR REMOVAL
LUBRICATING GUN
(4)
NATIONAL/NATO
STOCK NUMBER
5180-00-596-1474
4940-01-042-4855
6685-00-273-7007
5120-00-242-0762
5120-00-278-2423 47100 (00779)
5130-00-935-7354
5130-00-293-0983
5120-00-017-2849 98 (61957)
(11530)
5120-01-245-7549 TA7533 (08524)
5120-00-126-2008 HN7513-6
(08524)
5120-00-126-1964 HN7513-8
(08524)
5120-00-133-3830 HN7513-10
(08524)
5120-01-084-4094 HN7513-12
(08524)
5120-00-104-2685 HP7523-6
(08524)
5120-00-104-2626 HP7523-8
(08524)
5120-00-104-2528 HP7523-10
(08524)
5120-01-084-4092 HP7523-12
(08524)
H18 (26132)
5120-00-542-2281
P12 (17529)
7910-01-178-7953 S1015030W
(29335)
43N3-102-2
(98437)
4930-01-114-2121
B-12
(5)
TOOL
NUMBER
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS
MAINTENANCE ALLOCATION CHART
(1)
(2)
REFERENCE MAINTENANCE
CODE
LEVEL
(3)
NOMENCLATURE
16
17
18
19
O-F-H
H
H
H
20
H
21
H
SOLDERING IRON
THERMOMETER, DIGITAL
THERMOCOUPLE
WRENCH, TORQUE, 1/4"
30-200 INCH LBS
WRENCH, TORQUE, 1/2"
10-150 FT LBS
WRENCH SET, SOCKET
22
23
F
F
FILE, HAND
CALIPER SET, MICROMETER
24
25
F
F
26
F-H
GAUGE SET, TELESCOPIC
REGULATOR ASSY
(NITROGEN)
RECOVERY AND RECYCLING
UNIT, REFRIGERANT
B-13
(4)
NATIONAL/NATO
STOCK NUMBER
(5)
TOOL
NUMBER
3439-00-930-1638 450K4 (11103)
52 (53431)
80PK-1 (53431)
5120-00-177-7065
5120-00-902-3549
5120-01-187-8434 11OTMA
(55719)
5110-01-257-8922 12MA (55719)
5210-00-117-0468 CM6171
(55719)
5210-00-570-6894 5229G (57163)
6680-00-503-1327
4130-01-338-2707 175008
(07295)
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section IV. REMARKS
MAINTENANCE ALLOCATION CHART
REF
CODE
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
.
W
X
Y
Z
AA
AB
AC
REMARKS
VISUAL INSPECTION
REPLACE RIVETS
REPLACE CAPTIVE FASTENER, EJECTOR SPRING, THERMOPLASTIC WEAR WASHER
AND SPLIT RING RETAINER
REPLACE INSULATION MATERIAL
REPLACE RFI GASKET
REPLACE INSULATION RETAINER AND/OR WASHER
USE ADHESIVE COMPOUND
REPLACE RECEPTACLE
REPLACE STAINLESS STEEL HINGE
REPLACE INSULATOR BUSHING
REPLACE GROMMET
REPLACE GASKET
REPLACE CONDUIT FITTING
REPLACE COUNTER WEIGHT, REMOTE CONTROL LEVER
ADJUST LINKAGE FOR FRESH AIR DAMPER OPERATION AND/OR CONDENSER FAN
DAMPER OPERATION
CUT REPLACEMENT CONNECTING LINK ASSEMBLY TO 4 1/2 INCHES LONG FOR
FRESH AIR DAMPER OPERATION. CUT REPLACEMENT CONNECTING LINK ASSEMBLY
TO 13 INCHES FOR CONDENSER FAN ACTUATOR OPERATION
REPLACE RIVET NUT
REPLACE LOCKING RING
WHEN REPLACING FILTER, INSTALL FRESH RFI GASKET MATERIAL. USE CLEAR
SEALANT ADHESIVE.
CLEAN FILTERS. MILD DETERGENT AND WATER AND/OR VACUUM
FUNGUS PROOF REPLACEMENT ITEM PER MIL-V-173
ASSEMBLE REPLACEMENT DIODE WITH WIRE TERMINALS AND SHRINK TUBING.
COLOR BAND DENOTES CATHODE END
REPLACE CONTACTOR HEATER ELEMENTS
REPLACE KNOB
REPLACE SPLASH PROOF SEAL
ON REPLACEMENT ITEM, CUT AND STRIP ALL WIRES TO 6 1/2 INCHES LONG. DEAD
END RED AND ORANGE WIRES TOGETHER
REPLACE LAMP, LAMP HOLDER, LIGHT GUARD, AND/OR INSULATOR BUSHING
REPLACE WIRES, TERMINAL LUGS, CLAMPS AND/OR TIE WRAPS
LUBRICATE MOTOR
B-14
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section IV. REMARKS
MAINTENANCE ALLOCATION CHART - Continued
REF
CODE
AD
AE
AF
AG
AH
Al
AJ
AK
AL
AM
AN
AO
AP
AQ
AR
AS
AT
AU
AV
AW
AX
AY
AZ
BA
BB
BC
BD
REMARKS
REPLACE BEARINGS
WHEN REPLACING MOTOR, STRIP AND DEAD END WIRES TOGETHER FOR 208VAC, 3
PHASE OPERATIONINSTALL INSULATOR BUSHINGS TO MOTOR JUNCTION BOX.
INSTALL AND CRIMP PIG TAILS TO WIRES
TEST FOR PRESENCE OF AC VOLTAGE
REPLACE BEARINGS, SHAFT AND/OR BEARING COLLAR. REPLACEMENT SHAFT
MUST BE CUT TO LENGTH.
LUBRICATE IMPELLER SHAFT
ADJUST PULLEY ON EVAPORATOR (CIRCULATOR) MOTOR AND/OR CONDENSER
MOTOR FOR PROPER FAN ROTATION
INSPECT FOR LOOSE OR WORN FAN BELTS
ADJUST FAN BELT TENSION FOR 1/2 INCH DEFLECTION
SUBSTITUTE CAST IRON HARDWARE ON REPLACEMENT WITH STAINLESS STEEL.
APPLY SEALANT COMPOUND^
CONTINUITY CHECK
WHEN REPLACING CRANKCASE HEATER, PERFORM THE FOLLOWING ALTERATIONS:
CUT CONDUIT TO 10 1/2 INCHES
CUT WIRES TO -18 INCHES
STRIP WIRE ENDS TO 1/2 INCH MAXIMUM.
ADJUST LOW OIL PRESSURE LIMIT SET POINT
ADJUST HIGH REFRIGERANT PRESSURE LIMIT SET POINT
ADJUST LOW REFRIGERANT PRESSURE LIMIT SET POINT
DRILL (3) 5/32 INCH HOLES THROUGH TERMINALS OF REPLACEMENT PART
ADJUST THERMOSTAT TO NOMINAL 72 DEGREES F
ADJUST AND LOCK MINIMUM/MAXIMUM TEMPERATURE RANGE SETTING TO
NOMINAL 68 AND 95 DEGREES F
ADJUST THERMOSTAT TO NOMINAL 0 DEGREES F
ADJUST PRESSURE TO 0.4 INCHES WC
REPLACE FILTER ELEMENT UPON COMPRESSOR BURN-OUT OR WHENEVER
REFRIGERANT SYSTEM IS OPENED FOR PURGING OR EVACUATION
USE 9/16 X 2 INCH BOLTS FOR EARLY MODEL FILTER DRIER COVER PLATE AND 1/2 X
1 3/4 INCH BOLTS FOR LATER MODEL
RAISE/LOWER SUPERHEAT SETTING
REPLACE CAGE ASSEMBLY AND/OR POWER HEAD ASSEMBLY
STRIP AND DEAD END WIRES WHEN INSTALLING REPLACEMENT ITEM
ADJUST FOR VALVE RESPONSE RATE AND/OR SUCTION PRESSURE
ADJUST FOR DISCHARGE AIR TEMPERATURE
REPLACE SUBORDINATE HARDWARE
B-15
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Section IV. REMARKS
MAINTENANCE ALLOCATION CHART - Continued
REF
CODE
BE
BF
BG
BH
BI
BJ
BK
BL
BM
BN
BO
BP
BQ
BR
BS
BT
BU
BV
BW
BX
BY
BZ
CA
CB
CC
CD
CE
CF
REMARKS
REPLACE ENTIRE ASSEMBLY ON FAILURE
TIGHTEN SIGHT GLASS IF LEAK IS DETECTED
CLEAN FILTER SCREEN UPON COMPRESSOR BURN-OUT OR WHEN REFRIGERANT
SYSTEM IS OPENED FOR PURGING OR EVACUATING
CAP, CRIMP AND SOLDER INLET ON REPLACEMENT ITEM
MINIMUM 17 INCH EXTENSION IS REQUIRED TO REMOVE STRAINER CAP
POSITION RAGS TO ABSORB EXCESS OIL DURING SERVICE AND/OR REMOVAL
REPLACE VARISTOR
REPLACE FUSE OR FUSE HOLDER
USE SEALANT COMPOUND (LOCKTITE) FOR ALL BOLTS WITHOUT LOCKNUTS
USE INDUSTRIAL SEAL (DUX SEAL) TO SEAL HOLES BETWEEN COMPARTMENTS
AND/OR BOXES
REPLACE TUBING AND/OR HOSE MATERIAL
REPLACE FLEXIBLE CONDUIT
REPLACE RESISTOR
APPLY GAS PRESSURE TO VERIFY ACTUATOR OPERATION
BRAZE EXTERNAL TUBING
ASSEMBLE REPLACEMENT RESISTORS WITH WIRE TERMINALS AND SHRINK TUBING
STRAIGHTEN DAMAGED FINS WITH FIN COMB AND VACUUM
REMOVE ONE KNOCKOUT ON REPLACEMENT ITEM
INSTALL AND CRIMP PIG TAILS TO WIRES
REPLACE CONDUIT FITTING
MEASURE CURRENT
REPLACE PIVOT AND BLADE
INSPECT OIL LEVEL
INSPECT DRAIN PAN FOR CONDENSATION DRAINAGE. INSPECT FOR RUST AND
CORROSION. APPLY CORROSION PREVENTATIVE AS REQUIRED
CLEAN AND VACUUM DRAIN PAN AND/OR DRAIN HOLES
REPLACE FUSIBLE PLUG
REPLENISH REFRIGERANT OIL
SUBSTITUTE OIL IN REPLACEMENT ITEM WITH 2% SYNTHETIC OIL AND 98%
COMPRESSOR OIL
B-16
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
APPENDIX C
COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST
Section I. INTRODUCTION
C-1. SCOPE. This appendix lists components of end item and basic issue items for the air conditioner to help you
inventory the items for safe and efficient operation of the equipment.
C-2. GENERAL. The components of end item list and basic issue Items list are divided into the following sections:
a. Section II. Components of end item. This listing is for informational purposes only, and is not authority to
requisition replacements. These items are part of the end item, but are removed and separately packaged for
transportation or shipment. As part of the end item, these items must be with the end item whenever it is issued or
transferred between property accounts. Illustrations are furnished to assist you in identifying the items.
b. Section III. Basic issue items. These are the minimum essential items required to place the air conditioner in
operation, to operate it, and to perform emergency repairs. Although shipped separately, Basic Issue Items must be with
the air conditioner during operation and whenever it is transferred between property accounts. The illustration will assist
you with hard to identify items. This manual is your authority to request/requisition replacement Basic Issue Items, based
on TOE/MTOE authorization of the end item.
C-3. EXPLANATION OF COLUMNS.The following provides an explanation of columns found in the tabular listings.
a. Column (1) Illustration Number (Illus Number). This column indicates the number of the illustration in which the
item is shown.
b. Column (2) National Stock Number. This column indicates the national stock number assigned to the item and
will be used for requisitioning purposes.
c. Column (3) Description. Indicates the Federal item name and, if required, a minimum description to identify
and locate the item. The last line for each item indicates the CAGEC (in parentheses) followed by the part number.
d. Column (4) Unit of Measure (U/M). Indicates the measure used in performing the actual function.
measure is expressed by a two-character alphabetical abbreviation (e. g. ,-ea, in, pr).
This
e. Column (5) Quantity required (Qty rqr). Indicates the quantity of the item authorized to be used with/on the
equipment.
Section II. COMPONENTS OF END ITEM
NOT APPLICABLE
C-1
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
SECTION III. BASIC ISSUE ITEMS
(1)
NATIONAL
STOCK NUMBER
7240-00-943-7105
8415-00-266-8677
4240-00-052-3776
(2)
DESCRIPTION
CAGEC AND PART NUMBER
USABLE ON CODE
Pail, Utility (81348) L-P-65
Gloves, Chemical (81348)
Goggles, Industrial (58576)
(3)
U/M
ea
pr
ea.
C-2
(4)
QTY
AUTH
1
1
1
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
APPENDIX D
ADDITIONAL AUTHORIZATION LIST
Section I. INTRODUCTION
D-1. SCOPE. This appendix lists additional items you are authorized for the air conditioner.
D-2. GENERAL. This list identifies items that do not have to-accompany the air conditioner and that do not have to be
turned in with it. These items are all authorized to you by CTA, MTOE, TDA, or JTA.
D-3. EXPLANATION OF LISTINGS. National stock numbers, descriptions, and quantities are provided to help you
identify and request the additional items you require to support this equipment. The items are listed in alphabetical
sequence by item name under the type document (i.e., CTA, MTOE, TDA, or JTA) which authorized the item(s) to you.
SECTION II. ADDITIONAL AUTHORIZATION LIST
(1)
NATIONAL
STOCK NUMBER
4210-00-555-8837
(2)
DESCRIPTION
CAGEC AND PART NUMBER
USABLE ON CODE
FIRE EXTINGUISHER (06535) #FH900-2
D-1/(D-2 blank)
(3)
U/M
ea
(4)
QTY
AUTH
1
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
APPENDIX E
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Section I. INTRODUCTION
E-1. SCOPE.
This appendix lists expendable supplies and materials you will need to operate and maintain the air conditioner. This
listing is for informational purposes only and is not authority to requisition the listed items. These items are authorized to
you be CTA 50-970, Expendable/Durable Items (Except Medical, Class V, repair Parts, and Heraldic Items), or CTA 8100, Army Medical Department Expendable/Durable Items.
E-2. EXPLANATION OF COLUMNS IN SECTION II.
a. Column (1), Item Number. This number is assigned to the entry in the listing and is referenced in the narrative
instructions to identify the material(e.g. "Use lubricating oil, Item, Appendix E.").
b. Column (2), Level. This column identifies the lowest level of maintenance that requires the listed item.
C - Operator/Crew
O - Unit Maintenance
F - Direct Support Maintenance
H - General Support Maintenance
c. Column (3), National Stock Number.
requisition or request the item.
This is the National Stock Number assigned to the item; use it to
d. Column (4), Description. Indicates the federal item name and, if required, a description to identify the item.
The last line for each item indicates the Commercial and Government Entity Code (CAGEC) in parentheses followed by
the part number.
e. Column (5), Unit of Measure (U/M). Indicates the measure used in performing the actual maintenance function.
This measure is expressed by a two character alphabetical abbreviation (e. g. , ea, in pr). If the unit of measure differs
from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements.
E-1
ARMY TM 9-4210-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
SECTION II. EXPENDABLE / DURABLE SUPPLIES AND MATERIAL LIST
(1)
(2)
(3)
(4)
(5)
ITEM
NUMBER
LEVEL
NATIONAL STOCK
NUMBER
DESCRIPTION
CAGEC AND PART NUMBER
U/M
1
2
3
4
5
6
7
8
9
10
11
F
F
F
F
F
F
F
F
F
F
F
12
13
14
15
16
O
F
F
F
O
8810-00-799-9830
17
F
8030-01-041-1596
18
19
F
F
3439-00-269-9610
3439-00-045-7940
20
F
7930-00-764-5066
21
F
3439-00-853-9276
22
F
6830-00-872-5120
23
O
9150-00-086-3734
8040-00-225-4548
8030-01-129-7171
8040-00-841-9733
8030-01-135-0685
8030-01-262-9962
8030-00-275-8114
9150-01-064-2666
6850-00-837-9927
7920-00-205-1711
6830-00-292-0732
Adhesive #732 RTV (71984)
Grease aeroshell 22 (54527)
Adhesive #520 (03938)
Sealing compound #241-31 (05972)
Corrosion preventative #244 (04963)
Sealing compound #612 (04963)
Sealant #116 (94836)
Paint FED STD 595A #26250 (08882)
Lubricating oil #Zerol 15
0 (99252)
Lubricating oil SS-291
Monochlorodifluoromethane,
technical: w/cylinder 22 lb (Refrigerant 22) BB-F-1421 type 22 (81348)
Rags (81348)
Methyl-ethyl ketone (MEK)
Nitrogen, technical (81348)
Sealant tape #5354 (04963)
Varnish, moisture and fungus resistant MIL-V-173 (72688)
Corrosion preventative MIL-C-85054
TYPE 1 (80244)
Solder, lead-tin alloy (81348)
Flux, solder, liquid rosin base,
MIL-F-14256 (81348)
Detergent Dishwashing P-D-410
TY2 (80244)
Brazing alloy, silver, QQ-B-654,
Grade III
Trichlormonofluoromethane,
technical: w/cylinder 50 lb (refrigerant
-11) BB-F-1421 Type 11 (81348)
Oil, air filter, Filter Kotee (40736)
E-2
tube
tube
tube
bottle
gl
rl
2gl
gl
qt
qt
cl
pg
gl
cy
oz
gl
oz
sl
qt
oz
oz
cy
oz
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
A
Abbreviations, List of................................................................................................................................ 1-1
Access Panels Removal........................................................................................................................... 4-4
Adjustments and Checks, Initial................................................................................................................ 2-5
Air Conditioner Control............................................................................................................................. 4.32
Air Conditioner for Installation, Preparation of
.......................................................................................... 4-4
Air Filter, Fresh ........................................................................................................................................ 4-70
Air Filter, Return.......................................................................................................................................
3-5
Air Flow Switch (S8)................................................................................................................................. 4-164
Assembly and Preparation for Use........................................................................................................... 2-5
Assembly, Fresh Air Connecting Link.......................................................................................................
4-64
Assembly, Pump End Bearing.................................................................................................................. 5-111
Assembly, Valve Plate............................................................................................................................. 5-109
B
Board (TB4), Terminal.............................................................................................................................. 4-123
Box and Cover, Thermostat..................................................................................................................... 6-5
Bracket, Thermostat................................................................................................................................. 4-66
Brazing/Debrazing Procedures................................................................................................................. 5-24
C
Center Front Evaporator Panel................................................................................................................. 4-36
Charging Refrigerant System................................................................................................................... 5-31
Checks, Pulley ......................................................................................................................................... 4-8
Circuit Breakers (CB1 and CB2)............................................................................................................... 4-118
Circulating Air In RFI Filter....................................................................................................................... 4-68
Circulating Air Out RFI Filter.................................................................................................................... 4-75
Circulator Fan (Condenser)...................................................................................................................... 4-148
Circulator Fan (Evaporator)...................................................................................................................... 4-136
Coil, Evaporator .......................................................................................................................................
4-178
Coil Removal, Solenoid Valves (L1 and L2)............................................................................................. 4-172
Common Tools and Equipment................................................................................................................ 4-1, 5-1, 6-1
Compressor ............................................................................................................................................. 5-101
Compressor Contactor (K10).................................................................................................................... 4-98
Compressor Crankcase Heater (CCH)......................................................................................................
4-158
Compressor Crankcase Oil, Motor Lubrication/
......................................................................................... 4-1
Index-1
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
C - Continued.
Compressor, Discharging....................................................................................................................
5-37
Compressor, Purging .........................................................................................................................
5-39
Condenser Air In RFI Filter.................................................................................................................
4-74,6-17
Condenser Air Out RFI Filter..............................................................................................................
4-73,6-15
Condenser Coil ..................................................................................................................................
4-176. 5-125
Condenser Coil Removal...................................................................................................................
6-33
Condenser Fan Connecting Link Assembly
........................................................................................
4-174
Condenser Fan Damper Actuator.......................................................................................................
5-90
Condenser Motor (B3)........................................................................................................................
4-146.5-14
Condenser Motor and Housing Assembly
............................................................................................
4-143
Condenser Panels
Left Front .....................................................................................................................................
Rear .............................................................................................................................................
Right Front ...................................................................................................................................
4-47
6-11
4-50
Configurations, Operating...................................................................................................................
1-7
Contactor (K11), Heater......................................................................................................................
4-100
Contactors (K8 and K9), Fan..............................................................................................................
4-95
Control Box ........................................................................................................................................
4-120
Control Box and Components.............................................................................................................
4-83
Control, Heater...................................................................................................................................
4-33
Control Relays (K1 - K7, K18 - K20)...................................................................................................
4-91
Control Wire J-Box.............................................................................................................................
4-61
Controls and Indicators, Operator's....................................................................................................
2-1
Cool Control Thermostat (S14)
............................................................................................................
4-170
Crankshaft, Pistons and Rods............................................................................................................
5-113
Current Overloads (K23 and K24)
.......................................................................................................
5-123
Cycles, Operating...............................................................................................................................
1-7
D
Description and Use of Operator's Controls and Indicators
General ........................................................................................................................................
2-1
Description, Functional.......................................................................................................................
4-32
Description of Major Components, Location and
.................................................................................
1-2
Destruction of Army Material to Prevent Enemy Use
..........................................................................
1-2
Diodes (CR2 - CR11), Suppression....................................................................................................
4-87
Index-2
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
D - Continued
Direct Support Maintenance Procedures
General ........................................................................................................................................
5-9
Direct Support Troubleshooting
General ........................................................................................................................................
5-1
Dirty Filter Switch (S3) .......................................................................................................................
4-160
Discharge Valve (Compressor)...........................................................................................................
5-69
Discharging Compressor....................................................................................................................
5-37
Discharging Refrigeration System......................................................................................................
5-20
Distributor ..........................................................................................................................................
5-95.6-28
Down, Pump ......................................................................................................................................
5-41
Drain Areas ........................................................................................................................................
4-180
Drier Filter (Dehydrator).....................................................................................................................
5-54
E
Electric Heater (EH)...........................................................................................................................
4-155
Electric Plate, Left..............................................................................................................................
4-56
Electric Plate, Right............................................................................................................................
4-58
Electrical Box Assembly.....................................................................................................................
5-118
Eliminators, Vibration.........................................................................................................................
5-88
Equipment Characteristics, Capabilities, and Features
.......................................................................
1-2
Equipment Data .................................................................................................................................
1-5
Evacuating Refrigerant System..........................................................................................................
5-28
Evaporator (Circulator) Motor and Housing Supply
.............................................................................
4-131
Evaporator Coil ..................................................................................................................................
4-178, 5-127
Evaporator Coil Removal...................................................................................................................
6-37
Evaporator Motor (B1)........................................................................................................................
4-134, 5-11
Evaporator Panels
Center Front ................................................................................................................................
Fresh Air Inlet Filter Box (Evaporator Front Panel)
.......................................................................
Left Front .....................................................................................................................................
Rear .............................................................................................................................................
Right Front ...................................................................................................................................
4-36
4-41
4-38
4-60.6-2
4-43
Expansion Valve (Liquid Quench), Thermostatic
................................................................................
5-75
Expansion Valve (Primary), Thermostatic..........................................................................................
5-83
(Evaporator Front Panel), Fresh Air Inlet Filter Box
............................................................................
4-41
(Evaporator Motor and Housing Assembly), Fan Belt
.........................................................................
4-132
Index-3
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
F
Fan Belt (Condenser Motor and Housing Assembly)
................................
.
..........................................
4-144
Fan Belt (Evaporator Motor and Housing Assembly)
...........................................................................
4-132
Fan Contactors (K8 and K9)...............................................................................................................
4-95
Fan Damper Actuator, Condenser
.......................................................................................................
5-90
Fan (Evaporator), Circulator...............................................................................................................
4-136
Fault Reset Switch (S12)....................................................................................................................
4-112
Features, Equipment Characteristics, Capabilities, and
......................................................................
1-2
Filter (Dehydrator), Drier....................................................................................................................
5-54
Filter, RFI ...........................................................................................................................................
4-77, 6-19
Fittings, Tubing and............................................................................................................................
5-100, 6-32
Fresh Air Connecting Link Assembly..................................................................................................
4-64
Fresh Air Damper Solenoid (L3).........................................................................................................
4-127
Fresh Air Filter ...................................................................................................................................
4-70
Fresh Air Inlet Box .............................................................................................................................
6-7
Fresh Air Inlet Filter Box (Evaporator Front Panel)
.............................................................................
4-41
Fresh Air RFI Filter.............................................................................................................................
4-72, 6-13
Fresh Air Damper Operator Bracket...................................................................................................
6-9
Front Access Panels Installation.........................................................................................................
4-12
Front Service Valve Panel.................................................................................................................
4-53
Functional Description........................................................................................................................
4-32
Fuse Holder (RFI Box).......................................................................................................................
6-21
Fuses (F1 -F4) ...................................................................................................................................
4-79
G
General...............................................................................................................................................
2-1,2-5,2-14,
3-1,4-1,4-22,
5-1, 5-9,6-1
General Information
Scope ..........................................................................................................................................
1-1
General Maintenance.........................................................................................................................
4-35
General Support Maintenance Procedures
General ........................................................................................................................................
6-1
Glass, Sight Refrigerant.....................................................................................................................
5-59
lndex-4
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
H
Harness, Wire ....................................................................................................................................
4-129
Heat Control Thermostat (S9)............................................................................................................
4-166
Heater (CCH), Compressor Crankcase
...............................................................................................
4-158
Heater Contactor (K11).......................................................................................................................
4-100
Heater Control....................................................................................................................................
4-33
Heater (EH), Electric..........................................................................................................................
4-155
High Refrigerant Pressure Switch (S4)...............................................................................................
5-45
High Temperature Switch (S6)...........................................................................................................
4-162
Hot Gas Bypass Valve.......................................................................................................................
5-79
I
Indicator Lights (DS1 - DS7, DS9)......................................................................................................
4-89
Information Plates..............................................................................................................................
2-12, 4-46
Information Plates, Panels and...........................................................................................................
5-9
Information, Warranty ........................................................................................................................
1-1
Initial Adjustments and Checks...........................................................................................................
2-5
Inspection, Receiving.........................................................................................................................
4-3
Installation Instructions.......................................................................................................................
4-9
Installation, Front Access Panels........................................................................................................
4-12
Installation, Service Manifold.............................................................................................................
5-18
Installation Site Preparation...............................................................................................................
4-3
Introduction ........................................................................................................................................
4-15
K
Knob (Mode Select Switch (S1)).........................................................................................................
4-109
L
Leak Testing Refrigerant System.......................................................................................................
5-26
Left Electric Plate ................................
.
..............................................................................................
4-56
Left Front Condenser Panel...............................................................................................................
4-47
Left Front Evaporator Panel...............................................................................................................
4-38
Light (DS8), Service...........................................................................................................................
4-125
Light Switch (S2), Service..................................................................................................................
4-110
List of Abbreviations...........................................................................................................................
1-1
Location and Description of Major Components
..................................................................................
1-2
Low Ambient Temperature Thermostat (S13)
.....................................................................................
4-168
Index-5
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
L- Continued
Low Oil Pressure Switch (S7).............................................................................................................
5-51
Low Refrigerant Pressure Switch (S5)................................................................................................
5-48
M
Maintenance Forms, Records, and Reports
........................................................................................
1-1
Manual Valve (Bypass)......................................................................................................................
5-86
Mode Select Switch (S1)....................................................................................................................
4-106
Motor (B1), Evaporator.......................................................................................................................
5-11
Motor (B3), Condenser.......................................................................................................................
5-14
Motor and Housing Assembly, Condenser
..........................................................................................
4-143
Motor and Housing Supply, Evaporator (Circulator)
............................................................................
4-131
Motor Lubrication/Compressor Crankcase Oil
.....................................................................................
4-1
O
Operating Configurations....................................................................................................................
1-7
Operating Cycles................................................................................................................................
1-7
Operating Procedure..........................................................................................................................
2-6
Operation in AUTO Mode...................................................................................................................
2-7
Operation in COOL Mode...................................................................................................................
2-8
Operation in Dusty or Sandy Conditions.............................................................................................
2-15
Operation in Extreme Cold.................................................................................................................
2-14
Operation in Extreme Heat.................................................................................................................
2-14
Operation in HEAT Mode...................................................................................................................
2-9
Operation in REMOTE Mode..............................................................................................................
2-10
Operation in Salt Air or Sea Spray.....................................................................................................
2-15
Operation in Unusually Wet Conditions..............................................................................................
2-15
Operation Under Emergency Conditions............................................................................................
2-15
Operation Under Unusual Conditions
General ........................................................................................................................................
2-14
Operation Under Usual Conditions
General ........................................................................................................................................
2-5
Operator Bracket, Fresh-Air Damper..................................................................................................
6-9
Operator Lubrication Instructions
General ........................................................................................................................................
3-1
Operator Maintenance Procedures.....................................................................................................
3-5
Index-6
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
O - Continued
Operator Preventive Maintenance and Services (PMCS)
Introduction ..................................................................................................................................
2-3
Operator Troubleshooting
....................................................................................................................
3-1
Operator's Controls and Indicators.....................................................................................................
2-1
Overloads (K23 and K24), Current.....................................................................................................
5-123
P
Panel, Center Front Evaporator..........................................................................................................
4-36
Panel, Front Service Valve................................................................................................................
4-53
Panel, Left Front Condenser..............................................................................................................
4-47
Panel, Left Front Evaporator..............................................................................................................
4-38
Panel, Rear Evaporator......................................................................................................................
4-60
Panel, Right Front Condenser............................................................................................................
4-50
Panel, Right Front Evaporator............................................................................................................
4-43
Panels and Information Plates............................................................................................................
5-9
Pistons and Rods, Crankshaft............................................................................................................
5-113
Plate, Left Electric..............................................................................................................................
4-56
Plate, Right Electric............................................................................................................................
4-58
Plates, Information.............................................................................................................................
4-46
Preparation for Movement..................................................................................................................
2-12
Preparation for Storage and Shipment...............................................................................................
4-182
Preparation for Storage or Shipment..................................................................................................
1-2
Preparation for Use, Assembly and....................................................................................................
2-5
Preparation, Installation Site..............................................................................................................
4-3
Preparation of Air Conditioner for Installation
.....................................................................................
4-4
Pressure Check, Refrigerant..............................................................................................................
5-34
Pressure Regulator Valve...................................................................................................................
5-96, 6-30
Pressure Switch (S7), Low Oil............................................................................................................
5-51
Prevent Enemy Use, Destruction of Army Material to
.........................................................................
1-2
Procedures, Brazing/Debrazing..........................................................................................................
5-24
Pulley Checks ....................................................................................................................................
4-8
Pulleys 50 Hz, Red (Condenser Motor and Circulator Fan)
.................................................................
4-153
Pulleys 50 Hz, Red (Evaporator Motor and Circulator Fan)
................................................................
4-141
Pulleys 60 Hz, Green (Condenser Motor and Circulator Fan)
.............................................................
4-151
Pulleys 60 Hz, Green (Evaporator Motor and Circulator Fan)
.............................................................
4-139
Pump Down .......................................................................................................................................
5-41
Index-7
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
P - Continued
Pump End Bearing Assembly
..............................................................................................................
5-111
Purging Compressor ..........................................................................................................................
5-39
Purging Refrigerant System...............................................................................................................
5-22
R
Rear Condenser Panel.......................................................................................................................
6-11
Rear Evaporator Panel.......................................................................................................................
4-60, 6-2
Receiver ............................................................................................................................................
5-93
Receiving Inspection..........................................................................................................................
4-3
Records, and Reports, Maintenance Forms
........................................................................................
1-1
Rectifier (CR1) ...................................................................................................................................
4-85
Refrigerant Pressure Check...............................................................................................................
5-34
Refrigerant Pressure Switch (S4), High..............................................................................................
5-45
Refrigerant Pressure Switch (S5), Low
...............................................................................................
5-48
Refrigerant Strainer............................................................................................................................
5-57
Refrigerant System, Charging............................................................................................................
5-31
Refrigerant System, Evacuating.........................................................................................................
5-28
Refrigerant System, Leak Testing......................................................................................................
5-26
Refrigerant System, Purging..............................................................................................................
5-22
Refrigeration System, Discharging.....................................................................................................
5-20
Refrigeration System, General Repairs..............................................................................................
5-17
Regulator Valve, Pressure..................................................................................................................
5-96
Relay Sockets ....................................................................................................................................
4-93
Relays (K1 - K7, K18 - K20), Control..................................................................................................
4-91
Relays (K21 and K22), Time Delay (10 and 60 Sec)
...........................................................................
4-102
Removal, Access Panels....................................................................................................................
4-4
Removal, Condenser Coil..................................................................................................................
6-33
Removal, Evaporator Coil..................................................................................................................
6-37
Repair Parts .......................................................................................................................................
4-1 5-1, 6-1
Reporting Equipment Improvement Recommendations (EIR)
.............................................................
1-1
Reset Switch (S12), Fault...................................................................................................................
4-112
Resistors (R1 and R2)........................................................................................................................
4-104
Return Air Filter...................................................................................................................................
3-5
(RFI Box), Fuse Holder......................................................................................................................
6-21
RFI Filter ............................................................................................................................................
4-77, 6-19
Index-8
ARMY TM 9-4120-381-14
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AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
R - Continued
RFI Filter, Circulating Air In................................................................................................................
4-68
RFI Filter, Circulating Air Out.............................................................................................................
4-75
RFI Filter, Condenser Air In................................................................................................................
4-74, 6-17
RFI Filter, Condenser Air Out.............................................................................................................
4-73, 6-15
RFI Filter, Fresh Air............................................................................................................................
4-72, 6-13
Right Electric Plate.............................................................................................................................
4-58
Right Front Condenser Panel.............................................................................................................
4-50
Right Front Evaporator Panel.............................................................................................................
4-43
S
Safety, Care, and Handling.................................................................................................................
1-7
Scope.................................................................................................................................................
1-1, 1-7
Service Light (DS8)............................................................................................................................
4-125
Service Light Switch (S2)...................................................................................................................
4-110
Service Manifold Installation..............................................................................................................
5-18
Service Valve (Actuator)....................................................................................................................
5-65
Service Valve (Expansion).................................................................................................................
5-63
Service Valves (Head and Hotgas Bypass)
........................................................................................
5-61
Service Valves (Schrader).................................................................................................................
5-67
Sheet-Metal Parts (Chassis)...............................................................................................................
6-1
Shutdown (OFF).................................................................................................................................
2-11
Sight Refrigerant Glass......................................................................................................................
5-59
Solenoid (L3), Fresh Air Damper........................................................................................................
4-127
Solenoid Valves (L1 and L2)...............................................................................................................
5-73
Solenoid Valves (L1 and L2) Coil Removal
.........................................................................................
4-172
Special Tools, Test, Measurement and Diagnostic Equipment (TMDE), and Support Equipment
.........
4-1
Special Tools, TMDE, and Support Equipment
...................................................................................
5-1.6-1
Start Up After Repairs........................................................................................................................
5-43
Storage or Shipment, Preparation for.................................................................................................
1-2, 4-182
Strainer, Refrigerant...........................................................................................................................
5-57
Suction Valve (Compressor)...............................................................................................................
5-71
Suppression Diodes (CR2- CR11)......................................................................................................
4-87
Switch (S1), Mode Select...................................................................................................................
4-106
Index-9
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
S - Continued
Switch (S3), Dirty Filter ......................................................................................................................
4-160
Switch (S8), Air Flow..........................................................................................................................
4-164
T
Technical Principles of Operation
Scope ................................................................................................................................................
1-7
Temperature Switch (S6), High..........................................................................................................
4-162
Temperature Thermostat (S13), Low Ambient
....................................................................................
4-168
Terminal Board (TB4).........................................................................................................................
4-123
Terminal Boards (TB1 -TB3)..............................................................................................................
4-116
Terminal Plate....................................................................................................................................
5-120
Thermostat Box and Cover................................................................................................................
6-5
Thermostat Bracket............................................................................................................................
4-66
Thermostat (S14), Cool Control..........................................................................................................
4-170
Thermostat (S9), Heat Control...........................................................................................................
4-166
Thermostatic Expansion Valve (Liquid Quench)
..................................................................................
5-75
Thermostatic Expansion Valve (Primary)...........................................................................................
5-83, 6-25
Time Delay (10 and 60 Sec) Relays (K21 and K22)
............................................................................
4-102
Transformer (T1) ................................................................................................................................
4-114
Troubleshooting .................................................................................................................................
4-22, 5-1
Tubing and Fittings.............................................................................................................................
5-100, 6-32
U
Unit Lubrication Instructions
General ........................................................................................................................................
4-1
Unit Preventive Maintenance Checks and Services (PMCS)
Introduction ..................................................................................................................................
4-15
Unit Troubleshooting..........................................................................................................................
4-22
Unloading ...........................................................................................................................................
4-2
Unpacking ..........................................................................................................................................
4-2
Index-10
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
ALPHABETICAL INDEX
SUBJECT
PAGE
V
Valve Panel, Front Service................................................................................................................
4-53
Valve, Hot Gas Bypass,......................................................................................................................
4-79
Valve Plate Assembly.........................................................................................................................
5-109
Valve, Pressure Regulator..................................................................................................................
6-30
Valves (L1 and L2) Coil Removal, Solenoid.......................................................................................
4-172
Varistors (VR-1 thru VR-4).................................................................................................................
4-81,6-23
Vibration Eliminators ..........................................................................................................................
5-88
W
Warranty Information .........................................................................................................................
1-1
Wire Harness .....................................................................................................................................
4-129
Wire J-Box, Control............................................................................................................................
4-61
Index-11/(lndex-12 blank)
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
By Order of the Secretaries of the Army, Air Force, and Navy:
Official:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
06371
MERRILL A. McPEAK
General, USAF
Chief of Staff
Official:
RONALD W. YATES
General, USAF
Commander, Air Force Materiel Command
DAVID E. BOTTORFF
Rear Admiral, CEC, US Navy
Commander
Navy Facilities Engineering
Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25-E, block no. 6199, requirements for TM 9-4120-381-14.
IU.S. GOVERNMENT PRINTING OFFICE: 1994 - 555-028/00148
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure FO-1. Electrical Schematic.
FP-1/(FP-2 blank)
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure FO-2. Dimensions.
FP-3/(FP-4 blank)
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure FO-3. Wiring Diagram. (Sheet 1 of 2)
FP-5/(FP-6 blank)
ARMY TM 9-4120-381-14
NAVY EE-000-CA-MMA-010/7053-AC
AIR FORCE TO 35E9-136-31
Figure FO-3. Wiring Diagram. (Sheet 2 of 2)
FP-7/(FP-8 blank)
The Metric System and Equivalents
Linear Measure
Liquid Measure
1 centimeter = 10 millimeters = .39 inches
1 decimeter = 10 centimeters = 3.94 inches
1 meter = 10 decimeters = 39.37 inches
1dekameter = 10 meters = 32.8 feet
1 hectometer = 10 dekameters = 328.08 feet
1 kilometer = 10 hectometers = 3,280.8 feet
1 centiliter = 10 milliliters = .34 fl. ounce
1 deciliter = 10 centiliters = 3.38 fl. ounces
1 liter = 10 deciliters = 33.81 fl. ounces
1 dekaliter = 10 liters = 2.64 gallons
1 hectoliter = 10 dekaliters = 26.42 gallons
1 kiloliter = 10 hectoliters = 264.18 gallons
Weights
Square Measure
1 centigram = 10 milligrams = .15 grain
1 decigram = 10 centigrams = 1.54 grains
1 gram = 10 decigram = .035 ounce
1 dekagram = 10 grams = .35 ounce
1 hectogram = 10 dekagrams = 3.52 ounces
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. ft.
1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. Inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
Approximate Conversion Factors
To change
To
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
pounds-feet
pound-inches
Multiply by
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons
newton-meters
newton-meters
2.540
.305
.914
1.609
6.451
.093
.836
2.590
.405
.028
.765
29.573
.473
.946
3.785
28.349
.454
.907
1.356
.11296
To change
ounce-inches
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons
To
Multiply by
newton-meters
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
Temperature (Exact)
°F
Fahrenheit
temperature
5/9 (after
subtracting 32)
Celsius
temperature
°C
.007062
.394
3.280
1.094
.621
.155
10.764
1.196
.386
2.471
35.315
1.308
.034
2.113
1.057
.264
.035
2.205
1.102
PIN: 072243-000
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