air conditioner, horizontal, compact, 36000 btuhair conditioner, horizontal, compact, 36000 btuh 208...

T M 5 - 4 1 2 0 - 3 6 1 - 1 4

TECHNICAL MANUAL

O P E R A T O R ’ S O R G A N I Z A T I O N A L , D I R E C T S U P P O R T & G E N E R A L S U P P O R T

M A I N T E N A N C E M A N U A L

F O R

AIR CONDITIONER, HORIZONTAL, COMPACT, 36000 BTUH

2 0 8 V O L T , 3 P H A S E 4 0 0 H E R T Z

N S N 4 1 2 0 - 0 0 - 0 6 3 - 8 1 8 2

A M E R I C A N A I R F I L T E R C O . M O D E L C H 4 3 6 - 1

A N D

2 0 8 V O L T , 3 P H A S E , 5 0 / 6 0 H E R T Z

N S N 4 1 2 0 - 0 0 - 0 6 3 - 7 5 7 5

A M E R I C A N A I R F I L T E R C O . M O D E L C H 6 3 6 - 1

D E P A R T M E N T O F T H E A R M Y

30 MAY 1980

TM 5-4120-361-14

CHANGE HEADQUARTERSDEPARTMENT OF THE ARMY

No. 4 WASHINGTON D.C., 1 JULY 1992

C 4

Operator, Organizational, Direct Support and General SupportMaintenance Manual

AIR CONDITIONER, HORIZONTAL, COMPACT, 36,000 BTUH208 VOLT, 3 PHASE, 400 HERTZ, NSN 4120-01-063-8182

(AMERICAN AIR FILTER CO., MODEL CH436-1)208 VOLT, 3 PHASE, 50/60 HERTZ, NSN 4120-01-063-7573

(AMERICAN AIR FILTER CO., MODEL CH636-1)

Approved for public release; Distribution is unlimited

TM 5-4120-361-14, 30 May 1980 is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a verticalbar in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

6-1 through 6-6 6-1 through 6-6D-9 and D-10 D-9 and D-10F-1/(F-2 blank) F-1/(F–2 blank)

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVANGeneral, United States Army

Official: Chief of Staff

MILTON H. HAMILTONAdministrative Assistant to the

Secretary of the Army01569

DISTRIBUTION:

To be distributed in accordance with DA Form 12–25E, (qty rqr block no. 0085).

TM 5-4120-361-14

WARN ING

HIGH VOLTAGE

is used in the operation of this equipment.

DEATH ON CONTACT

or severe injury may result if personnel fail

to observe safety precautions.

Always disconnect the air conditioner from

power source before performing maintenance

on this equipment.

If power must remain on for troubleshooting,

exercise extreme care to avoid contact with

any electrical component, fan, fan motor, etc.

Do not operate the air conditioner without

louvers, top covers, and guards in place and

tightly secured.

WARNING

REFRIGERANT UNDER PRESSURE

is used in the operation of this equipment

DEATH

or severe injury may result if personnel fail

to observe safety precautions.

Never use a heating torch on any part

that contains refrigerant-22.

Avoid bodily contact with liquid refrigerant

and avoid inhaling refrigerant gas.

WARNING

The burning of polyurethane foams is dangerous.

Due to the chemical composition of a polyurethane foam,

toxic fumes are released when it is burned or heated.

If it is burned or heated indoors~

such as during a welding operation in its proximity,

precautions should be taken to adequately ventilate the area.

An exhaust system equivalent to that of a

‘paint spray both should be used.

Air supplied respirators, approved by the

National Institute for Occupational Safety and Health

or the US Burerau of Mines,

should be used for all welding in confined spaces

and when ventilation is inadequate.

Individuals who have chronic or recurrent respiratory

conditions, including allergies and asthma,

should not be employed in this type of environment.

WARNING

Dry cleaning solvent, P-D-680, used to clean parts,

is potentially dangerous to personnel and property.

Avoid repeated and prolonged skin contact.

M not use near open flame or excessive heat.

Flash point of solvent is 100° -138°F (38” -59”C).

i

TM 5-4120-361-14

TECHNICAL MANUAL HEADQUARTERS

NO. 5-4120-361-14 DEPARTMENT OF THE ARMY

WASHINGTON, D.C., 30 May 1980

OPERATOR, ORGANIZATIONAL,

DIRECT SUPPORT AND GENEML SUPPORT

MAINTENANCE MANUAL

AIR CONDITIONER, HORIZONTAL, COMPACT, 36,000 BTUH

208 VOLT, 3 PHASE, 400 HERTZ

NSN 4120-01-063-8182


208 VOLT, 3 PHASE, 50/60 HERTZ

NSN 4120-01-063-7573


R E P O R T I N G E R R O R S A N D R E C O M M E N D I N G I M P R O V E M E N T S

You can help improve this manual. If you find any mistake or if you know of a way to improve the pro-

cedures, 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 direct to Commander, U.S. Amy

Troop Support Command, ATTN: AMSTR-MCTS, 4300 Goodfellow Boulevard, St. Louis, M0 63120-1798.

A reply will be furnished directly to you.

C H A P T E R 1 .Section I.

II.III.


II.

III.IV.


TABLE OF CONTENTS

Page

INTRODUCTIONGeneral Information. . . . . . . . . . . . . . . . 1-1Equipment Description. . . . . . . . . . . . . . . 1-2Technical Principles of Operation. . . . . . . . . 1-4OPERATING INSTRUCTIONSControls and Instruments . . . . . . . . . . . . . 2-1Preventive Maintenance Checks

and Services . . . . . . . . . . .. . . . . . . . .. . . . . . . 2-4Operating Under Usual Conditions . . . . . . . . . . . . . . . . . 2-6Operating Under Unusual Conditions . . . . . . . . . . . . . 2-16MAINTENANCE INSTRUCTIONSLubrication Instructions . . . . . . . . . . . . . . . . . . . . 3-1Troubleshooting. . . . . . . . . . . . . . . . . . 3-1Maintenance Procedures . . . . . . . . . . . . . . 3-1

Change 1

I I .III.

TM 5-4120-361-14

CHAPTER 4.

Section I.II.

III.

IV.v.

VI .VII.

CHAPTER 5.

Section I.

II.III.IV.

CHAPTER 6.Section I.

APPENDIX A.B.

Section I.II.

III.APPENDIX C.Section I.

II.APPENDIX D.Section I.

II.APPENDIX E.

F.INDEX. . . .

TABLE OF CONTENTS (CONTINUED)

ORGANIZATIONAL MAINTENANCEINSTRUCTIONS

Service Upon Receipt of Material . . . . . . . . .Movement to a New Worksite . . . . . . . . . . . .Repair Parts, Special Tools and

Equipment. . . . . . . . . . . . . . . . . . . .Lubrication Instructions . . . . . . . . . . . . .Preventive Maintenance Checks andServices. . . . . . . . . . . . . . . . . . . .

Troubleshooting. . . . . . . . . . . . . . . . . .Maintenance of Air Conditioner . . . . . . . . . .DIRECT AND GENERAL SUPPORTMAINTENANCE INSTRUCTIONS

Repair Parts, Special Tools andEquipment. . . . . . . . . . . . . . . . . . . .

Troubleshooting. . . . . . . . . . . . . . . . . .General Maintenance Instructions . . . . . . . . .Removal and Installation of MajorComponents and Assemblies. . . . . . . . . . . .

REPAIR INSTRUCTIONSRefrigeration System . . . . . . . . . . . . . . .

REFERENCES. . . . . . . . . . . .COMPONENTS OF END ITEM LIST. . . .Introduction . . . . . . . . . . .Integral Components of End Item. .Basic Issue Items. . . . . . . . .ADDITIONAL AUTHORIZATION LIST. . .Introduction . . . . , . . . . . .Additional Authorization List. . .MAINTENANCE ALLOCATION CHART . . .Introduction , . . . . . . . . . .Maintenance Allocation Chart . . .REPAIR PARTS AND SPECIAL TOOLS . .EXPENDABLE SUPPLIES AND MATERIALS.. .... . . . . . . . . . . . . . .

Page

4-14-6

4-64-6

4-74-84-15

5-15-15-6

5-7

6-1

A-1B-1B-2B-2B-2C-1C-1C-1D-1D-1D-3E-1F-1I-1

*u.s.130vERw4ENT PRINmNGOFFlCE 1w7–7s4.03w01 79

ii

PIN: 046441-001

TM 5-4120-361-14

CHAPTER 1

INTRODUCTION

1-1. Scope.

Section I. GENERAL INFORMATION

This manual is for your use in opera-ting and maintaining the AAF ModelsCH436-1 and CH636-1 air conditioners.

1-2. Maintenance Forms and Records.

Maintenance forms and records thatyou are required to use are explained inTM 38-750.

1-3. Reporting of Equipment Improve-ments Recommendations.

EIR can and must be submitted by any-one who is aware of any unsatisfactorycondition with the equipment design oruse. It is not necessary to show a newdesign or list a better way to perform aprocedure, just simply to tell why thedesign is unfavorable or why a procedureis difficult. EIR may be submitted on

Figure 1-1. Air conditioner, right front, three quarter view, with shippingdimensions

1-1

TM 5-4120-361-14

SF 368 (Quality Deficiency Report). In- Blvd., St. Louis, MO 63120. A replystructions for preparing EIR’s are pro- will be forwarded directly to you.vialed in TM 38-750, the Army Mainte-nance Managements System. Mail directly 1-4. Equipment and Serviceabilityto Commander Headquarters, U. S. Army Criteria.Troop Support and Aviation Material Com- mand, ATTN: DRSTS-MEM, 4300 Goodfellow This equipment is not covered by an

ECS.

Figure 1-2. Air conditioner left rear, three quarters view

Section II. EQUIPMENT DESCRIPTION

1-5. Equipment Purpose, Capabilitiesand Features.

Air conditioner Model CH436-1 orCH636-1 (figures 1-1 and 1-2) is a com-pletely self-contained, compact, hori-zontal unit designed for cooling andheating air to a desired predeterminedrange, and circulating the conditionedair to provide heating or cooling ofequipment or personnel within the air-conditioned area. It is designed forcontinuous operation, with varyingloads. It is used primarily in van typeenclosures to provide the filtered cool-ing and ventilating or heated air re-quired to maintain service conditionsnecessary for efficient operation ofelectronic equipment and the comfort ofoperating personnel. It is equipped

with internal ducting so that ventila-tion air may be drawn into the area be-ing air conditioned. The evaporator andcondenser sections of the air condi-tioner are separated by an insulatedmetal partition that forms part of theunit housing.

1-6. Location and Description of MajorComponents.

a. Evaporator Section. The evapor-ator section (fig. 1-3), located in thefront of the air conditioner, containsintake and discharge air louvers, airfilter, mist eliminator, evaporatorcoil, evaporator motor and fans, heaterelements, heater thermal protector, pri-mary expansion valve, condensate drain

1-2

TM 5-4120-361-14

Figure 1-3. Air conditioner top view, top covers removed

hoses, electrical control panel and con-trols, main input power connector, con-trol mdule, and the ventilation airdamper door and control knob. The evap-orator fan draws air into the unit, fromthe space being conditioned, through theinlet louver and air conditioning fil-ter, or when required, from the outsideof the unit, through the fresh air fil-ter and ventilation duct; air is thenforced over the heater elements throughevaporator coil, mist eliminator andoutlet louver. The outlet louver hasadjustable blades for directing the airflow into a desired pattern within thespace being conditioned. The evaporatorfan speed is controlled by a toggleswitch on the control module.

b. Condenser Section. The condensersection (fig. 1-3) located in the rear

part of the air conditioner contains thecondenser coil, condenser coil guard,two condenser motors and fans, motorcompressor, condenser fan housings andlouvers, louver actuator, ventilationair duct, fresh air filter and ventscreen, thermal switch, refrigerantliquid sight indicator, solenoid valves,expansion quench valve, discharge bypassregulation valve, pressure relief valve,system access service valves, filter-drier, refrigerant liquid receiver, ac-cumulator, associated electrical wiringand refrigerant tubing and an alternatepower input connector. The condenserfan speed is controlled by a thermalswitch located on rear of unit. At am-bient temperatures of 100°F +5°F (38°C+3°C) or higher, the condenser fanmotors will operate at high speed (3750RPM); and at ambient temperatures below100°F (38°C), the motor will operate at

1-3

TM 5-4120-361-14

low speed (1800 RPM). Due to possiblethermal lag, the changeover may be slowto react when the ambient temperaturedrops below the 100°F (38°C) changeoverpoint.

1-7. Difference Between Models.

This manual covers the following twomodels.

(1) AAF Model CH436-1ates on 208-volt, 3-phase,power

(2) AAF Model CH636-1ates on 208-volt, 3-phase,ac power

which oper-400-Hertz ac

which oper-50-60 Hertz

In this manual, difference in modelsis identified by reference to the opera-ting frequency, that is, either as the400-Hertz model or the 60-Hertz model.

1-8. Performance Data.

The following listing contains theperformance and dimensional data appli-cable to the air conditioner.

(1) Air conditioner, models CH436-1and CH636-1:

Nomenclature . . . . Air conditioner,horizontal, compact

Manufacturer . . . .

Capacity:

Cooling . . . .

Heating:

High . . . .Low . . . .Ventilation. .

Phase . . . .

Hertz . . . .

AC volts . . . .

American AirFilter Co., Inc.

36,000 BTU/hr

35,600 BTU/hr.20,400 BTU/hr.1285 CFM

3

400 (ModelCH436-1)50/60 (ModelCH636-1)208

Current input, full load, amperesCooling . . . . 28.5High heat . . . . 31Low heat . . . . 15.5Ventilating. . . . 3.2Refrigerant. . . . R22

(2) Dimensions and weights:

Length . . . . 34.8 in.(88.4 cm)

Height . . . . 27.0 in.(68.6 cm)

Width . . . . 38.0 in.(96.5 cm)

Weight . . . . 435 lbs(198 kg)

Section III. TECHNICAL PRINCIPLES OF OPERATION

1-9. Refer to paragraphs 1-5 and 1-6 various controls available to the opera-for a description of the functions per- ter. Refer to figure 1-4 for the elec-formed by the air conditioner and identical schematic and figure 1-5 for thetification of the components that per- wiring diagram of the air conditionerform the various functions. Refer to electrical system.paragraph 2-2 for a description of the

Index, Figures 1-4 and 1-5.

ELECREF PART NUMBER DESCRIPTIONDESIG

B1 D13216E6309 COMPRESSORB2 D13216E6140 MOTOR, CONDENSER FANB3 D13216E6451 MOTOR, EVAPORATOR FANB4 D13216E6140 MOTOR, CONDENSER FAN

1-4

1-5

TM 5-4120-361-14

Figures 1-4

ELECREF PART NUMBER DESCRIPTIONDESIG

I

J1O D13216E ----I I1 I1 Jll D1321(--”’”= .

-,” k ..-5. n,

. . , 1 -----

K8 MS24___KQ I MS2A192-i . . - ..-.L1 cl~dlbk

L2 C132- “-PI MS31P2 D1 :‘P.3 PAL. v. uP4 P,P5 PP6 MP7 M---Pf? nl?~

}Plo I EPll F

m-l~tw A

D umnmnn I\---- -A---- -.. -...q

,“ I

EiEl

c1 I M39014/05-2461 CAPACITOR, FILTERCB1 D13216E6205 CIRCUIT BREAKER, COMPRESSOR

6E6178 CIRCUIT BREAKER, CONTROL---6E6223 RECTIFIER, SEMICONDUCTOR DEVICE24693-S74 TERNINAL STUD (JUNCTION BOX GRD)24693-S50 TERFiINAL STUD (CONTROL MODULE GRD)

LJ ina35206-266 TERMINAL STUD (SYSTEM GRD)HR1 THRU 6 C13216E6124-5 HEATER ELF”””m

HR7 PART OF D13216E6309 COMPRESSOh, nunAJJn71 ““’’’’OR-24-22P CONNECTOR, RECEPTAWB, ruwciK ~Nru~

6E6177 CONNECTOR, RECEPTACLE, JUNCTION BOA6E6193-2 CONNECTOR, RECEPTACLE, EVAPORATOR FAN

J4 I D13216E6193-2 CONNECTOR, RECEPTACLE, CONDENSER FANJ5 D13216E6193-2 CONNECTOR, RECEPTACLE, CONDENSER FAN

RT OF D13216E6309 CONNECTOR, RECEPTACLE, COMPRESSOR3216E6193-6 CONNECTOR, RECEPTACLE, COMPRESSOR3216E6193-1 CONNECTOR, RECEPTACLE, SOLENOID BY3216E6193-4 CONNECTOR, RECEPTA~T.~ 1-

1 THERMOSTATIC SWITC..z6193-1 I CONNECTOR, RECEPTAC

SOLENOI D VALVE EQU~

L.-U.. FAN IKU,DZi~OR FAN

._J’OR FANRtnln. RV-PASS

,. . . . .‘-lR I

TOR“ “nm\RY SELECTOR

—-—— .—..6.”””2 4 TRANSFORHEi?

I

--- ---216E6464 TERMINAL BOATB2 I C13216E6220-3 TE~Il,.7 =fin

TB3 C13216E6232 TERMIww WW-..U, uw..-..wu. -v.. I

, -------- . -.ii; PART OF D13216E6309 I COMPRESSOR, ALT1 (---371CI7C9TF31 C13: ~RD, POWER INPUT

~vnu CJUARIINAT nnac.n T1l?JflrPTfiK.I nny

TM 5-4120-361-14

Figure 1-4.

Control system

schematic diagram

1-6

1-17

/(1-

18 b

lank

)

TM 5-

4120

-361

-14

diag

ram

Figu

re 1-

5.Wi

ring

TM 5-4120-361-14

CHAPTER 2

OPERATING INSTRUCTIONS

If equipment fails to operaterefer to troubleshooting pro-cedures in chapter 3.

Section I. CONTROLS AND INSTRUMENTS.

2-1. General.

This section describes, locates andillustrates the various controls andprovides the operator/crew sufficientinformation to insure proper operationof the air conditioner.

2-2. Controls and Instruments.

a. General. The location and thefunction controls and instrumentsare illustrated in figure 2-1. The con-trol module contains the control circuitbreaker, the manually operated tempera-ture selector switch, mode selectorswitch, evaporator fan speed switch andcompressor circuit breaker. The controlmodule Is designed to permit remote con-trol operation of the air conditionerwhen connected with a remote controlcable. The thermostatic control pointof the air temperature is determined bythe location of the temperature selectorswitch sensing bulb. Normally, the airconditioner is operated with the con-trol module remaining on the unit andthe sensing bulb of temperature selec-tor switch located in the inlet airstream inside the unit evaporator sec-tion.

b. Temperature Selector Switch. Thetemmrature selector switch is a thermo-static switch which responds to temper-ature variations from 60°F in the maxi-mum cooler position to 90°F (15.6°C to32.2°C) in maximum warmer position. Thebest preliminary adjustment of the temp-erature selector is midway between thecooler and warmer positions, corre-sponding to approximately 75°F (24°C). Aten minute period should be allowed be-tween adjustments of the temperatureselector for the full effect of the ad-justment to be realized. Once the de-sired temperature of the air conditionerspace is obtained, no further adjust-ment is required for either cooling orheating modes of operation.

c. Mode Selector Switch. The modeselector switch iS an electrical switchthat can be manually positioned to se-lect the desired operational mode of theair conditioner. The five positions ofthe mode selector are:

(1) Off. The off mode position isused to stop operation. All major elec-trical components are isolated fromelectrical power except the compressorcrankcase heater, which is thermostat-ically controlled as long as input poweris connected to the unit.

(2) Vent. In the vent mode posi-tion, the evaporator motor operates andthe fans circulate filtered air. Venti-lation air will be drawn into the unitthrough the fresh air filter and ventduct if the damper door in the vent ductis open. Some cooling effect will occurif the ventilation air is cold. Venti-lation air flow is controlled by open-ing and closing the damper door with thevent adjusting knob.

(3) Cooler. In the cooler modeposition, the refrigerant cycle begins,and the unit will cool under the thermo-static control of the temperature selec-tor switch. The evaporator fan motor,condenser fan motors and compressor areactivated and will operate continuously.The speed of the evaporator fan motor iscontrolled by manually selecting the de-sired speed position of the evaporatorfan speed switch. The speed of conden-ser fan motors is automatically con-trolled by an outdoor thermal switch.The motors will operate in low speedwhen ambient temperature is below 100°F(38°C). The thermal switch automatic-ally switches the motors to high speedif ambient temperature rises above 100°F(38°C). To prevent starting surge cur-rent of the compressor coinciding withthe starting surge current of the fanmotors, the compressor starts about 30

2-1

TM 5-4120-361-14

seconds after the fan motors. Althoughthe compressor and fan motors operatecontinuously in this mode, thermostaticaction of the temperature selectorswitch causes refrigerant to bypass theevaporator coil and stop cooling whenthe desired temperature setting of thetemperature selector switch is satis-fied. Ventilation air will be drawn in-to the unit if the vent damper door isopen.

(4) Low Heat. In the low heatmode, the evaporator fan motor operatescontinuously and three of the six heaterelements are activated. The three heat-er elements cycle on and off under ther-mostatic control of the temperature se-lector switch. This mode will producehalf of the unit’s heating capability.Ventilation air will be drawn into theunit if the vent damper door is open.

(5) High Heat. In the high heatmode, the evaporator fan motor operatescontinuously and all six of the heaterelements are activated, but only threeof the heater elements will cycle on andoff under thermostatic control of thetemperature selector switch. This modewill produce maximum heating capabilityof the unit. Ventilation air will bedrawn into the unit if the vent damperdoor is open.

d. Evaporator Fan Speed Switch. Theevaporator fan speed switch has two po-sitions, “low” and “high.” The posi-tions are manually selected to controlthe evaporator fan speed in all operat-ing modes. Normally the “low” speedshould be selected as it is quieter andrequires less electrical power; however,the “high” speed position has three ad-vantages over “low” which may dictateits selection:

(1) Maximum cooling capacity canonly be achieved in “high.”

(2) The increased flow of evapora-tor air improves air distribution in theconditioned space.

(3) Twice as much ventilation airis drawn into the unit in “high.”

e. Vent Adjusting Knob. The ventadjusting knob controls the flow of ven-tilation air into the unit. The knob isconnected by the damper cable to a damp-er located in the vent duct. The knobcontrols the flow of ventilation air byadjusting the position of the damper

from full closed to full open. Turningthe knob to the right closes the damper,turning the knob to the left opens thedamper. The force that draws ventila-tion air into the unit is the smallpressure difference between the ambientand the evaporator fan. This is thesame small pressure difference thatexists between the conditioned space andthe evaporator fan; the pressure differ-ence that draws return air through theinlet louver and the return air filter.When ventilation air enters the condi-tioned space a like flow of air must ex-haust from the space to prevent a pres-sure buildup. Cracks in the space maybe sufficient; but if a large flow ofventilation air is desired, some posi-tive means of air exhaust should be pro-vided.

f. Inlet Louver. The inlet louveris finger-adjustable from full open tofull closed. Normally the louver shut-ter tab adjustment is kept at 45° posi-tion, which is essentially the same as afull open inlet louver. If the inletlouver is closed, return air will stillmanage to flow through it; but at a re-duced rate with high pressure drop. Theincrease in pressure drop will cause ad-ditional ventilation air to be drawn in-to the unit. The “vent” mode of oper-ation is normally the only mode whereclosing the inlet louver (to create in-creased ventilation airflow) would beconsidered a real advantage. suf-ficient ventilation air flow for othermodes of operation can be achieved withthe inlet louver open and the damperopen. The return air filter is attachedto the back side of the inlet louver. Adirty filter can easily be observed bylooking through the inlet louver blades.Since maximum cooling capability of theunit is obtained with maximum evapora-tor air flow, a closed inlet louver or adirty air filter will decrease coolingcapacity, and may cause ice to form onthe evaporator coil.

g. Outlet Louver. The outlet louveris finger-adjustable in both horizontaland vertical planes. This adjustment onan individual blade basis allows maximumcontrol over the direction of outletair. The best distribution pattern foroutlet air is left to the operator’sjudgment; but blades should not be ad-justed beyond 45°, as evaporator airflow will be impeded.

h. Condenser Louvers. The condens-er louvers, located on the rear of the

2-2

TM 5-4120-361-14

Figure 2-1.

Controls and

instruments

2-3

TM 5-4120-361-14

air conditioner (figure 1-2), areautomatically opened and closed by theaction of the refrigerant system. Thecondenser louvers cannot be manuallyopened and closed.

i. Compressor Circuit Breaker. Thecompressor circult breaker is a safetydevice which provides overcurrentprotection for the compressor. Thecompressor circuit breaker is not a con-trol switch to be used for operating theunit. This breaker should always bekept in the ON position. If the breakertrips to the OFF position, a defectivecompressor or related defective elec-trical components, or faulty wiring, isindicated. Inadequate input powervoltage will also cause the circuitbreaker to trip. The unit control cir-cuit is also connected to auxiliarycontacts on the compressor circuit

breaker. When this circuit breakertrips to OFF, it disconnects the controlcircuit allowing the time delay relay toreset and the refrigerant system pres-sures to equalize. Manually resettingthe compressor circuit breaker to ON re-stores electrical continuity.

j. Control Circuit Breaker. Thecontrol circuit breaker iS a safety de-vice which provides overcurrent protec-tion for the control circuit of theunit. The control circuit breaker isnot a control switch to be used for op-erating the unit. This breaker shouldalways be maintained in the ON position.If the breaker trips to the OFF posi-tion, an electrical defect in the con-trol circuit is indicated and correctiveaction should be taken. Manually reset-ting the circuit breaker to ON restoreselectrical continuity.

Section II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

2-3. General.

To insure that the air conditioner isready for operation at all times, itmust be inspected systematically so thatdefects may be discovered and correctedbefore they result in serious damage orfailure. The necessary preventive main-tenance checks and services (PMCS) to beperformed are listed and described inparagraph 2-4. The item numbers indi-cate the sequence of minimum inspectionrequirements.

a. Before you operate. Always keepin mind the CAUTIONS and WARNINGS. Per-form your before (B) PMCS.

b. While you operate. Always keepin mind the CAUTIONS and WARNINGS. Per-form your during (D) PMCS.

After you operate. Be sure toperfrm your after (A) PMCS.

d. If your equipment fails to oper-ate Troubleshoot with proper equip-ment. Report any deficiencies using theproper forms, see TM 38-750.

Defects discovered during operationof the unit will be noted for futurecorrection to be made as soon as opera-tion of the unit has ceased. Stop oper-

ation immediately if during operation adeficiency is noted which would damagethe equipment if operation were contin-ued. All deficiencies and shortcomingswill be recorded, together with thecorrective action taken, on DA Form2404nity

2-4.Servi

at the earliest possible opportu-

Daily Preventive Maintenanceces.

This paragraph contains a tabulatedlisting of preventive maintenance ser-vices which must be performed by the op-erator. The item numbers are listedconsecutively and indicate the sequenceof minimum requirements. Refer to table2-1 for the daily preventive maintenanceservices.

NOTE

Use the numbers in the ItemNo. Column as a source of itemnumbers for the “TM Number”column on DA Form 2404, Equip-ment Inspection and Mainte-nance Worksheet, in recordingresults at PMCS.

2-4

TM 5-4120-361-14

Table 2-1.

2-5

TM 5-4120-361-14

Section III. OPERATING UNDER USUAL CONDITIONS

2-5. General.

a. The instructions in this sectionare published for the information andguidance of the personnel responsiblefor the operation of the air condi-tioner.

b. The operator must know how toperform every operation of which theair conditioner is capable. This sec-tion gives instructions on starting andstopping the air conditioner, and de-tailed operating instructions. Sincenearly every condition presents a dif-ferent problem, the operator may have tovary the given procedure to fit thecondition.

b. Lifting.

2-6. Unloading Equipment.

The total weight of the air condi-tioner is 435 pounds (198 kg.). Use ahand truck or forklift of at least 500pounds capacity to unload the unit.Keep unit upright during the unloadingoperation.

2-7. Unpacking Equipment.

Move the unit as near to the siteof installation as possible. Removecrating hardware and metal straps beingcareful not to damage the unit with thetools used for uncrating.

2-8. Inspecting and Servicing Equip-ment.

a. Inspection. Inspect the entireair conditioner for signs of damage,missing or loose hardware, and any de-fects that may have been incurred duringshipment. Report all damage and de-fects to organizational maintenance.

b. Servicing. Perform the dailypreventive maintenance services listedin paragraph 2-4. Be sure all hardwareis securely in place.

2-9. Installation.

a. General. The air conditioner isshipped assembled and ready for opera-tion. It contains a full charge of re-frigerant and compressor oil. Installthe unit on a firm, level surface to al-low proper condensate drainage. Placeit so that the control panel and con-denser and evaporator louvers are acces-sible to the operator and to maintenance

personnel. Be sure there are noobstructions in front of any air intakeor discharge louvers or other openingsthat may cause insufficient flow of airin to or out of the air conditioner. Ifthe unit is van mounted, report any suchobstructions to organizational mainte-nance.

Check for broken or de-formed lifting ring attachment and hard-ware before lifting air conditioner.Lift with crane or forklift truck.

Use lifting harness with 4-legspreader bar. Each leg mustbe. capable of withstanding aconcentrated load of more than500 pounds. If spreader barcannot be used, the angle be-tween the harness legs and thetop of the air conditionermust be not less than 45-degrees.

c. Mounting. Base mounting holedimensions are shown on figure 2-2. Theresilient mount parts shown in figure2-3 are shipped with the air condition-er.

For safe operation connect aNo. 10 AWG (min.) ground wirebetween the air conditionerground connection and an earthground, as shown in figure2-4.

d. Connections.—

(1) Connect air ducts to the unitas applicable to the site of installa-tion. If the inlet grille is removed, areturn air filter should be relocated inthe return air duct at a maintainablelocation. Operation of unit without areturn air filter will cause fouling ofthe evaporator fan and evaporator.

(2) Connect a condensate drain lineto carry condensate water away from siteof installation only if the drop of con-densate is objectionable.

2-6

TM 5-4120-361-14

Figure 2-3.

Figure 2-2.

2-7

TM 5-4120-361-14

(3) Connect the MS3106R-24-22S powerinput connector plug furnished with the air condi-tioner to a suitable electrical power cable. Connectthe cable to the proper electrical power sourceand install the plug end of cable to either themain power receptacle or the alternate powerreceptacle. If alternate power receptacle J12 isused, refer to wiring diagram (figure 1-5) andchange wire lead connection at TB1.

CAUTION

To avoid damage to the compressorelectrical input power must be appliedto energize the compressor crankcaseheater at least 4 hours before opera-ting unit in the cool mode. For pro-longed periods of storage, long shutdown periods or lengthly exposure(14 days or more) to sub-zero temp-eratures, the preheater should beenergized for twelve (12 hrs) priorto operation of the air conditioningunit in the cool mode.

2-10. Starting and Operating Instructions.

a. Preparation for Starting.—

(1) Perform the daily preventivemaintenance service (para 2-4).

(2) Connect the main power cable.

(3) Check drain holes to insure thatthey were open.

(4) Be sure the unit is firmly secured.

(5) Roll up condenser cover and tieat top of air conditioner to clear condenseropening.

NOTE

When vent damper door is open toadmit fresh air, partially close evapor-ator inlet, louver to balance incomingair. Keep vent or damper doorclosed during heavy rain.

b. Starting Instructions for Cooling.Start the air conditioner for cooling as shownin figure 2-5.

c. Operating Instructions for Cooling.Operate the air conditioner for cooling asshown by figure 2-6.

Figure 2-4. Ground wire installation.

2-8 Change 2

TM 5-4120-361-14

CAUTION

To avoid damage to the compressorelectrical input power must reappliedto energize the compressor crankcaseheater at least 4 hours before opera-ting unit in the cool mode. For pro-longed periods of storage, long shutdown periods or lengthly exposure(14 days or more) to sub-zero temperatures, the preheater should beenergizad for twelve (12 hrs) priorto. operation of the air conditioningunit in the cool mode.

STEP 1. ROLL UP AND TIE CONDENSER COVER.STEP 2. OPEN INTAKE LOUVERS BY LIFTING TABS.STEP 3. TURN VENT CONTROL ACTUATOR TO CLOSE VENTILATION DAMPER.STEP 4. TURN TEMPERATURE SELECTOR SWITCH TO MAXIMUM CLOCKWISE

POSITION (WARMER).STEP 5. TURN ON COMPRESSOR AND CONTROL CIRCUIT BREAKERS.STEP 6. TURN MODE SELECTOR SWITCH TO VENT AND ALLOW FAN TO REACH

FULL SPEED, THEN TURN TO COOL.

Figure 2-5. Starting instructions for cooling.

2 - 9

TM 5-4120-361-14

STEP 1. WITH MODE SELECTOR SWITCH ON COOL, ADJUST TEMPERATURE SELECTOR SWITCHTO DEGREE OF COOLING DESIRED.

STEP 2. SET EVAPORATOR FAN SPEED SWITCH TO DESIRED POSITION.

STEP 3. ADJUST AIR OUTLET LOUVERS TO DIRECT AIR FLOW AS DESIRED.

STEP 4. ADJUST VENT CONTROL ACTUATOR TO ADMIT DESIRED AMOUNT OF VENTILATION AIR.

Figure 2-6. Operating instructions for cooling

2-10 PIN: 046441-002

TM 5-4120-361-14

STEP 1. MAKE SURE CONDENSER COVER IS ROLLED UP.

STEP 2. OPEN INTAKE LOUVERS BY LIFTING TABS.

STEP 3. TURN VENT CONTROL ACTUATOR TO CLOSE VENTILATION DAMPER.

STEP 4. TURN TEMPERATURE SELECTOR SWITCH TO MAXIMUM COUNTERCLOCKWISE POSITION (WARMER).

STEP 5. TURN ON CONTROL CIRCUIT BREAKER.

STEP 6. TURN MODE SELECTOR SWITCH TO LOW HEAT. TURN TO HIGH IF MORE HEAT IS DESIRED.

Figure 2-7. Starting instructions for heating

2-11

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NOTE : AFTER STARTING, ADJUST TEMPERATURESELECTOR SWITCH TO OBTAINDESIRED ENCLOSURE TEMPERATURE

STEP 1. TURN VENT CONTROL ACTUATOR TO OPEN DAMPER DOOR.

STEP 2. POSITION TABS TO PARTIALLY CLOSE INTAKE LOUVER BLADES.

STEP 3. TURN MODE SELECTOR TO HIGH HEAT OR LOW HEAT FOR DESIREDRANGE .

STEP 4. ADJUST TEMPERATURE SELECTOR SWITCH TO DESIRED ENCLOSURE

STEP 5. ADJUST AIR OUTLET LOUVERS TO DIRECT AIRFLOW AS DESIRED.

TEMPERATURE

TEMPERATURE.

NOTE : AFTER TURNOFF, OPERATE IN VENT MODECOOL OFF HEATING ELEMENTS.

(FIGURE 2-9) FOR 2 - 3 MINUTES TO

Figure 2-8. Operating instructions for heating

2-12

TM 5-4120-361-14

STEP 1. MAKE SURE CONDENSER COVER IS ROLLED UP.

STEP 2. TURN VENT CONTROL ACTUATOR TO OPEN DAMPER DOOR.

STEP 3. POSITION TABS TO PARTIALLY CLOSE INTAKE LOUVER BLADES.

STEP 4. TURN MODE SELECTOR SWITCH TO VENT.

Figure 2-9. Operating instructions for ventilation

2-13

TM 5-4120-361-14

STEP 1.

STEP 2.

STEP 3.

NOTE : IF SHUTDOWNGRILLES AND

TURN MODE SELECTOR SWITCH TO OFF.

POSITION TABS TO CLOSE INTAKE LOUVERS.

TURN ACTUATOR TO CLOSE FRESH AIR VENT DAMPER.

IS FOR AN EXTENDED PERIOD, COVER EVAPORATOR AND CONDENSERDISCONNECT POWER CABLE.

Figure 2-10. Air conditioner stopping instructions

2-14

figure 2-7

figure 2-8

figure 2-9

2-12. Preparation for Movement. Toprepare the air conditioner for move-ment, proceed as follows.

2-13. Dismantling for Movement.

a. Disconnect main power Cable.

b. Disconnect drain line from out-let.

c. Disconnect air ducts and installthe-evaporator inlet and outletgrilles.

d.face.

e.over a

2-14.

Remove unit from mounting sur-

If air conditioner is to be movedlong distance, recrate it.

Reinstallation After Movement.

After movement, follow procedures inparagraph 2-9 to reinstall the airconditioner.

2-15. Identification.

a. Identification. Each air condi-tioner has one major identificationplate mounted on the side of the unit.The plate specifies nomenclature, manu-facturer, military part number, BTU/hr.,phase, hertz, volts, serial number, con-tract number, and shipping weight. Amanufacturer’s identification platemounted just below the military platecontains the manufacturer's name and ad-dress and the model and serial numbers.

b. Information Plates. The air con-ditioner has the following informationplates pertinent to operation.

(1) Wiring Diagram Plate. It islocated on the top of the unit. Thisillustrates complete air conditionerwiring.

TM 5-4120-361-14

(2) Fluid Diagram Plate. It is lo-cated on the top of the unit. The plateillustrates complete air conditioner re-frigerant system.

(3) Ventilation Instruction Plate.It is located on the left front side ofthe unit. This plate indicates the di-rection to turn vent adjusting knob toopen or close the damper door in theventilation air duct.

(4) Control Module InstructionPlate. It is located on the front ofthe unit. This plate indicates the fol-lowing.

(a) The ON and OFF positions ofthe control circuit breaker.

(b) The ON and OFF positions ofthe compressor circuit breaker.

(c) The various heating and cool-ing positions for the mode selectorswitch.

(d) Temperature increase and de-crease positions for the temperature se-lector switch.

(e) The HIGH and LOW positions ofthe evaporator fan speed switch.

(f) The manufacturer’s model num-ber of the unit.

(g) The part number of theplate.

(5) Main Power Plate. It is lo-cated on the front of the unit above thecontrol module and contains the mainpower receptacle.

(6) High Pressure and Low PressureReset Plates. They are located on theleft side of the unit below the servicevalve access panel. These plates indi-cate location of the high and low pres-sure reset buttons.

(7) Service Valves. The high pres-sure and low pressure service valveplates are located on the left side ofthe unit above the service valve accesspanel. These plates indicate the loca-tion of the service valves.

(8) Danger Warning Plate. It islocated on the right side of the airconditioner near the front. This platewarns of the hazard in operating the airconditioner without a grounding wire.

2-15

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(9) Nameplate. It is located on the left side of facturer’s name, the air conditioner serial and modelthe air conditioner near the front, and contains the manu– numbers and other pertinent nameplate data.

Section IV. OPERATION UNDER UNUSUAL CONDITIONS

2-16. Operation in Extreme Cold.

a. General. The air conditioner is designed tooperate on the heating cycle in ambient temperatures as lowas minus 50°F (-45°C) and on cooling cycle with 0°F(-18°C) air entering the condenser and 70°F (21°C) airentering the evaporator.

b. Before Operation. Before starting on coolingcycle be sure cover is removed from condenser air intake anddischarge. Clear all ice and snow from openings. Be sure alldampers are in operating condition.

c. After Operation. Install cover over condenserair intake and discharge openings.

2-17.

Do not disturb wiring during cold weatherunless absolutely necessary. Coldtemperatures make wiring and insulationbrittle and easily broken.

Operation in Extreme Heat.

NOTE

Unit Preventive Maintenance Checks andServices (PMCS) should be performed atdaily intervals.

a. General. The air conditioner is designed tooperate in temperatures up to 120°F (49°C). Extra careshould be taken to minimize the cooling load when operatingin extreme high temperatures.

b. Protection.

(1) Check all openings in the enclosure,especially doors and windows, to be sure they are tightlyclosed. Limit in and out traffic if possible.

(2) When appropriate, use shades or awningsto shut out direct rays of the sun.

(3) When possible, limit the use of electriclights and other heat producing equipment.

(4) Limit the amount of hot, outside airintroduced through the fresh air damper to that essential forventilation.

2-16 Change 3

NOTE

Weatherstripping, the installation ofstorm doors, and windows, if appropriate,and insulation of surfaces exposed to theoutside is recommended when operatingin extremely high temperatures forextended periods.

c. Cleaning.

(1) Clean outside grilles, coils, filters, andmist eliminator more frequently.

2-18. Operation in Dusty or Sandy Areas.

NOTE

Unit Preventive Maintenance Checks andServices (PMCS) should be performed atdaily intervals.

a. General. Dusty and sandy conditions canseriously reduce the efficiency of the air conditioner byclogging the air filter, mist eliminator, and coils. This willcause a restriction in the volume of airflow. Accumulationof dust or sand in the condenser coil and/or in the compressorcompartment may cause overheating of the refrigerationsystem. Dust or sand may also clog the condensate trap andwater drain lines.

Never operate the air conditioner withouthaving the air filters in place.

b. Protection.

(1) Shield the air conditioner from dust asmuch as possible.

(2) Take advantage of any natural barrierswhich offer protection.

(3) Limit the amount of dusty or sandyoutside air introduced through the fresh air damper.

(4) Roll down and secure the fabric cover onthe back of the cabinet during periods of shutdown.

c. Cleaning.

(1) Keep the airpossible.

(2) Pay particulargrilles, condenser, filters, mistelectrical components.

conditioner as clean as

attention to the outsideeliminator, louvers, and

(3) In extreme conditions, daily cleaning ofcondenser, filters, and outside grilles may be necessary.

2-19. Operation Under Rainy or Humid Conditions.

Take special precautions to keep equipment dry. Ifinstalled outdoors, cover the equipment with a waterproofcover when it is not in use. Remove cover during dryo&. Take all necessary precautions to keep the electricalcomponents free from moisture.

Make sure power is disconnected from airconditioner before touching any wiring or .other electrical parts.

2-20. Operation in Salt Water Areas.

TM 5-4120-361-14

Disconnect power source prior to washingthe air conditioner.

a. General. Wash the exterior and condensersection of the unit, particularly condenser air dischargelouver control mechanism, with clean freshwater at frequentintervals. Be careful not to damage electrical system withwater. Special attention must be given to prevent rust andcorrosion.

b. Painting. Paint all exposed areas where painthas cracked, peeled, or blistered, or report condition toorganizational maintenance. Coat all exposed areas ofpolished metal with a light coat of grease.

Change 3 2-17/(2-18 blank)

TM 5-4120-361-14

Chapter 3

MAINTENANCE INSTRUCTIONS

Section I. LUBRICATION INSTRUCTIONS

3-1. Fan Motors. 3-2. Compressor.

The evaporator and condenser motors The compressor and compressor motorare permanently lubricated by the manu- are fully lubricated by the manufac-facturer and require no additional turer and require no additional lubrica-lubrication. tion.

3-3. General.

Section II.

This section contains informationthat is useful in diagnosing andcorrecting troubles which cause unsat-isfactory operation or failure of theair conditioner.

3-4. Operator’s Troubleshooting Chart.

Troubleshooting procedures for opera-tor-crew are listed in table 3-1.

TROUBLESHOOTING

followed by a list of tests or inspec-tions which will help you to determinecorrective actions to take. You shouldperform the tests/inspections and cor-rective actions in the order listed.

b. This manual cannot list all mal-functions that may occur, nor all testsor inspections and corrective actions.If a malfunction is not listed or is notcorrected by listed corrective actions,notify your supervisor.

a. This section contains trouble- c. The table lists the common mal-shooting information for locating and functions which you may find during thecorrecting most of the operating operation or maintenance of the air con-troubles which may develop in the air ditioner or its components. You shouldconditioner. Each malfunction for an perform the tests/inspections and cor-individual component, unit, or system is rective actions in the order listed.

Section III. MAINTENANCE PROCEDURES.

3-5. General.

This section contains maintenanceprocedures for the operator of the airconditioner. Operator maintenance islimited to inspection and proceduresthat can be accomplished without the aidof servicing tools. Any indications ofneed for servicing resulting from in-spection are to be reported to organiza-tional or direct support maintenance.

3-6. Condenser Fabric Cover.

Inspect condenser fabric cover fortorn places. Repair minor tears withwaterproof tape. Report extensive dam-age to organizational maintenance.

3-7. Drains.

Inspect condensate water drains, fig-ure 1-2, for obstructions. Remove ob-structions. Report total blockage toorganizational maintenance.

3-8. Liquid Sight Indicator.

Wipe refrigerant liquid sight indica-tor glass, figure 1-2, with a soft,clean cloth, set controls, figure 2-1,at COOL-COOLER, operate air conditionerfor 15 minutes, then observe liquidsight indicator. Yellow appearanceindicates moisture in system. Bubblesor milky flow indicate low refrigerantcharge. Report presence of these condi-tions to direct support maintenance.

3-1

TM 5-4120-361-14

Table 3-1. Troubleshooting .

1. AIR CONDITIONER FAILS TO OPERATE

Step 1. Check to see if main power cord is plugged in.

Connect power cable to receptacle (fig. 2-1) supplying 208 VAC,3 phase power of the proper frequency.

Step 2. Check to see if compressor circuit breaker is in OFF position.

Reset circuit breaker (fig. 2-1).

Step 3. Check to see if mode selector switch is in OFF position.

Turn selector switch to desired operation (fig. 2-1).

Step 4. If air conditioner still is inoperative, report condition toorganizational maintenance.

2. INSUFFICIENT COOLING

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

Check to see if mode selector switch is in proper

Set switch to COOL (fig. 2-1).

Check to see if temperature selector switch is in

Adjust setting to COOLER (fig. 2-1).

position.

correct position.

Check to see if sufficient air is passing over evaporator coil.

Open evaporator inlet louvers (fig. 2-1). Remove any obstructionsfrom evaporator inlet and outlet louvers.

Inspect for clogged air filter.

Report clogged filter condition to organizational maintenance.

Check to see if too much outside air is entering unit.

Close or adjust damper door (fig. 2-1).

Check to see if the system contains sufficient refrigerant byinspecting liquid sight indicator (para 3-8).

Report low refrigerant condition to direct support maintenance.

Check to see if evaporator fan speed switch is set to LOW speedposition.

Reset switch to HIGH speed position (fig. 2-1).

Check to see if sufficient air is passing through condenser coil.

Remove any obstructions from condenser fan inlet and outlet.

3-2

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Table 3-1. Troubleshooting. - Continued

MALFUNCTIONTEST OR INSPECTION

CORRECTIVE ACTION

3. NO HEAT OR LOW CAPACITY HEAT

Step 1. Check to see if mode selector switch is properly set.

Set switch to LOW HEAT or HIGH HEAT (fig. 2-1).

Step 2. Check to see if temperature selector switch is set correctly.

Adjust to WARNER setting (fig. 2-1).

Step 3. Check for insufficient air movement over heaters.

Remove any obstructions from evaporator air intake and dischargeMake sure intake louvers are open (fig. 2-1).louvers.

3-3/(3-4 Blank)

TM 5-4120-361-14

CHAPTER 4

ORGANIZATIONAL MAINTENANCE INSTRUCTIONS

Section I. SERVICE UPON RECEIPT OF MATERIAL

4-1. General.

Instructions for unloading, unpackingand installing the air conditioner arecovered in Chapter 2, Section III.

4-2. Inspecting and Servicing Equip-ment.

General inspection of the equipmentis covered in Chapter 2, Section II. Ifpossible damage has occurred, requiringremoval of covers or other componentsnot authorized for removal by the opera-tor, further inspection of internal com-ponents is to be performed by organi-zational maintenance personnel. Ifother than new equipment has been re-ceived, a thorough inspection is to beperformed. Make a thorough check to see

that all wiring, lines and tubing aresecure. Pay particular attention to theevaporator and condenser coils and mainpower receptacle connectors. Be surethat all visible wiring and insulationare not broken or frayed. Also checkthe evaporator and condenser fan motors.

4-3. Return Air Filter.

a. Removal.

(1) Refer to figure 4-1 and removeevaporator air inlet louver.

(2) Refer to figure 4-2 and slidethe return air filter from the four fil-ter retaining clips.

b. Service. Service the return airfilter as follows:

Figure 4-1. Evaporator inlet and outlet louvers, removal and installation

4-1

TM 5-4120-361-14

Figure 4-2.

Cleaning solvent, FederalSpecification P-D-680, TypeII, used for cleaning elec-trical parts, is flammable andgives off poisonous vapors.Use only in a well ventilatedarea. Avoid prolongedbreathing of vapors. Keepsolvent and vapors away fromopen flame. Do not use inexcessive amounts.

Return air filter

water soluble filter coater is used asthe duct collecting adhesive. Flush thefilter with solvent or water in oppositedirection of air flow. Be careful notto damage filter during cleaning. Re-place filter if the frame is bent or thefiltering material is damaged.

(2) Shake excess solvent or waterfrom filter and allow to dry thoroughly.If available, low pressure compressedair (15 psig) can be used to speed dry-inq. When usinq compressed air for dry-ing filter always direct the air streamin the opposite direction of the filter

(1) Clean filter with cleaning sol- air flow. Hold the air nozzle a safevent (Fed. Spec. P-D-680) if lubricating distance away from the filter to preventoil is used as the dust collecting adhe- compressing or separating the filterings ive . Clean filter with water if a material.

4-2

TM 5-4120-361-14

(3) Coat the filter with a dustcollecting adhesive (see Appendix F) byimmersion or spraying. Make sure thatthe total air filtering surface is thor-oughly covered with the adhesive whenspraying the filter. Allow excessiveadhesive to drain before installingfilter.

c. Installation.

(1) Refer to figure 4-2 and slidethe air filter into four filter retain-ing clips.

(2) Refer to figure 4-1 and in-stall evaporator inlet louver.

4-4. Condenser Guard.

Remove any obstructions. Brush offloose dirt and wipe clean.

a. Removal.

(1) Refer to figure 4-3 and removecondenser guard.

(2) With guard removed, wipe con-denser coil clean.

b. Installation.

(1) Refer to figure 4-3 and in-stall guard.

4-5. Evaporator Coil and CondensingCoil.

The coils (heat exchangers) should beserviced as often as necessary to insuremaximum operating capacity of unit.Dirt and lint loaded coils or bent coilfins not only restrict normal volume ofair flow but also insulate the coils,thus reducing their efficiency as heat

Figure 4-3. Condenser guard removal and installation

4-3

TM 5-4120-361-14

exchangers. Frequent cleaning of theexternal coil surfaces may avoid inter-nal clogging. Clean external surfaceswith a softbristled brush or a plasticfin comb. The plastic fin comb can beused to straighten bent coil fins.Clean internally-clogged coils with com-pressed air. Always direct the com-pressed air stream straight into coils,to avoid bending fins, and in the oppo-site direction of normal air flow. Re-move covers and louvers (figure 4-1, 4-3and 4-4) to service coils.

4-6. Top Covers and Condenser Cover.

a. Removal.—

(1) Refer to figure 4-4 and removetop front cover. Remove this coverfirst as it provides access to one screwof the center cover that is not visiblefrom the outside.

(2) Remove condenser cover and toprear cover.

(3) Remove top center cover.

b. Inspection and Repair. Inspectcondenser fabric cover for tears. Re-pair minor tears with waterproof tape.Inspect top covers for dents, breaks,chipped paint and damaged gaskets or in-sulation. Inspect for minor dents intop covers and make sure that covers areinstalled flush with mating surfaces ofthe housing. If top covers cannot berepaired, install replacement covers.

c. Installation. Refer to figure4-4 and install top covers and condensercover as follows:

(1) Install top center cover.

(2) Install top rear cover and con-denser cover.

(3) Install top front cover.

4-7. Evaporator Inlet and Outlet Lou-vers.

a. Removal. Refer to figure 4-1 andremove evaporator inlet and outlet lou-vers.

Figure 4-4. Top covers and condenser cover, removal and installation

4-4

TM 5-4120-361-14

b. Installation. Refer to figure b. Service Fresh Air Filter. Flush4-1 and install evaporator inlet and the-filter (in the damper door ventoutlet louvers. screen pocket) with clear water and dry.

NOTE4-8. Damper Door Vent Screen and FreshAir Filter. The fresh air filter is a 1/2-

inch thick piece of cellulosea. Removal. Refer to figure 4-5 and sponge 4 inches wide and 6

remove damper door vent screen with fil- inches long, inserted into theter. vent door screen.

NOTE : DO NOT REMOVE FRESH AIR FILTER FROM SCREEN POCKET -- FLUSH FILTER WITH CLEANWATER AND DRY THROUGHLY.

Figure 4-5. Damper door vent screen and fresh air filters, removal and installation

c. Installation. Refer to figure4-5 and install vent door screen withfilter.

4-9. Mist Eliminator.

a. Removal.

(1) Refer to figure 4-4 and removetop front cover.

(2) Refer to figure 4-6 and liftout mist eliminator.

b. Inspection and Service.

(1) Inspect the face area of themist eliminator for breaks, or any otherphysical damage, and clogged areas.

(2) Although the mist eliminatorshould not require any service normally,it may become clogged and dirty. Thecleaning procedure is the same as forservicing the fresh air filter (para4-3).

4-5

TM 5-4120-361-14

c. Installation.— 4-10. Air Condit

(1) Refer to figure 4-6 and install

oner Installation.

mist eliminator by sliding down into Check air conditioner for proper im-position. stallation. If auxiliary power connec-

tion is to be used, change leads as(2) Refer to figure 4-4 and re- shown on wiring diagram, figure 1-5.

place top front cover.

Figure 4-6. Mist eliminator removal and installation

Section II. MOVEMENT TO A NEW WORKSITE

Not applicable.

Section III. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT

4-11. Tools and Equipment. 4-13. Maintenance Repair Parts.

No tools or equipment are issued with Repair parts and equipment are listedthe air conditioner. and illustrated in the repair parts and

4-12.special tool list covering organi-

Special Tools and Equipment. zational maintenance for this equipment.

No special tools or equipment are re-quired for maintenance of the air condi-tioner.

Section IV. LUBRICATION INSTRUCTIONS

4-14. Fan Motors. 4-15. Compressor.

The evaporator fan and condenser fan The compressor and compressor motormotors are permanently lubricated by the are fully lubricated by the manufacturermanufacturer and require no additional and require no additional lubrication.lubrication.

4-6

TM 5-4120-361-14

(para. 4-3

(para 4-5)

(para. 4-6)

Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

4-16. General.

Periodic maintenance checks are re-quired by organizational maintenancepersonnel to check the performance ofdaily preventive maintenance services.Additional periodic maintenance servicesare required beyond the scope of the op-erator’s maintenance.

4-17. Quarterly Preventive MaintenanceServices.

a. This paragraph contains a tabu-lated listing of preventive maintenanceservices which must be performed by or-

ganizational maintenance personnel atquarterly intervals. A quarterly inter-val is equal to three calendar months,or 250 hours of operation, whichever oc-curs first.

b. The item numbers are listed con-secutively and indicate the sequence ofinspection and minimum requirements.Refer to table 4-1 for quarterly preven-tive maintenance services.

c. Some services are required at ashorter interval and are so noted. Ser-vice intervals should be shortened underextreme or unusual conditions.

Table 4-1. Organizational Preventive Maintenance Checks and Services

4-7

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Section VI. TROUBLESHOOTING

4-18. General.

This section contains troubleshootinginstructions for the isolation of causesand common troubles that may occur dur-ing operation, and also gives the pos-sible remedies to correct the trouble.

4-19. Organizational TroubleshootingChart.

a. General. Troubleshooting proce-dures for organizational maintenancepersonnel are listed in table 4-2. ASshown in the table, troubleshooting be-gins by identifying the malfunction.Next, suitable tests or inspections aremade in step-by-step order. Finally, acorrective action is given. Remediesbeyond the scope of organizational main-tenance must be reported to direct sup-port maintenance personnel. Additionalprocedures are given in paragraphs(b)and (c) which follow:

b. Control Circuit. The cause forthe–failure of the system to operate canbe narrowed to a specific portion of thesystem if the control component associ-ated with the failure can be isolated.It is the purpose of safety devices toopen the circuit under certain overload

or fault conditions. If a safety deviceis open, additional checking is requiredto determine if the open is due to afaulty safety device or if the safetydevice is performing its intended func-tion, and the fault is located elsewherein the system. To check the controlcircuit, proceed as follows:

(1) Disconnect air conditioner fromsource of power.

(2) Using a series test lamp orohmmeter, check the continuity througheach control in the affected circuitwith the control in the closed positionwhile being checked. Use the systemschematic and wiring diagram for point-to-point circuit tracing.

(3) Replace each defective partwith a serviceable like item.

c. Safety Devices. When testing thecontrol circuit and associated compo-nents, take into account the normalstate of the safety device. Determine(1) whether it is normal for the deviceto be open under the existing conditionsor (2) if the open condition indicatestrouble elsewhere in the air condition-er.

4-8

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Table 4-2.

Note: Before you use this table, be sure you have performed all applicable


CORRECTIVE ACTION

1. AIR CONDITIONER FAILS TO OPERATE

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Check to see if main power cable is connected.

Connect cable to power source.

Check to see if main power receptacle is defective.

Replace defective connector.

Check for loose electrical connections.

Tighten loose connections.

Check to see if mode selector rotary switch isor is defective.

Turn selector to COOL or VENT. Replace switch(para 4-26).

improperly positioned

if defective

Check to see if control circuit breaker or compressor circuitbreaker is in OFF position or is defective.

Reset circuit breaker(s) or replace defective circuit breaker(para 4-26).

Remove service valve access panel (figure 1-2) and check to seeif high pressure or low pressure switch has cutout.

Reset high pressure or low pressure cutout . Note that time delayrelay starts compressor 30 seconds after reset.

Test control circuit transformer and rectifier for faultyoperation.

Replace defective transformer and/or rectifier (para 4-28 and4-29).

Step 7.


Step 1. Check to see if the mode selector switch is improperly positioned.

Set switch to COOL.

Step 2. Check to see if temperature selector control is improperlypositioned or is defective.

Adjust setting or replace switch (para 4-26).

4-9

TM 5-4120-361-14

Table 4-2. Troubleshooting - Continued

2. INSUFFICIENT COOLING - Continued

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

Step 9.

Step 10.

Step 11.

Check to see if fresh air damper control is incorrectly set orimproperly adjusted.

Verify setting and, if necessary, correct adjustment of dampercontrol (para 4-39).

Check to see if evaporator outlet louver is bent or stuck inclosed position.

Repair or replace louver. (para 4-7)

Inspect condenser coil for dirt accumulation.

Clean coil (para 4-5).

Inspect evaporator return air filter for dirt accumul

Clean filter (para 4-3).

Check to see if evaporator fan is loose or defective.

ation

Tighten if loose or replace if defective (para 4-21).

Check evaporator fan motor for a defective thermal protectivedevice.

Replace thermal protector (para 4-22).

Check to see if evaporator fan motor is worn or defective.

Report deficiency to direct support maintenance or replace motor(para 4-21).

Check refrigerant system for insufficient charge by inspectingliquid sight indicator. Presence of bubbles indicates a lowrefrigerant charge.

Report low-charge condition to direct support maintenance.

Check for intermittent compressor operation.

Report condition to direct support maintenance.

3. EVAPORATOR OR CONDENSER FAN FAILS TO OPERATE

Step 1. Check to see if main power cable is connected.

Connect cable to power source.

Step 2. Check to see if main power receptacle or plug connectors aredefective.

Replace connectors or receptacle.

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CORRECTIVE ACTION

3. EVAPORATOR

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

Step 9.

Step 10.

4. COMPRESSOR

Step 1.

Step 3.

OR CONDENSER FAN FAILS TO OPERATE - Continued

Check to see if mode selector rotary switch is improperly adjustedor is defective.

Replace switch if defective (para 4-26).

Check to see if evaporator fan speed control switch is defective.

Replace defective switch (para 4-26).

Check to see if condenser fan motor thermal protector is defective.

Replace defective thermal protector (para 4-24).

Check to see if evaporator fan motor thermal protector is defective.

Replace defective thermal protector (para 4-22).

Check to see if evaporator fan or condenser fans are binding.

Relieve binding or replace fan (para 4-21).

Check to see if condenser fan high-low thermostat switch isdefective.

Replace defective thermostat switch (para 4-31).

Test condenser fan relay for defective operation.

Replace defective relay (para 4-27).

Test evaporator fan motor and condenser fan motor for defectiveoperation.

Replace defective fan motor (para 4-21 and 4-23).

WILL NOT START

Set circuit breakers to ON position. Turn mode selector switch toCOOL position and temperature selector switch to COOLER position.

Reset controls properly.

Check for defective or tripped compressor internal temperatureoverload switch.

Set circuit breaker and mode selector switch to off. Disconnectmain power cable for 45 minutes; then, reconnect cable and resetcontrols. If condition continues, report deficiency to directsupport maintenance.

Check for loose electrical connections or faulty wiring.

Tighten loose connections. Repair faulty wiring.

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CORRECTIVE ACTION

4.

5.

6.

COMPRESSOR

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

Step 9.

Step 10.

COMPRESSOR

Step 1.

Step 2.

WILL NOT START - Continued

Test for open control circuit by4-32).

Report open-circuit condition to

Check to see if contacts on highare open.

means of continuity check (para

direct support maintenance.

or low pressure cutout switch

Reset pressure switches. If condition continues, report deficiencyto direct support maintenance.

Test control circuit breaker and compressor circuit breaker forfaulty operation.

Replace defective circuit breaker (para 4-27).

Test control transformer and rectifier for defective operation.

Replace defective transformer (para 4-28) and defective rectifier(para 4-29).

Test for defective time delay relay.


Test for defective compressor relay.


Check to see if compressor motor is defective.grounded winding (para 4-35).

Report motor-fault condition to direct support

STARTS BUT CUTS OUT ON OVERLOAD

Test for open

maintenance.

Check for high pressure due to improper condenser coil airflow.

Clean condenser coil and louvers. Verify proper operation ofcondenser fans and louvers.

Test condenser fan for motor failure.

or

Replace defective motor (para 4-23).

EVAPORATOR AIR OUTPUT VOLUME LOW

Step 1. Check to see if evaporator fan speed switch is set at low speed.

Reset switch to HIGH speed.

Step 2. Check for dirty or damaged filter or mist eliminator.

Clean or replace filter (para 4-3). Clean or replace misteliminator (para 4-9).

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CORRECTIVE ACTION

6. EVAPORATOR AIR OUTPUT VOLUME LOW - Continued

Step 3. Check for iced or dirty evaporator coil.

De-ice and clean coil (para 4-5).

Step 4. Inspect evaporator fan for defect.

Replace defective fan.

Step 5. Test fan motor for faulty operation.

Replace motor (para 4-21).

7. CONDENSER AIR OUTLET VOLUME LOW

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Check for dirty condenser coil or guard.

Clean coil and guard (para 4-4).

Check to see if air outlet louvers are stuck in closed position.

Free louvers and control cable. Adjust control, or notify directsupport maintenance if actuating cylinder is not functioningproperly.

Check for defective HIGH-LOW condenser fan thermostatic switch.

Replace switch (para 4-26).

Inspect for defective condenser fan.

Replace fan.

Test for defective fan motor.


8. AIR CONDITIONER FAILS TO HEAT

Step

Step

Step

Step

1. Check to see if mode selector switch is improperly adjusted.

Reset selector LOW heat or HIGH heat.

2. Check to see if temperature selector control is set correctly.

Adjust control to WARMER.

3. Inspect evaporator return air filter for dirty condition.

Clean filter (para 4-3).

4. Inspect for defective temperature selector switch or mode selectorswitch.


4-13

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CORRECTIVE ACTION

8. AIR CONDITIONER FAILS TO HEAT - Continued

Step 5. Inspect for defective heater high temperature cutout thermostaticswitch.

Replace defective thermostatic switch (para 4-31).

Step 6. Test for defective heater relay.

Relay defective relay (para 4-27).

Step 7. Inspect and test for defective heaters and associated wiring.

Tighten connections and repair damaged wiring. Replace defectiveheaters (para 4-30).

Step 8. Test for defective evaporator fan motor.


9. EXCESSIVE NOISE

Step 1. Check evaporator fan or condenser fan for loose blade or loosemounting.

Tighten fan blade on motor shaft. Tighten all mounting hardware.

Step 2. Test for defective or worn evaporator or condenser fan motor.

Replace worn or defective motor (para 4-21 and 4-23).

Step 3. Check to see if compressor knocks or chatters.

Stop air conditioner and report condition to direct supportmaintenance.

4-14

TM 5-4120-361-14

Section VII. MAINTENANCE OF AIR CONDITIONER

4-20. Electrical System.

This section describes the testing,removal, and installation of the elec-trical system compnents which are theresponsibility of organizational main-tenance. Refer to the schematic (figure1-4) for cmponent nomenclature and as aguide for troubleshooting. use the wir-ing diagram (figure 1-5) to check theexact connections of wiring.

4-21. Evaporator Fan and Motor Assem-bly.

a. General. The evaprator fan mo-tor is a multispeed motor. The 400 Hzmotor operates at 3750 RPM in high speedand 1800 RPM in low speed. The 60 Hzmotor operates at 3450 RPM in high speedand 1725 RPM in low speed. The motorcontains separate windings for high orlow speed operation and each winding isthermally protected. Motor speed is

manually controlled by the evaporatorfan speed switch.

b. Controls. Before removing theevaporator fan and motor assembly, test the mode selector switch, evaporator fanspeed switch, and control circuit break-er (para 4-26) and evaporator fan motorlow/high speed switch (para 4-27) whichcontrol operation of the motor. Ifelectrical control components or wiringthat supply power to the motor are notdefective and the motor does not oper-ate, proceed as follows:

c. Removal.

(1) Refer to figure 4-1 and removethe evaporator air inlet louver.

(2) Refer to fiqure 4-7 and removethe evaporator fan and motor assembly.

(3) Refer to figure 4-8 and dis-assemble the fan and motor assembly.

Figure 4-7. Evaporator fan and motor assembly, removal and installation

4-15

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NOTE : REMOVE AND INSTALL CONDENSER MOTOR THERMAL PROTECTOR IN SAME MANNER

Figure 4-8. Evaporator, fan, motor, and thermal protector, removal and installation

d. Test.

(1) Refer to figure 4-8 and removehousing from the high and low speed mo-tor winding thermal protectors. Referto para 4-22c and test thermal protec-tors.

(2) Test the motor for open-cir-cuited or grounded windings as follows.

(a) Using a multimeter, test atP3 for continuity across a combinationof two leads until each of the threehigh speed winding leads is tested. Dothe same for the three low speed windingleads. If continuity is not indicated,the winding is open and the motor shouldbe replaced.

(b) Using a multimeter, test forcontinuity by placing one test probeagainst the motor housing (on bare metalonly) and the other probe against eachof the motor winding leads. If contin-uity is indicated, the winding isgrounded, and the motor should be re-placed.

(c) Reinstall housing on thermalprotector.

e. Installation.—

(1) Refer to figure 4-8 and assem-ble the fan and motor assembly.

(2) Refer to figure 4-7 and installevaporator fan and motor assembly.

(3) Refer to figure 4-1 and installthe evaporator air inlet louver.

4-22. Evaporator Fan Motor Thermal Pro-tector.

a. General. There are two automaticreset thermal protectors on the evapora-tor fan motor. Both thermal protectorsare similar in appearance. One of theprotectors provides overload protectionfor the low speed motor winding whilethe other provides protection for thehigh speed motor winding.

b. Removal.

(1) Refer to paragraph 4-21c andremove evaporator fan and motor assem-bly .

(2) Refer to figure 4-8 and un-solder thermal protectors.

4-16

TM 5-4120-361-14

c. Test. Using a multimeter, testfor continuity across each pair of ter-minal connections. If continuity is notindicated, the thermal protector is de-fective and must be replaced.

(b) Using a multimeter, test forcontinuity by placing one test probeagainst the motor housing (on bare metalonly) and the other probe against eachof the motor winding leads. If contin-uity is indicated, the winding isgrounded and the motor should be re-placed.

d. Installation.

(1) Refer to figure 4-8, installthermal protectors. c. Removal.

(1) Refer to figure 4-4 and removethe condenser cover and top rear cover.

(2) Refer to paragraph 4-21e andinstall evaporator fan and motor assem-bly.

(2) Refer to figure 4-9 and removethe condenser fan and motor assembly.4-23. Condenser Fan and Motor Assem-

bly.

d. Installation.a. General. The condenser fan mo-tors are multispeed motors. The 400 HZmotors operate at 3750 RPM in high speedand 1800 RPM in low speed. The 60 Hzmotors operate at 3450 RPM in high speedand 1725 RPM in low speed. The motorscontain separate windings for high orlow speed operation and each winding isthermally protected. Motor speed is au-tomatically controlled by an outdoorthermal switch (figure 1-2). The motorswill operate at low speed until the out-door ambient temperature rises above100°F ±5°F (37.8°C ±3°C).

(1) Refer to figure 4-9 and in-stall the condenser fan and motor assem-bly . Refer to figures 1-4 and 1-5 forelectrical connections.

(2) Refer to figure 4-4 and in-stall the condenser cover and top rearcover.

4-24. Condenser Fan Motor Thermal Pro-tector.

a. General. There are two automaticreset thermal protectors on each of thecondenser fan motors. Both thermal pro-tectors are similar in appearance. Oneof the protectors provides overload pro-tection for the high speed motor wind-ings and the other provides overloadprotection for the low speed motor wind-ings.

b. Test. Before removing a conden-ser fan motor, test mode selector switchand control circuit breaker (para 4-26)and the fan motor high/low speed switch(para 4-27) that control operation ofthe condenser fan motor. If electricalcontrol components or wiring that supplypower to the motor are not defective andthe motor does not operate, remove thecondenser fan and motor assembly (c.below) and make the following tests: b. Removal.

(1) Test the high and low motorwinding thermal protectors, as in para4-24c. Replace a defective protector(para 4-24c).

(1) Refer to paragraph 4-23 and re-move the condenser fan and motor assem-bly.

(2) Refer to figure 4-8 and removethe thermal protector.(2) With the high and low speed mo-

tor winding leads disconnected from thethermal protectors, test for open orgrounded windings as follows:

c. Test. Using a multimeter, test for continuity across each terminal con-nection. If continuity is not indica-ted, the thermal protector is defective(a) Using a multimeter, test for

continuity across a combination of twoleads until each of the three high speedwinding leads is tested. DO the samefor the three low speed winding leads.If continuity is not indicated, thewinding is open and the motor should bereplaced.

and must be replaced.

d.

stall

Installation.

in-

4-17

(1) Refer to figure 4-8 andthe thermal protector.

TM 5-4120-361-14

NOTE : REMOVE OTHER MOTOR IN SIMILAR MANNER

Figure 4-9. Condenser fan and motor assembly, removal and installation

(2) Refer to paragraph 4-23 and in-stall the condenser fan and motor assem-bly. Ensure correct direction of rota-tion.

4-25. Control Module and Junction Box.

a. General. The control panel islocated in the upper left front cornerof evaporator section. The control mod-ule is mounted on the junction box by along bolt with a slotted steel knob.The junction box and control modulecontain all of the electrical controlson the unit.

Do not turn control modulemounting bolt unless unit hasbeen disconnected from powersource.

b. Removal.

(1) Refer to figure 4-4 and removethe top front cover.

(2) Refer to figure 4-1 and removethe evaporator inlet louver.

4-18

TM 5-4120-361-14

(3) Refer to figure 4-10 and re-move control module and junction box.

c. Installation.

(1) Refer to figure 4-10 and in-stall control module and junction box.

(2) Refer to figure 4-4 and in-stall top front cover.

4-26. Control Module Components.

a. General. The control module com-ponents consist of the compressor cir-cuit breaker, control circuit breaker,mode selector switch (rotary), tempera-ture control switch, and the evaporatorfan speed relay switch. All components

CAUTION:

CAUTION:

have the same inspection and test re-quirements. The compressor circuitbreaker is a safety device which pro-vides overcurrent protection for thecompressor. The control circuit break-er provides protection for the DC con-trol system.

b. Inspection and Test. Before re-moving any of the control module compo-nents-check for loose connections,pitted contacts, and cracked or brokencasings. Refer to wiring diagram (fig-ure 1-5) and check for continuity witha multimeter. If no continuity existswith the circuit breaker in the ON posi-tion, or if a casing is broken orcracked, replace the circuit breaker.

BEFORE ATTEMPTING TO FULLY REMOVE CONTROL MODULE OR JUNCTION BOX, DISCONNECTTHERMOSTAT SENSING BULB FROM HOUSING AND CAREFULLY THREAD BULB THROUGH OPENINGINJUNCTION BOX.

DO NOT TURN CONTROL MODULE MOUNTING BOLT UNLESS UNIT HAS BEEN DISCONNECTEDFROM POWER SOURCE.

NOTE : INSTALL JUNCTION BOX IN UNIT. INSTALL CONTROL MODULE IN JUNCTION BOX.OBSERVING CAUTION ABOVE ADD ATTACHING HARDWARE.

Figure 4-10. Junction box and control module, removal and installation

4-19

TM 5-4120-361-14

CAUTION: BE CAREFUL NOT TO DAMAGE SENSING BULB

Figure 4-11. Compressor circuit breaker, removal and installation

CAUTION: BE CAREFUL NOT TO DAMAGE SENSING BULB

Figure 4-12. Mode selector switch removal and installation

4-20

(1) Compressor circuit breaker.

TM 5-4120-361-14

the capil lary tube is damaged, replacethe temperature control switch. if knobis loose, tighten set screw. If knob isdefective, replace.

(a) Removal.

(i) Refer to figure 4-10 andremove the control module. (b) Removal.

(ii) Refer to figure 4-11 andremove the compressor circuit breaker.The pin assembly must be removed firstbefore removing circuit breaker.

(i) Refer to figure 4-10 andremove the control module.

(ii) Refer to figure 4-13 andremove the temperature control switch.

(b) Installation.

(i) Refer to figure 4-11 andinstall the compressor circuit breaker.

(c) Installation.

(i) Refer to figure 4-13 andinstall the temperature controlswitch.(ii) Refer to figure 4-10 and

install the control module.(ii) Refer to figure 4-10 and

install the control module.(2) Mode Selector Switch (Rotary)is an electrical switch that can be man-ually positioned to select the desiredoperational mode of air conditioner.Refer to para 2-2c.

(4) Evaporator Fan Speed Switch.

(a) Testing. Check for looseconnections, mountings, and cracked orbroken casing. Check for continuitywith a multimeter. If no continuity ex-ists, or if the casing is broken orcracked, replace switch.

(a) Testing. Check for looseconnections, loose control knob andcracked or broken casing. Check forcontinuity with a multimeter.

If no continuity exists with switch ineither one of the four “ON” positions,or if the casing is broken or cracked,replace the mode selector switch. Ifknob is loose, tighten set screw. Ifknob is defective, replace.

(b) Removal.


(ii) Refer to figure 4-14 andremove the evaporator fan speed switch.

(b) Removal.(c) Installation.

(i) Refer to figure 4-10 andremove the control module. (i) Refer to figure 4-14 and

install the evaporator fan speed switch.(ii) Refer to figure 4-12 and

remove the mode selector switch. (ii) Refer to figure 4-10 andinstall the control module.

(c) Installation.(5) Control Circuit Breaker.

(i) Refer to figure 4-12 andinstall the selector switch. (a) Testing. Check for loose

connections, mountings, and cracked orbroken casing. Check for continuitywith a multimeter. If no continuityexists, or if the casing is broken orcracked, replace the circuit breaker.

(ii) Refer to figure 4-10 andinstall the control module.

(3) Temperature Control Switch.

(a) Testing. Check for looseconnections, loose control knob, crackedor broken casing, and kinked or brokencapillary tube. Refer to wiring diagram(figure 1-5) and make a continuitycheck. If no continuity exists when inthe cooling mode and the thermostat tem-perature is above its set point or if

(b) Removal.


(ii) Refer to figure 4-14 andremove the control circuit breaker.

4-21

TM 5-4120-361-14

Figure 4-13. Temperature control

(c) Installation.

(i) Refer to figure 4-14 andinstall the control circuit breaker.

(ii) Refer to figure 4-10 andinstall the control module.

4-27. Junction Box Components.

a. General. The junction box compo-nents consist of the following: timedelay relay, evaporator fan motor lowspeed relay, fixed heater relay, cyclingheater relay, evaporator fan motor highspeed relay, condenser fan motor highspeed relay, condenser fan motor lowspeed relay, compressor relay, andterminal boards.

switch,

b.moving

removal and installation

Inspection and Test. Before re-any of the junction box compo-

nents check for loose connections,pitted contacts, and cracked or brokencasings. Refer to wiring diagram (fig-ure 1-5) and check for continuity with amultimeter. If no continuity exists, ora casing is broken or cracked, replacethe component.

(1) Time Delay Relay.

(a) Testing. Turn mode selectorswitch to cool and note time lapse be-tween starting of fan motors and start-ing of compressor. If time lapse isless than 27 seconds or more than 33seconds, replace the relay.

4-22

TM 5-4120-361-14

(b) Removal.

(i) Refer to figure 4-10 andremove the junction box.

(ii) Refer to figure 4-15 andremove the time delay relay.

(c) Installation.

(i) Refer to figure 4-15 andinstall the time delay relay.

(2) Evaporator Fan Motor Low SpeedRelay.

(a) Removal.


(ii) Refer to figure 4-15 andremove the evaporator fan low speed re-lay.

(b) Testing. Check for looseconnections and cracked or broken cas-ing. Check for continuity with a multi-meter. If no continuity exists, or if

(ii) Refer to figure 4-10 andinstall the junction box.

Figure 4-14. Evaporator fan motor speed switch and control circuit breaker, removaland installation

4-23

TM 5-4120-361-14

Figure 4-15. Time delay relay and evaporator fan motor low speed relay, removal andinstallation

the casing is cracked or broken, re-place the relay.

(c) Installation.

(i) Refer to figure 4-15 andinstall the evaporator fan low speed re-lay.


(3) Fixed Heater Relay.

(a) Removal.


(ii) Refer to figure 4-16 andremove the fixed heater relay.

(b) Testing. Check for looseconnections and cracked or broken cas-ing. Check for continuity with a multi-meter. If no continuity exists, or ifthe casing is cracked or broken, re-place the relay.

(c) Installation.

(i) Refer to figure 4-16 andinstall the fixed heater relay.


4-24

TM 5-4120-361-14

(4) Cycling Heater Relay.

(a) Testing. Check for looseconnections and cracked or broken cas-ing. Check for continuity with a multi-meter. If no continuity exists, or ifthe casing is cracked or broken, replacethe relay.

(b) Removal.


(ii) Refer to figure 4-16 forremoval of the cycling heater relay.

(c) Inshallation.

(i) Refer to figure 4-16 andinstall the cycling heater relay.


(5) Evaporator Fan Motor High SpeedRelay.

(a) Testing. Check for looseconnections and cracked or broken cas-ing. Check for continuity with a multi-meter. If no continuity exists, or ifthe casing is cracked or broken, replacethe relay.

(b) Removal.


(ii) Refer to figure 4-16 andremove the evaporator fan motor highspeed relay.

(c) Installation.

(i) Refer to figure 4-16 andinstall the evaporator fan motor highspeed relay.

Figure 4-16. Heater relays, evaporator fan motor high speed relay, condenser fanmotor relays, compressor relay and terminal boards, removal andinstallation.

4-25

TM 5-4120-361-14


(6) Condenser Fan Motor High SpeedRelay.

(a) Testing. Check for looseconnections and cracked or broken cas-ing. Check for continuity with a multi-meter. If no continuity exists or ifthe casing is cracked or broken, replacethe relay.

(b) Removal.


(ii) Refer to figure 4-16 andremove the condenser high speed relay.

(c) Installation.

install

install

Relay.

connect

(i) Refer to figure 4-16 andthe condenser high speed relay.

(ii) Refer to figure 4-10 andthe junction box.

(7) Condenser Fan Motor Low Speed

(a) Testing. Check for looseions and cracked or broken cas-

ing. Check for continuity with a multi-meter. If no continuity exists, or ifthe casing is cracked or broken, replacethe relay.

(b) Removal.


(ii) Refer to figure 4-16 andremove the condenser low speed relay.

(c) Installation.

(i) Refer to figure 4-16 andinstall the condenser low speed relay.


(8) Compressor Relay.

(a) Testing. Check for looseconnections and cracked or broken cas-ing. Check for continuity with a multi-meter. If no continuity exists or if

the casing is cracked or broken, replacethe relay.

(b) Removal.


(ii) Refer to figure 4-16 andremove the compressor relay.

(c) Installation.

(i) Refer to figure 4-16 andinstall the compressor relay.


(9) Terminal Boards.

(a) Testing. Check for looseconnections, loose mounting or crackedor broken casing; replace if defective.

(b) Removal.


(ii) Refer to figure 4-16 andremove the terminal boards.

(c) Installation.

(i) Refer to figure 4-16 andinstall the terminal boards.


4-28. Transformer and Resistor.

a. Removal.

(1) Refer to figure 4-10 and re-move the junction box.

(2) Refer to figure 4-17 and re-move the transformer and resistor. Re-move resistor from transformer if eitheris faulty when tested as follows:

b. Testing.—

(1) Refer to wiring diagram (fig-ure 1-5) and use a multimeter to testthe transformer for continuity throughboth the primary winding and the secon-dary winding. If no continuity existsthrough either winding, replace thetransformer.

4-26

TM 5-4120-361-14

(2) use the multimeter to verifythe resistor ohms. If measurement showsother than 10 ±1 ohm, replace the resis-tor.

c. Installation.—

(1) Refer to figure 4-17 and in-stall the transformer and resistor.

(2) Refer to figure 4-10 and in-stall the junction box.

4-29. Rectifier and Capacitors

a. General. The rectifier and cap-acitors are located on the bottom of thejunction box compartment. The rectifieris a 4-diode unit providing full-wave

rectification which converts the ac todc for the 24-volt control circuit. Thecapacitors reduce EMI radiation tospecified levels.

b. Removal.—

(1) Refer to figure 4-10 and re-move the junction box.

(2) Refer to figure 4-17 and de-tach the cable from the rectifier.

(3) Remove the capacitors from therectifier cable terminals.

(4) Remove the rectifier by remov-ing the two mounting screws and washers.

Figure 4-17. Transformer, resistor, rectifier and capacitors, removal andinstallation

4-27

TM 5-4120-361-14

c. Inspection and Test.—

(1) Inspect rectifier and both ca-pacitors for cracked or broken case andsigns of overheating. Replace ifscorched or blistered, or if case isdamaged.

(2) Using the ohms function of amultimeter, measure the resistance be-tween the + and - terminals of the rec-tifier:

(a) With the + lead of the meteron the - terminal of the rectifier andthe - lead of the meter on the + termi-nal of the rectifier, conductivityshould be indicated.

(b) Reverse the meter leads tothe rectifier; meter should indicate anopen circuit (infinity).

(c) Replace rectifier if measure-ments differ from those given in (a) and(b).

(3) Using multimeter, test capaci-tor for continuity. Replace capacitorif continuity exists.

d. Installation.—

(1) Refer to figure 4-17 and in-stall rectifier.

(2) Refer to figure 1-5 and in-stall capacitors by crimping leads intocable terminals.

(3) Refer to figure 1-5 and attachcable to rectifier.

(4) Refer to figure 4-10 and in-stall the junction box.

4-30. Heating Elements and Heater Cut-out Switch.

a. General. A bank of six elementsprovides heat for the heating mode;three elements are energized in the LOWand all six in the HIGH heat position.Temperature is controlled by thermo-static cycling. Dangerously high temp-eratures are prevented by the heatercutout switch.

b. Removal.—


(2)move thebox .

Refer to figure 4-10 and re-control module and junction

(3)move the

Refer to fiqure 4-18 and re-heating elements or the heater

cutout switch.

c. Testing. Refer to wiring diagram(figure 1-5) and test across the heatinqelement leads for continuity, using amultimeter. If no continuity exists,replace the heating element. Using amultimeter, test the heater cutoutswitch for continuity between terminals1 and 2 (also between terminals 3 and4). If no continuity exists, replacethe heater cutout switch.

d. Installation.—

(1) Refer to figure 4-18 and in-stall the heating element or heater cut-out switch.

(2) Refer to figure 4-10 and in-stall the junction box and control mod-ule.

(3) Refer to figure 4-4 and in-stall the top front cover.

4-31. Thermostatic Switch.

a. General. The thermostatic switchautomatically changes the condenser fanspeed by sensing ambient temperature.With the ambient temperature at 95°F(35°C) or below, the condenser fan willrun at low speed. If the ambient tem-perature rises to approximately 105°F(40.6°C), the condenser fan will run athigh speed. Conversely, if the fan isrunning at high speed and the ambientdrops to approximately 95°F (35°C), thefan will run at low speed.

b. Testing. If no speed change isnoted (change in noise level) duringoperation, when the ambient temperatureschange as described in paragraph a.above, the switch is defective and mustbe replaced.

c. Removal.—


(2) Refer to figure 4-19 and re-move thermostatic switch.

4-28

TM 5-4120-361-14

TO REMOVE HEATING ELEMENT:

GRIP HEATING ELEMENT FITTING FLANGE WITH WRENCH PLIERS, AND WITH END WRENCH, REMOVELOCKNUT AND WASHERS. SLIDE ELEMENT FREE OF HOUSING PANEL, THEN OUT OF MOUNTINGBRACKET. START WITH TOP ELEMENT

Figure 4-18. Heating element and

d.

stall

stall

4-32.

AND WORK DOWN.

heater

Installation

(1) Refer to figure 4-19 and in-the thermostatic switch.

(2) Refer to figure 4-4 and in-the top front cover.

Wiring.

a. Inspection. Inspect insulationfor cracks and signs of deterioration.Pay particular attention to wires pass-ing through holes in the frame and overrough metal edges. If inspection re-veals a broken or cut wire, and the wireis exposed, it must be repaired. If thebreak in the wire is in the wiring har-

cutout switch, removal and installation

ness or in an inaccessible area, replacewire (c. below).

b. Testing. Test a wire for con-tinuity by disconnecting each end fromthe component(s) to which it is con-nected. Touch the test probes of amultimeter to the ends of the wire undertest. If continuity is not indicated,the wire is defective and must be re-paired or replaced.

c. Replacement. To replace a defec-tive wire lead, disconnect both ends atthe components and install new wire withan exact duplicate of wire being re-placed. If the defective wire is diffi-cult to remove from wiring harness, cut

4-29

TM 5-4120-361-14

the wire back from the components abouttwo inches and cover ends to outside ofharness with electrical tape or plasticclamps.

4-33. High Pressure Cutout Switch andLow Pressure Cutout Switch.

a. General. The high pressure cut-out (HPCO) switch prevents the com-pressor from operating if the dischargepressure exceeds 445 ±10 psig. The lowpressure cutout (LPCO) switch preventsthe compressor from operating if the suc-tion pressure drops below 15 ±5 psig.Each is reset manually. Inspect and

test the HPCO and LPCO switches if thecompressor fails to operate after theswitch is reset.

b. Inspection.—

(1) Refer to figure 4-20 and re-move the access cover.

(2) Inspect for broken or damagedwire leads and kinked or broken capil-lary tubes.

c. Testing. (See WARNING insidefront cover.

Figure 4-19. Thermostatic switch removal and installation

4-30

TM 5-4120-361-14

Figure 4-20. Access to pressure cutout switches

(1) Using a multimeter, test forcontinuity between terminals 1 and 2 ofeach pressure cutout switch.

(2) If continuity is not indi-cated, the pressure cutout switch is de-fective and must be replaced. Report todirect supprt maintenance for replace-ment of defective switch.

4-34. Compressor (See WARNING insidefront cover.)

a. General. The compressor is ahermetically sealed unit and is notreparable. An inoperative compressoris usually due to a mechanical failurecausing the copressor to freeze, a con-trol failure, or motor burnout. Com-pressor replacement is required in allcases of mechanical or motor burnout.If the motor is defective report to di-rect or general support maintenance.

b. Test.

(1) Refer to figure 4-4 and removethe condenser cover and top rear cover.

(2) Refer to figure 4-9 and removecondenser fan motor and the compressorelectrical junction box.

(3) Disconnect receptacle connec-tor from compressor junction box and re-move junction box cover.

(4) Refer to wiring diagram (fig-ure 1-5) and test for continuity using amultimeter. Lack of continuity indi-cates an open winding.

(5) Place one contact of the meteragainst the compressor housing and theother against the motor terminals, oneat a time. If a circuit is indicated,the motor is grounded.

4-35. Condensate Water Drain Tubes.

a. General. Refer to paragraph2-4c(2).

b. Removal.


4-31

TM 5-4120-361-14

Figure 4-21. Drain tubes,

(2) Refer to figure 4-21 and re-move clamps which hold plastic draintubes to fittings.

c. Inspection and Servicing.—

(1) Inspect tubes for cracks, ob-structions and loose connections.

(2) Clean tubes with low pressurecompressed air or flush with water.

d. Installation.—

(1) Refer to figure 4-21 and re-place tubes and clamp securely.

(2) Refer to figure 4-1 and re-place the evaporator inlet louver.

4-36. Liquid Line Solenoid Valve, L1

a. General. The normally-open liq-uid line solenoid valve is electricallyclosed when the mode selector switch isturned to COOL. When the temperaturecontrol thermostat is satisfied, theliquid line solenoid valve opens placingthe refrigerant system in the bypasscondition.

removal and installation

b. Inspectionfront cover)

(1) Refer torear top cover.

(2) Refer tonut from valve.

(See WARNING inside

figure 4-4 and remove


(3) Remove valve cover and inspectcoil for cracks, breaks, loose connec-tions, frayed wires or other defects.

(4) Report any defects to directsupport maintenance.

c. Test. Using a multimeter, testacross the valve coil leads for contin-uity. If no continuity is indicated,the coil may be defective. Report todirect support maintenance.

4-37. Pressure Equalizing SolenoidValve, L2

a. General. The normally-openequalizing solenoid valve is electri-cally closed when the mode selector isturned to COOL. When power is switchedfrom the solenoid coil the valve opens,equalizing the high side to low sidepressure.

4-32

TM 5-4120-361-14

b. Inspect.


(2) Remove the valve cover and in-spect coil for cracks, breaks, looseconnections, frayed wires or other de-fects.

(3) During the cooling cycle, in-spect the compressor suction line. Ifit feels hot, the pressure equalizingsolenoid valve (figure 5-7) is defec-tive.

(4) Report all defects to directsupprt maintenance.

c. Test. Test the pressure equaliz-ing solenoid valve for continuity acrosselectrical leads with a multimeter. Ifno continuity is indicated, the valve isdefective and should be replaced. Re-port all defects to direct support main-tenance.

4-38. Expansion Valve (Primary) Inspec-tion and Test.

a. General. If the air conditioningunits is not cooling properly, inspectand test the expansion valve for de-fects.

b. Inspection.


(2) Refer to figure 4-22 and para5-29c(4) and check that the requiredlength of the expansion valve’s sensingbulb is fully in the suction line bulbwell.

(3) Refer to figure 4-22 and exam-ine the flow restrictor capillary tubescarefully. They should be very cold andevenly frosted. Unfrosted tubes areblocked and should be re-placed.

(4) If none of the capillary tubesis cold and frosted, the valve is

Figure 4-22. Expansion valve, primary

4-33

TM 5-4120-361-14

blocked or the valve’s power assembly isruptured. The test for the power assem-bly is listed in the following paragraph(c).

c. Test. Test the power assembly byremoving the valve’s sensing bulb fromthe suction bulb well (figure 4-22).Hold the sensing bulb firmly in bothhands for two or three minutes. Thewarmth from holding the bulb should putenough pressure on the bellows to startthe refrigerant flowing into the sys-tem. If cooling does not commence, theexpansion valve is defective and shouldbe replaced. Report all defects to di-rect support maintenance.

4-39. Vent Damper Actuator.

a. Removal.—


(2) Refer to figure 4-23 and dis-assemble the vent damper actuator andcontrol assembly as follows:

(a) Loosen the setscrew in theactuator.

(b) Remove the actuator topbracket by removing one nut, threescrews and three washers.

(c) Raise the actuator nut andthe actuator from the lower bracket.

(d) Remove the screw and nut fromthe bracket on the vent door.

(e) Remove inner cable from con-trol assembly.

(f) Remove outer nuts and grom-met on control assembly.

(9) Remove control assembly outercable.

b. Installation.—

(1) Refer to figure 4-23 and in-stall the vent actuator as follows:

Figure 4-23. Vent damper actuator removal and installation

4-34

TM 5-4120-361-14

(a) With inner nuts in place, in- the bushing flange adjacent to the actu-stall the outer cable in the support ator nut. Rotate actuator nut to thebracket. left (counterclockwise) to place the ac-

(b) Install the grommet in theintermediate cable support.

(c) Fasten the cable ends in thesupport brackets by installing the outernuts.

(d) Thread the inner cablethrough the outer cable. Attach thelooped end of the inner cable to thevent door.

(e) Lubricate the threads on theactuator, install actuator and actuatornut in the fixed actuator bracket, theninstall the removable bracket. Ensurethat bushings are in both brackets with

tuator in the uppermost position.

(2) Adjust the damper actuator asfollows:

a. Ensure that the damper dooris closed.

b. Insert cable end in actuator,adjusting, if necessary, the cable nutsto properly seat the cable end in theactuator.

c. Tighten the actuator setscrewonto the cable.

(3) Refer to figure 4-1 and installthe evaporator inlet louver.

4-35/(4-36 Blank)

TM 5-4120-361-14

CHAPTER 5

DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE INSTRUCTIONS

Section I. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT

5-1. Tools and Equipment. 5-3. Maintenance Repair Parts.

NO tools or equipment are issued withthe air conditioner.

5-2. Special Tools and Equipment. Repair parts and equipment are listedand illustrated in the repair parts and

NO special tools or equipment are re- special tool list covering direct andquired for maintenance of the air condi- general support maintenance for this

5-4. General.

equipment.

Section II. TROUBLESHOOTING

pressure test instructions are in para-graph 6-2. Troubleshooting procedures

This section provides information for-direct and general support mainte-useful in diagnosing and correcting nance are listed in table 5-1. Eachunsatisfactory operation or failure of trouble symptom or malfunction statedthe air conditioner or any of its com- is followed by a step-by-step procedureponents. Electrical schematic and wir- for inspecting and testing the system toing diagrams shown in figures 1-4 and determine the specific cause of fault or1-5 will be helfpul for checking elec- failure. The corrective action recom-trical circuits.diagram is shown

A refrigerant flow mended follows the determination ofin figure 5-1. System probable cause.

5-1

TM 5-4120-361-14

Figure 5-1. Refrigerant flow diagram

5-2

(figure 6-3)

TM 5-4120-361-14

Table 5-1. Troubleshooting.


CORRECTIVE ACTION

1. COMPRESSOR WILL NOT START

Step 1.

Step 2.

Step 3.

Step 4.

Test for an open-circuit condition in the control circuit by meansof a continuity check.

Replace component or wire causing open circuit (para 4-32).

Test circuit breaker for defective operation.

Replace defective circuit breaker (para 4-26).

Check to see if high or low pressure cutout switch is defective.


Check to see if compressor motor or thermal protectors aredefective.

Replace compressor (para 5-16).

2. COMPRESSOR STARTS BUT IMMEDIATELY STOPS

Step 1. Check to see if thermal protector or circuit breaker is tripped.

Reset circuit breaker, or allow thermal protector to cool andreset. If condition repeats, replace compressor (para 5-16).

3. LITTLE OR NO HEATING CAPACITY.

Step 1.

Step 2.

Step 3.

Step 4.

Check for loose electrical connections or faulty wiring.

Repair or replace wiring as necessary (para 4-32).

Test mode selector switch and temperature selector for faultyclosure in heat control circuit.


Test heater relay for faulty contact closure.


Test for defective operation of heater high temperature cutout,

Step 5.


Step 1. Test for low refrigerant charge.

Replace defective thermostat switch (para 4-30).

Test heater for open-circuited element.

Replace defective heaters (para 4-30).

5-3

TM 5-4120-361-14



CORRECTIVE ACTION

4. INSUFFICIENT COOLING - Continued

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

5. LOW SUCTION

Step 1.

Step 2.

Step 3.

Check for indications of a clogged dehydrator.

Replace clogged dehydrator (para 5-24).

Check for indications of a defective pressure regulator valve.

Replace defective valve (para 5-30).

Check for indications of air in system.

Purge and charge system (fig. 6-1 and 6-2).

Check for indications of a defective thermal expansion valve.


Check for indications of defective solenoid valve.

Replace defective solenoid valve (para 5-25).

Check for indications of defective quench valve.


PRESSURE (See Table 6-1)

Check for indications of a

Replace clogged dehydrator

Check for indications of a

clogged dehydrator.

(para 5-24).

defective thermal expansion valve.


Check for indications of a defective quench valve.


6. LOW DISCHARGE PRESSURE (See Table 6-1)

Step 1.

Step 2.

7. LOW SUCTION

Step 1.

Check to see if compressor is not pumping due to defect.

Check to see if HIGH/LOW condenser fan thermostatic switch isdefective.


AND DISCHARGE PRESSURE (See Table 6-1)

Check for low refrigerant charge by inspecting sight glass forbubbles or milky appearances. Also check system for leaks.

Repair leaks and add refrigerant as necessary.

5-4

TM 5-4120-361-14

Table 5-1.


CORRECTIVE ACTION

7. LOW SUCTION

Step 2.

Step 3.

8. HIGH SUCTION PRESSURE (See Table 6-1)

AND DISCHARGE PRESSURE - Continued

Check for indications of defective thermal expansion valve.

Replace valve (para 5-28).



Step 1. Check for indications of defective thermal expansion valve.


Step 2. Check for indications of defective quench valve.


9. HIGH HEAD PRESSURE (See Table 6-1)

Step 1. Check to see if condenser coil is dirty.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Clean coil.

Check condenser coil temperature gradient for indications ofrefrigerant overcharge.

Discharge refrigerant (fig. 6-1) while observing head pressureand sight glass.

Inspect or test condenser fan motor for defective operation.

Repair motor (para 6-8).

Inspect condenser louvers and actuating mechanism for correctadjustment and proper operation.

Adjust and clean as necessary. Replace in operative components(para 5-20).



Check to see if the compressor is defective.

Replace defective compressor (para 5-16).

5-5

TM 5-4120-361-14

Section III. GENERAL MAINTENANCE

5-5. General.

This section contains general servic-ing instructions that otherwise wouldhave to be repeated several times inthis manual.

5-6. Testing for Leaks.

The air conditioner can be tested forrefrigerant leaks by the use of an elec-tronic leak detector, by the halide testor by the soap bubble method. The pre-ferred method is use of the electronicleak detector. If sufficient pressureis not present in the system to accom-plish an adequate leak test, add drynitrogen at the receiver charging valveto increase the system pressure to 300psig, then conduct the leak test. Ifthe system is totally discharged, toconserve leak test refrigerant, pres-surize the system with R-12 to 72 psig,isolate the compressor by front-seatingthe service valves (1 and 2, figure3-2). At the receiver charging valvepressurize the system with dry nitrogento 300 psig, then conduct the leaktest.

(1) By Electronic Leak Detector.Using a G.E. Type H-2 Leak Detector, orequivalent, proceed as follows:

(a) Turn on and calibrate theleak detector as described in the in-structions supplied with the instru-ment.

(b) Slowly pass the detectorprobe tip over the sweat fittings, mech-anical couplings and valves in the re-frigerant circuit. If refrigerant isleaking, detector will provide a visibleor audible signal.

(c) Use the soap-bubble method tolocalize the leak to a defective com-ponent or connection.

(2) By Halide Leak Test. Using apropane flame halide leak detector, pro-ceed as follows.

(a) Slowly pass the exploringtube on the torch over the sweat fit-tings, mechanical couplings and valves.If refrigerant is leaking, the flamewill be affected as follows:

INSTRUCTIONS

Small leak -- flame changes fromblue to green

Large leak -- flame changes fromblue to dense bluewith reddish tip

Massive leak- may extinguish flame

(b) Use the soap-bubble method tolocalize the leak to a defective com-ponent or connection.

(3) By Soap Solution Method. Usingeither a prepared bubble-type leak de-tector compound or a solution of handsoap in water, proceed as follows.

(a) Apply the solution to allpoints of possible leakage, and watchfor bubble formation indicating a re-frigerant leak.

NOTE

Allow solution to remaijoints long enough forleaks to form noticeabbles.

n onsmalle bub-

(b) Wipe solution from joints andmark spots where leakage is observed.

5-7. Refrigeration System.

a. Opening System. When the refrig-eration system must undergo maintenancethat requires the system to be openedfor removal of parts, the system mustfirst be discharged (para 6-3). Afterthe repair has been made and all solder-ing completed, the system must be testedfor leaks and charged (para 6-3).

b. Removal of Parts. When the re-frigeration system must undergo main-tenance that requires the refrigerantsystem to be opened for removal ofparts, the system must first be dis-charged and purged (figure 6-1). Afterthe repair has been made and all solder-ing completed, the system must be testedfor leaks and charged (para 6-3). Ex-cept for flare nut connection, all thetubing attachments in the refrigerationsystem are “sweat-joints” which areopened by heating with a brazing torch.During unseating, shield the wiring,insulation, painted metal, and valvesfrom the heat of the torch. Use wet

5-6

TM 5-4120-361-14

cloths to protect the gas charge in ex-pansion valve bulbs and capillary tub-ing.

1. Brazing operations shouldbe carried out using approvedeye protection equipment androds not containing cadmium.

2. Certain brazing operationsmay require mechanicalventilation.

3. Local preventive medicinepersonnel should be queriedif doubt exists as to rodcomposition or ventilationrequirements.

c. Brazing. Braze copper-to-copperjoints with silver solder type 3, 4 or6A specification QQ-S-561 and copper-to-brass or copper-to-steel with type 4 or6A specification QQ-S-561 per MIL-B-7883. Solder melting point is 1160°F(625°C). All brazed or soldered jointsshall be made with an atmosphere of in-ert gas to prevent internal oxidation.

5-8. Insulation and Gaskets.

Replace dmaged insulation and gas-kets. Cement loose insulation.

5-9. Hardware.

Replace any damaged screws, washers,lockwashers or nuts. use screws of cor-rect length to hold parts securely. Insome applications screws that are toolong may hit bottom before the head istight against part it is to hold or maycause damage to the threads or otherparts.

5-10. Shims.

Be sure to remove all shims whereused. Keep shims together and identifythem as to location.

5-11. Repairing Damaged Threads.

Damaged threads should be repaired byuse of a thread restorer or by chasingin a lathe. Internal threads should berepaired with a tap of the correct size.If threads cannot be satisfactorily re-paired, replace the part. Drill out andreplace blind rivet nuts having defec-tive threads.

5-12. Repair of Damaged Machined andPolished Surfaces.

Smooth rough spots, scores, burrs,galling, and gouges from damaged ma-chined and polished surfaces so thatpart will efficiently perform its normalfunction. The finish of the repairedpart is to approximate that of the orig-inal finish. In perfoming any of theseoperations, critical dimensions must notbe altered.

5-13. Removal of Rust or Corrosion.

Remove corrosion from all parts of ma-terial. To remove rust or corrosion,use wire brush, abrasive cloth, sandblast, vapor blast equipment, or rustremover except on highly polished sur-faces. On these surfaces, buffing orthe use of crocus cloth is recommended.

5-14. Tubes and Fittings.

Check tubes and fittings for crackedor split condition. Check tubing forkinks. Replace defective fittings. Re-place damaged tubing with tubing of samesize. Take care in making bends in tub-ing to prevent kinking of tubing. Alltubing and fittings must be completelyclean on inside prior to installation.

5-15. Valves.

Valves and other parts should behandled carefully to prevent damage.Capillary tubes must be handled verycarefully to prevent kinking of thetubes.

Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS AND ASSEMBLIES.

5-16. General. (See WARNING inside ect support and general support mainte-front cover.) nance. The refrigerant piping and

valves cannot be removed as a unit, andThis section covers removal of all only those parts that require replace-

major assemblies of the air conditioner ment should be removed. Removal and in-which are the responsibility of the dir- stallation instructions for individual

5-7

TM 5-4120-361-14

valves and other components of the re-frigeration system are contained in thissection. Refer to paragraph 5-6 beforeperforming maintenance on the refrigera-tion system.

5-17. Compressor.

a. General. The compressor is aself-contained hermetically sealed unitand cannot be repaired.

b. Removal. Refer to figure 5-2 andremove compressor as follows:

1. Caution should be exer-cised with fluorocarbon re-frigerant gas (freons) as theycan displace oxygen andthereby cause suffocation.

2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should be

made aware of the potentialfor aggravation rhythm abnor-malities or the induction ofarrhythmias, as a result of ex-posure to fluorocarbon re-frigerant gases (freons).Such individuals should beevaluated by local medical au-thorities before working inenvironments where potentialfreon exposure may occur.

(1) Refer to figure 6-1 and dis-charge the refrigerant system.

(2) Refer to figure 4-4 and removetop covers.

(3) Refer to figure 5-2 and dis-connect condenser louver actuator withbracket attached. Move aside withoutaltering actuator adjustments.

(4) Refer to figure 4-9 and removecondenser fan motors and motor support.

(5) Disconnect electrical con-nector P1 from compressor, also

Figure 5-2. Compressor and accumulator, removal and installation

5-8

refrigerant tubing as required to per-mit removal of compressor.

(6) Remove four screws, washers,lock washers and compressor mount bush-ings.

(7) Lift compressor from air condi-tioner.

If compressor is being re-placed because of a motorburnout, decontaminate systemas instructed in paragraph6-5. Failure of the replace-ment compressor will result ifall the contaminants are notremoved.

c. Installation. Install compressoras follows:

(1) Refer to figure 5-2, place com-pressor on mounts and install four com-pressor mount bushings. Secure com-pressor with four screws, washers andlock washers.

(2) Connect compressor tubing. Re-fer to figure 5-7 and install dehydra-tor.

(3) Refer to paragraph 5-6a andleak-test connections.

(4) Connect electrical connectorP 6 .

(5) Refer to figure 4-9 and in-stall condenser motor and motor sup-ports.

(6) Refer to figure 5-2 and in-stall condenser louver actuator andmounting bracket.

(7) Refer to figure 6-1 and purgethe refrigerant system.


2. Personnel with

TM 5-4120-361-14

a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-mias, as a result of exposureto fluorocarbon refrigerantgases (freons). Such indivi-duals should be evaluated bylocal medical authorities be-fore working in environmentswhere potential freon exposuremay occur.

(8) Refer to figure 6-2 and re-charge the refrigerant system.

(9) Refer to figure 4-4 and in-stall top covers.

5-18. Evaporator Coil and Mist Elimina-tor Holder.

a. General. A portion of the evapo-rator coil mounting hardware is used toattach the mist eliminator holder.Therefore coil and mist eliminatorholder are removed under the same pro-cedure.

b. Removal. Remove the evaporatorcoil and mist eliminator holder as fol-lows :


(2) Refer to figure 4-4 and re-move housing top covers.

(3) Refer to figure 4-1 and re-move evaporator air outlet louvers andmist eliminator.

(4) Refer to para 4-30 and removeheating elements.

(5) Refer to figure 5-3 and re-move support plate that holds coil tohousing.

(6) Refer to figure 5-3 and discon-nect tubing from evaporator coil.

(7) Remove six screws, washers, andlockwashers that hold evaporator coiland mist eliminator holders to air con-ditioner. Remove holders and coil.

c. Installation. Install evapo-rator coil and mist eliminator holder asfollows:

5-9

Figure 5-3.

TM 5-4120-361-14

(1) Install coil and mist elimina-tor holder in air conditioner and secureto brackets with six screws, washers,and lock washers. The upper fourscrews, washers and lockwashers attachboth the coil and mist eliminator hold-er; the lower two hold the coil only.

(2) Refer to figure 5-3 and installcoil support plate.

(3) Connect tubing to coil. Leaktest as described in 5-6.

(4) Refer to figure 4-1 and installevaporator air outlet louver.

(5) Refer to figure 4-18 and in-stall heating elements.

(6) Refer to figure 4-4 and in-stall housing top covers.


2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-mias, as a result of exposureto fluorocarbon refrigerantgases (freons). Such indivi-duals should be evaluated bylocal medical authorities be-fore working in environmentswhere potential freon exposuremay occur.

5-10

Figure 5-4.

TM 5-4120-361-14

(7) Refer to figure 6-1 and purge cardiac rhythm abnormalitiesthe refrigerant system. or the induction of arryth-

mias, as a result of exposure(8) Refer to figure 6-2 and charge to fluorocarbon refrigerant

the refrigerant system. gases (freons). Such indivi-duals should be evaluated bylocal medical authorities be-

5-19. Condenser Coil. fore working in environmentswhere potential freon exposure

a. Removal. Remove condenser coil may occur.as follows:

1. Caution should be exer-cised with fluorocarbon re-frigerant gas (freons) as theycan displace oxygen and there-by cause suffocation.

2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existing


(2) Refer to figure 4-4 and removehousing top covers.

(3) Refer to figure 4-3 and removecondenser guard.

(4) Refer to figure 4-9 and removepower actuator, bracket and left con-denser fan motor and supports.

(5) Disconnect tubing from con-denser coil and remove other tubing andfittings as required.

5-11

TM 5-4120-361-14

(6) Remove screws that secure coilto base of housing.

(7) Remove coil from air condi-tioner. Use care when removing coil toprevent damage to coils and fins.

b. Installation. Install condensercoil as follows:

(1) Be sure sheet spring nuts arein place on bottom of coil. Positioncoil in air conditioner and install fourcountersunk-head screws from undersideof housing.

(2) Connect tubing to condenser andattach actuator flare nut.

(3) Leak test as described in para5-6.

(4) Refer to figure 4-3 and in-stall condenser guard.

(5) Refer to figure 4-9 and in-stall condenser fan motors and supportsand actuator.



1. Caution should be exer-cised with fluorocarbonrefrigerant gas (freons) asthey can displace oxygen andthereby cause suffocation.


(8) Refer to figure 6-2 and chargethe refrigerant system.

5-20. Condenser Louver Actuator andControl.

a. Removal. Remove actuator andpush-pull control as follows:



(1) Refer to 6-1 and discharge therefrigerant system.

(2) Refer to figure 4-3 and removehousing covers.

(3) Refer to figure 5-5 and loosenmechanical post screws at each end toloosen control wire.

(4) Remove screw, lockwasher andloop clamp.

(5) Remove push-pull control assem-bly clips at each end and remove push-pull control.

(6) Disconnect flare nut from endof actuator cylinder.

(7) Remove two nuts and lockwashersfrom bracket and remove actuator cylin-der. If cylinder is to be replaced, re-move rivets and retain push-pull con-trol assembly brackets.

b. Installation. Install actuatorcylinder and control as follows:

5-12

Figure 5-5.

TM 5-4120-361-14

(1) Reinstall push-pull control as-sembly brackets on replacement cylin-der.

(2) Install actuator cylinder (fig-ure 5-5) with studs through openings inbracket. Install lockwashers and nutson studs.

(3) Connect flare nut.

(4) Install push-pull control.Place outer control casing clips overwire and insert wire ends into openingsin mechanical posts on louver lever andactuator cylinders.

(5) Install push-pull control clipsto hold control in position. Installloop clamp, screw, and lockwashers.

(6) Adjust control as described inc. below.

c. Adjustment. Before system ischarged, adjust louver push-pull controlas follows:

(1) Close louver blades and tightenscrew in mechanical post to lock wire onthat end.

(2) Extend actuator rod until thereis a 1/4 inch space between inner edgeof mechanical post bracket and the

face of the cylinder. Tighten the mech-anical post screw.





5-13

TM 5-4120-361-14

b. Installation.5-21. Service Valves.

a. Removal.

(1) Refer to figure 4-20 and re-move charging valve box access cover.



(2) Refer to figure 6-1 and dis-charge the refrigeration system.

(3) Refer to figure 5-6 and discon-nect the service valve flare nuts.

(4) Remove four screws and pullcharging valve box outward as allowed bythe cutout switch wiring and capillarytubes. Take care not to damage the cap-illary tubes.

(5) Remove service valve by remov-ing mounting screws on side of chargingvalve box.

(1) Refer to figure 5-6 and mountservice valve in charging valve box.

(2) Place charging valve box inposition and attach to housing.

(3) Attach refrigerant line flarenut to service valve.



(4) Refer to para 5-6 and leak testthe system.

(5) Refer to figure 6-1 and purgethe refrigeration system.

(6) Refer to figure 6-2 and chargethe refrigeration system.

(7) Refer to figure 4-20 and in-stall charging valve box access cover.

5-22. High Pressure Cutout (HPCO) andLow Pressure Cutout (LPCO) Switches.

NOTE

If new cap is installed onvalve, remove keeper and chainto avoid chain contact withcutout switch terminals.

a. Removal.

(1) Refer to figure 4-20 and re-move the charging valve box accesscover.

5-14

Figure 5-6.

TM 5-4120-361-14


2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-

fore working in environmentswhere potential freon exposuremay occur.


(3) Refer to paragraph 5-21 anddisconnect the service valve flare nuts.

(4) Remove four screws and pullcharging valve box outward as allowed bywiring and capillary tubes. Take carenot to damage the capillary tubes.

(5) Refer to figure 5-6 and discon-nect the pressure cutout switch elec-

mias, as a result of exposure trical leads.to fluorocarbon refrigerantgases (freons). Such indivi- (6) Removeduals should be evaluated by mounting screwslocal medical authorities be- valve box.

pressure cutout switchon side of charging

5-15

TM 5-4120-361-14

(7) Disconnect the pressure cutoutswitch flare nut from the refrigerantline tee.

(8) Remove the capillary tube grom-met in the back wall of the chargingvalve box and extract the capillary tubeand flare nut through the opening.

b. Testing. Test the pressure cut-out switch as described in paragraph4-33.

c. Installation.

(1) Refer to figure 5-6 and in-stall capillary tube and grommet incharging valve box.

(2) Mount pressure cutout switch tocharging valve box.

(3) Attach pressure cutout switchand charging valve flare nuts to refrig-eration lines.

(4) Refer to para 5-6 and leak testthe refrigeration system.

(5) Place charging valve box in po-sition and attach to housing.

(6) Refer to wiring diagram (fig-ure 1-5 or figure 1-6) and attach elec-trical leads to pressure cutout switch.Attach service valve flare nuts.

(7) Refer to figure 6-1 and purgetile refrigeration system.


2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-mias, as a result of exposureto fluorocarbon refrigerantgases (freons). Such indivi-duals should be evaluated by

local medical authorities be-fore working in environmentswhere potential freon exposuremay occur.


(9) Refer to figure 4-20 and in-stall charging valve box access cover.

5-23. Pressure Relief Valve.

a. General. In the event the re-frigerant system pressure should exceed455 ± 10 psig, the pressure relief valve“pops off” to restore normal pressure inthe system. It may happen, that havingonce opened, the pressure relief valvedoes not totally seal closed when normalpressure is restored. In order not toconstitute a continuous system leak, thevalve must be replaced.

b. Removal.

(1) Refer to figure 4-4 and removefront top cover.


2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-hmias, as a result of exposureto fluorocarbon refrigerantgases (freons). Such indivi-duals should be evaluated bylocal medical authorities be-fore working in environmentswhere potential freon exposuremay occur.

(2) Refer to figure 6-1 and dis-charge the refrigeration system.

(3) Refer to figure 5-7 and removethe clamp around the pressure reliefvalve by removing the screw and washerthat hold the clamp to the condenser fanhousing.

5-16

Figure 5-7.

TM 5-4120-361-14

(4) Unscrew the flare nut and re-move the pressure relief valve.

b. Installation.

(1) Refer to figure 5-7 and in-stall the pressure relief valve by fast-ening the refrigerant circuit flare nutto the pressure relief valve.

(2) Using the screw and washer re-moved in 5-23a(3), install the clamp_that fastens the pressure relief valveto the condenser fan housing.






5-17

TM 5-4120-361-14

stall

5-24.

a.drier

(6) Refer to figure 4-4 and in-top front cover.

D e hydrator.

General. The dehydrator (filter-is to be replaced whenever the

refrigeration system is opened formaintenance.


2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-mias, as a result of exposureto fluorocarbon refrigerantgases (freons). Such individ-uals should be evaluated bylocal medical authorities be-fore working in environmentswhere potential freon exposuremay occur.

b. Removal.


(2) Refer to figure 4-4 and re-move housing rear top cover.

(3) Refer to figure 5-7 and re-move screws, washers and dehydratorclamps.

(4) Unscrew flare nuts and removedehydrator.

c. Installation.

(1) Refer to figure 5-7 and con-nect dehydrator to refrigerant systemtubing by tightening flare nuts. Usesealing compound on screw threads.

(2) Attach clamps to dehydrator.

(3) Refer to para 5-6 and leaktest the refrigeration system.


(5) Refer to figure 4-4 and in-stall housing rear top cover.


2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-mias, as a result of exposureto fluorocarbon refrigerantgases (freons). Such individ-uals should be evaluated bylocal medical authorities be-fore working in environmentswhere potential freon exposuremay occur.

(6) Refer to figure 6-2 andcharge the refrigerant system.

5-25. Liquid Line and Pressure Equal-izing Solenoid Valves L1 and L2

a. General. L1 and L2 are elec-trically-operated valves, which closewhen electrical power is applied to thesolenoid coils. Both are alike, onlythe usage is different. L2 which openswhen the air conditioner is switched offthe cooling mode, allows low side andhigh side pressures to equalize. Whenthe air in the conditioned space haslowered to the thermostat (S8) setting,L1 opens allowing refrigerant to bypassthe expansion valve thereby discon-tinuing cooling without shutting downthe compressor.

5-18

TM 5-4120-361-14

b. Removal.

1. Caution should be exer-cised with fluorocarbon re-frigerant gas (freons) as they

3. Local preventive medicinepersonnel should be queried ifdoubt exists as to rod compo-sition or ventilation require-ments.

(2) Refer to paragraph 5-6 andsolder solenoid valve to refrigerantsystem tubing.

can displace oxygen and there-by cause suffocation.



(2) Refer to figure 4-4 and removetop covers.

(3) Refer to figure 5-7 and removesolenoid cover and coil as described inparagraph 4-34.

(4) Remove two solenoid valvemounting screws.

(5) Unsolder solenoid valve fromtubing.

c. Installation.

(1) Refer to figure 5-7 and mountsolenoid on compartment wall.


2. Certain brazing operationsmay require mechanicalventilation.

(3) Install coil and cover on sole-noid valve.



(6) Refer to figure 4-4 and installtop covers.



(7) Refer to figure 6-2 and chargerefrigerant system.

5-26. Receiver.

a. General. The receiver is locatedbelow the left side (counterclockwiserotating) condenser fan motor. To ob-tain access to the receiver, the motorand its mounting bracket must be r e -moved.

5-19

TM 5-4120-361-14




(2) Refer to figure 4-4 and removerear top cover.

(3) Refer to figure 4-9 and removecounterclockwise rotation condenser fanassembly and mounting bracket.

(4) Refer to figure 5-8 and removereceiver mounting bracket.

(5) Unsolder receiver from refrig-eration system tubing.

c. Installation.—

(1) Refer to figure 5-8 and mountreceiver on compartment wall.


2. Certain brazing operationsmay require mechanical venti-lation.

3. Local preventive medicinepersonnel should be queried if

doubt exists as to rod compo-sition or ventilation require-ments.

(2) Refer to paragraph 5-6 andsolder receiver to refrigerant systemtubing.

NOTE

Curved end of tube installedin top at receiver enters inlength sufficient for tip oftube to face inner wall of re-ceiver.

(3) Refer to paragraph 5-6 andleak test the refrigeration system.

(4) Refer to figure 4-9 and in-stall condenser fan assembly.

(5) Refer to figure 4-4 and in-stall rear top cover.




(7) Refer to figure 6-2 and chargerefrigeration system.

5-27. Accumulator

a. General. Refer to 5.26a.—

5-20

Figure 5-8.

TM 5-4120-361-14

b. Removal

1. Caution should be exer-cised with fluorocarbon refrig-erant gas (freons) as they candisplace oxygen and therebycause suffocation.

2. Personnel with a historyor other evidence of cardiac

cardiac rythm abnormalities orthe induction of arrhythmias,as a result of exposure tofluorocarbon refrigerantgases (freons). Such indivi-duals should be evaluated bylocal medical authorities be-fore working in environmentswhere potential freon exposuremay occur.


rythm abnormalities should bemade aware of the potential (2) Refer tofor aggravation of existing rear top cover.


5-21

TM 5-4120-361-14

(3) Refer to figure 4-9 and removecounterclockwise rotation condenser fanassembly and mounting bracket.

(4) Refer to figure 5-8 and unsold-er system tubing from accumulator.

(5) Remove two screws and washersholding accumulator bracket. Remove ac-cumulator.

(6) Remove nut to separate accumu-lator from bracket.




c . Installation—

(1) Mount bracket on accumulator.

(2) Refer to figure 4-9 and in-stall accumulator using bracket attach-ing hardware.

(3) Refer to paragraph 5-7 and sol-der system tubing to accumulator.

(4) Refer to paragraph 5-6 and leaktest the refrigeration system.

(5) Refer to figure 4-9 and in-stall condenser fan assembly and mount-ing bracket.

(6) Refer to figure 4-4 and in-stall rear top cover.



5-28. Liquid Sight Indicator

a. General. The liquid sightindicator provides a heavy glass port-hole to give visible indication of re-frigerant flow. Figure 1-2 shows thelocation and figure 5-9 is a closeupview.

b. Removal.—


2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-miasr as a result of exposureto fluorocarbon refrigerantgases (freons). Such indivi-duals should be evaluated bylocal medical authorities be-fore working in environmentswhere potential freon exposuremay occur.


(2) Refer to figure 4-4 and removerear top cover.

(3) Refer to figure 4-9 and removethe counterclockwise rotation condenserfan assembly and mounting bracket.

(4) Refer to figure 5-9 and removethe liquid sight indicator mountingplate.

(5) Unsolder the liquid sight indi-cator from the refrigerant system tub-ing.

c. Installation.

(1) Refer to figure 5-9 and in-stall the liquid sight indicator and itsmounting bracket.

5-22

TM 5-4120-361-14




(2) Refer to paragraph 5-6 and sol-der the liquid sight indicator to therefrigerant system tubing.



(5) Refer to figure 4-9 and in-stall the counterclockwise rotation con-denser fan assembly and fan mountingbracket.

(6) Refer to figure 4-4 and in-stall the rear top cover.

Figure 5-9. Liquid sight indicator removal and installation

5-23

Figure 5-10.

TM 5-4120-361-14


2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-mias, as a result of exposure

to fluorocarbon refrigerantgases (freons). Such indivi-duals should be evaluated bylocal medical authorities be-fore working in environmentswhere potential freon exposuremay occur.


5-29. Primary Thermal Expansion Valve.

a. General. The primary thermal ex-pansion valve is hermetically sealed andcannot be repaired.

5-24

TM 5-4120-361-14

b. Removal.




(2) Refer to figure 4-4 and removethe top front cover.

(3) Refer to figure 5-10. Softenthe mastic in the bulb well and removethe expansion valve bulb. Take care toavoid damaging the capillary tube.

(4) Remove the expansion valveclamp.

(5) Unsolder the expansion valvefrom the refrigerant system tubing.

c. Installation.

(1) Refer to figure 5-10 and mountthe expansion valve against the compart-ment wall using the mounting clamp.




(2) Solder the expansion valve tothe refrigerant system tubing.


(4) Insert approximately one ounceof thermal mastic in bulb well. Insertsensing bulb of expansion valve and movebulb back and forth to distributemastic. Position bulb approximately oneinch beyond open end of bulb well. -

(5) Refer to figure 6-1the refrigerant system.

(6) Refer to figure 4-4stall top front cover.

and purge

and in-

1. Caution should be exer-cised with fluorocarbonrefrigerant gas (freons) asthey can displace oxygen andthereby cause suffocation.


(7) Refer to figure 6-2 and chargerefrigerant system. -

5-30. Quench Thermal Expansion Valve.

a. General. The quench thermal ex-pansion. valve is hermetically sealed andcannot be repaired.

5-25

TM 5-4120-361-14

b. Removal.


2. Personnel with a historyor other evidence of cardiac

rhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-mias, as a result of exposureto fluorocarbon refrigerantgases (freons). Such indivi-duals should be evaluated bylocal medical authorities be-fore working in environmentswhere potential freon exposuremay occur.

5-26

Figure 5-11. Quench thermal expansion valve and fluid pressure regulator, removaland installation


(2) Refer to figure 4-4 and removethe top rear cover.

(3) Refer to figure 5-11. Softenthe mastic in the bulb well and removethe expansion valve bulb. Take care toavoid damaging the capillary tube.

(4) Remove the expansion valveclamp.

(5) Unsolder the expansion valvefrom the refrigerant system tubing.

c. Installation.

(1) Refer to figure 5-11 and mountthe expansion valve aqainst the compart-

TM 5-4120-361-14


2. Personnel with a historyor other evidence of cardiacrhythm abnormalities should bemade aware of the potentialfor aggravation of existingcardiac rhythm abnormalitiesor the induction of arryth-mias, as a result of exposureto fluorocarbon refrigerantgases (freons). Such indivi-duals should be evaluated bylocal medical authorities be-

ment wall using the mounting clamp. fore working in environmentswhere potential freon exposuremay occur.



Fluid Pressure Regulator Valve.

General. The fluid pressure reg-valve is hermetically sealed andbe repaired.

5-31.

a.ulatorcannot2. Certain brazing operations

may require mechanical venti-lation. b. Removal.

3. Local preventive medicinepersonnel should be queried ifdoubt exists as to rod compo-sition or ventilation require-ments. 1. Caution should be exer-

cised with fluorocarbon re-frigerant gas (freons) as theycan displace oxygen and there-by cause suffocation.

(2) Solder the expansion valve tothe refrigerant system tubing.

(3) Refer to para 5-6 and leaktest the refrigerant system.

(4) Insert approximately one ounceof thermal mastic in bulb well. Insertsensing bulb of expansion valve and movebulb back and forth to distributemastic. Position bulb approximately oneinch beyond open end of bulb well.


(5) Refer to figurethe refrigeration system.

(6) Refer to figurestall top rear cover.

6-1 and purge

4-4 and in-

5-27

TM 5-4120-361-14

(1) Refercharge the refr

(2) Referthe air conditi

(3) Referclamp the regul

to figure 6-1 and dis-igerant system.

to figure 4-4 and removeoner top covers.

to figure 5-11 and un-ator valve sensing bulb.

(4) Remove the regulator valvemounting clamp.

(5) Unsolder the regulator valvefrom the refrigerant system tubing. Re-move by drawing the bulb through thecompartment wall.

c. Installation.

(1) Refer to figure 5-11 and mountthe fluid pressure regulator against thecompartment wall using the mountingclamp.




(2) Solder the pressure regulatorto the refrigerant system tubing.

(3) Feed the sensing bulb throughthe compartment wall and clamp in place.



(6) Refer to figure 4-4 and in-stall the top covers.



(7) Refer to figure 6-2 andcharge the refrigerant system.

5-28

CHAPTER 6

REPAIR INSTRUCTIONS

Section I. REFRIGERATION SYSTEM

6-1. General.

The refrigerant system, illustratedby the refrigerant flow diagram (figure5-1), is a mechanical, vapor cycle typecircuit consisting of the evaporator,thermal expansion valve, motor-compres-sor, condenser, and the necessary valvesand cutout devices for automatic controlduring operation. The thermal expansionvalve releases high-pressure liquid re-frigerant into the evaporator at reducedpressure. The liquid refrigerant beginsto vaporize by absorbing heat from theair passing over the external surface ofthe evaporator coil. The heated vaporis sucked out of the evaporator sectionby the motor-compressor and forced intothe condenser section under high pres-sure where it is cooled and condensedback into a liquid. The heat releasedduring condensation is carried off bythe condensing air stream. The liquidrefrigerant flows from the condenser toa receiver, to a subcooler, and then tothe thermal expansion valve. If thetemperature control switch (evaporatorreturn air thermostat) becomes satis-fied, or the evaporator return air tem-perature is lower than the controlswitch set point, the refrigerant systemwill switch to a bypass condition. Thetemperature control switch will activatethe normally-open liquid bypass solenoidvalve, closing the valve, and thereforeshutting off the evaporator section ofthe unit. The motor-compressor willcontinue to pump as usual and the suc-tion pressure will begin to drop. Whenit reaches approximately 58 psig (400kPa), the pressure regulating valve willstart to open in an effort to maintainthe suction pressure above 55 psig (380kPa) (approximately). As the suctiontemperature increases, due to the pres-sure regulating valve opening, the

TM 5-4120-361-14

quench expansion valve will start tometer liquid refrigerant into the suc-tion line in an effort to maintain thesuction temperature below 75°F (24°C)(approximately), or 30°F (-1°C) super-heat (approximately). This action (thepressure regulator and quench valve ac-tions) is totally automatic and also mayoccur at extreme conditions in an at-tempt to maintain the suction pressures(even during the cooling mode) at acondition above 55 psig (380 kPa) andthe suction temperatures (measured atthe quench bulb well) below 75°F (24°C).The condenser louvers are operated by arefrigerant powered piston located inthe high pressure part of the system.This piston should be fully extended(louvers open at 80°F (27°C) -proximately) at 250 psig (1140 kPa) headpressure and fully closed at 165 psig(1140 kPa). Failure to perform thisfunction could result in icing of theevaporator coil and/or cutout on the lowpressure cutout.

6-2. Pressure Testing the RefrigerantSystem.

a. General. A pressure test Willindicate whether the air conditioner isoperating at normal or at abnormal pres-sures. When the air conditioner is notoperating at normal pressures, the causeshould be ascertained and corrected.Refer to table 5-1 for troubleshootingchart.

b. System Pressure Test. Removecaps from high and low pressure servicevalves (fig. 5-6), connect suction anddischarge pressure gages to their re-spective service valves. Compare thegage reading with the normal range ofsystem pressure shown in table 6-1.

6-1

TM 5-4120-361-14

Table 6-1. Normal Operating Pressures.

Outdoor Ambient Temperature

50” F(10”C) 75 °C(24”C) 1OO”F(38”C) 120 °F(490C)

At 90” F(32”C) DB return air to unit

Suction 58-65 psi 58-70 psi 60-75 psi 75-90 psi

Pressure (400-450 kPa) (400-485 kPa) (255-295 kPa) (5 15-620 kPa)

Discharge 125-160 psi 175-210 psi 255-295 psi 370-4 i O psi

Pressure (860-1 100kPa) ( 1200-1450kPa) ( 1750-2025kPa) (2550-2825kPa)

At 80 °F(270C) DB return air to unit

Suction 58-65 psi 58-70 psi 60-75 psi 65-75 psi

Pressure (400-450 kPa) (400-485 kPa) (415 -515 kPa) (450-5 15 kPa)

Discharge 120-155 psi 170-205 psi (250-290 psi 370-410 psi

Pressure (8~5-]070kpa) (1170-1415kPa) ( 1725-2000kPa) (~550.2825kpa)

6-3. Servicing Refrigerant System.

1. Caution should be exercised with flu-orocarbon refrigerant gas (freons) as theycan displace oxygen and thereby cause suf-focation.

2. Personnel with a history or other evi-dence of cardiac rhythm abnormalitiesshould be made aware of the potential foraggravation of existing cardiac rhythmabnormalities or the induction of arryth-mias, as a result of exposure to fluorocar-bon refrigerant gases (freons). Such indi-viduals should be evaluated by localmedical authorities before working inenvironments where potential freon expo-sure may occur.

a. General. When the air conditioner must undergomaintenance that requires opening the system, the systemmust be discharged with a recovery/recycling unit prior tomaintenance, then leak tested and purged, a new dehydratorinstalled, and the system charged after maintenance. Basicprocedures involved in servicing the refrigerant system areas follows:

b. Discharging System. Refer to figure 6-1 forinstructions on discharging the refrigerant system.

c. Testing System for Leaks. Refer to paragraph 5-6and leak test the refrigeration system.

d. Purging the Refrigerant System. Refer to figure6-1 and purge the refrigerant system.

e. Charging the System. Refer to figure 6-2 forinstructions on charging the system with refrigerant.

6-4. Repairing Refrigerant Leaks.

a. Locate leak (para 5-6).

b. Discharge system (figure 6-1 ). repair leak. andrecharge system (figure 6-2).

NOTE

If soldering is necessary on any part of the sys-tem. a constant purge of dry nitrogen must befed through the system being soldered to preventscale formation within the system.

6-5. Decontamination.

a. General. The compressor is a hermetically sealedunit and cannot be

6-2 Change 4

TM 5-4120-361-14

NOTEIN ACCORDANCE WITH ENVIRONMENTAL PRO-TECTION AGENCY REGULATIONS REFRIGERANTSCANNOT BE DISCHARGED INTO THE ATMO-SPHERE. A REFRIGERANT RECOVERY & RECY-CLING UNIT MUST BE USED WHENEVER DIS-CHARGING THE REFRIGERANT SYSTEM.

OPERATION OF THE RECOVERY/RECYCLING UNITMUST BE BY AUTHORIZED PERSONNEL ONLY

TO DISCHARGE SYSTEM:REMOVE ACCESS COVER. REMOVE LOW PRESSURECHARGING VALVE CAP. ATTACH A SUITABLEHOSE TO CHARGING VALVE. CONNECT ANDOPERATE A RECOVER/RECYCLING UNIT INACCORDANCE WITH THE MANUFACTURER’SINSTRUCTIONS.

TO PURGE SYSTEM:REMOVE HIGH PRESSURE CHARGING VALVE CAP.CONNECT VALVE TO A CYLINDER OF DRY NITRO-GEN. ATTACH A SUITABLE DISCHARGE HOSE TOLOW PRESSURE CHARGING VALVE. OPEN NITRO-GEN VALVE AND ALLOW NITROGEN TO FLOWTHROUGH SYSTEM UNTIL ALL MOISTURE ISFORCED OUT. CLOSE NITROGEN CYLINDERVALVE.

TO EVACUATE SYSTEM:CONNECT A VACUUM PUMP TO HIGH AND LOWPRESSURE CHARGING VALVES. START VACUUMPUMP AND RECORD TIME FOR MAXIMUM VAC-UUM READING ON GAGE. CONTINUE EVACUAT-ING FOR EQUAL PERIOD OF TIME. STOP PUMP ANDOBSERVE GAGE. IF VACUUM HOLDS FOR A TIMEEQUAL TO PUMP DOWN TIME, EVACUATION ISSATISFACTORY. SEE FIGURE 6-2 FOR CHARGINGSYSTEM.

Figure 6-1. Discharging and purging refrigerant system

6-3

TM 5-4120-361-14

NOTE:

NOTE:

STEP 1.

STEP 2.

STEP 3.

STEPS 1,2,3 AND 4 APPLY ONLY TO A COMPLETELYEVACUATED SYSTEM, A FULLY CHARGED SYSTEM CON-TAINS 11.5 ± .5 POUNDS (5.23 ± .23 KG) OF REFRIGERANT22. TO ADD REFRIGERANT TO AN INCOMPLETELYCHARGED SYSTEM, REFER TO STEP 5.

WHENEVER AVAILABLE, USE RECYCLED REFRIGERANTFOR CHARGING THE REFRIGERATION SYSTEM.

REMOVE SERVICE VALVE ACCESS COVER. REMOVEVALVE CAPS AND LOOSELY CONNECT CHARGING MANI-FOLD SERVICE LINES TO AIR CONDITIONER CHARGINGVALVES. ATTACH LINE FROM REFRIGERANT DRUM TOMANIFOLD.

OPEN REFRIGERANT DRUM VALVE AND MANIFOLDVALVES AND PURGE AIR BOTH FROM MANIFOLD ANDSERVICE LINES. TIGHTEN SERVICE LINE CONNECTIONSAT CHARGING VALVES AND CLOSE LOW SIDE VALVE ONCHARGING MANIFOLD.

POSITION REFRIGERANT DRUM UPSIDE DOWN ON ASCALE. OPEN AIR CONDITIONER HIGH PRESSURECHARGING VALVE AND CHARGE SYSTEM UNTIL SCALEINDICATES A FULL CHARGE, THEN CLOSE BOTH HIGHPRESSURE CHARGING VALVE AND DRUM VALVE. DIS-CONNECT CHARGING LINES UNLESS. DUE TO PRESSUREEQUALIZATION IN DRUM AND AIR CONDITIONER SYS-TEM, A FULL CHARGE IS NOT MEASURED. THEN PRO-CEED TO STEP 4.

Figure 6-2. Charging refrigerant system (Sheet 1 of 2)

6-4 Change 4

TM 5-4120-361-14

repaired. An inoperative compressor is usually due to a (7) Triple evacuate system and charge withmechanical failure or motor burnout. If the compressor is refrigerant R22.mechanically frozen or sustains a motor burnout, it must bereplaced. A compressor failure generates high temperature (8) Start air conditioner (figure 2-5) and operatecausing a breakdown of oil, refrigerant and motor insula- unit for 24 hours.tion, with the resulting formation of acid, moisture, andsludge. These products are extremely corrosive and must be (9) Discharge system and purge with nitrogenflushed from the system or repeated burnouts will occur. (figure 6-1).

b. Procedure. (10) Install new dehydrator (figure 5-7).

(1) Discharge system and purge with nitrogen NOTE(figure 6-1).

Whenever available, use recycled refrigerant for(2) Remove defective motor-compressor charging the refrigeration system.

(figure 5-2).(11) Evacuate system and recharge with refriger-

(3) Remove dehydrator (figure 5-7). ant (figure 6-2).

(4) With compressor out of system, purge all (12) Operate air conditioner.lines with dry nitrogen.

6-6. Evaporator and Condenser Coils.(5) Install a new compressor (figure 5-2) con-

taining a full and proper oil charge. a. Inspection. Inspect coils for damaged tubing andbent fins. Inspect threaded holes for damaged or stripped

(6) Install new dehydrator (figure 5-7). In step threads.(10) this dehydrator will again be replaced.

STEP 4.

STEP 5.

POSITION REFRIGERANT DRUM UPRIGHT ON SCALEWITH LINES CONNECTED FOR GAS CHARGING. IF THEWEIGHT OF REFRIGERANT TO FULLY CHARGE THE SYS-TEM IS KNOWN, OPERATE AIR CONDITIONER WITH CON-TROLS SET FOR MAXIMUM COOLING. OPEN REFRIGER-ANT DRUM VALVE, LOW PRESSURE CHARGING VALVE,AND LOW SIDE MANIFOLD VALVE. CONTINUE OPERA-TION UNTIL THE SYSTEM IS FULLY CHARGED, THENCLOSE VALVES. STOP AIR CONDITIONER OPERATIONAND DISCONNECT CHARGING LINES.

TO ADD REFRIGERANT TO SYSTEM WITH LOW CHARGEAS INDICATED BY BUBBLES IN LIQUID SIGHT INDICA-TOR:WITH REFRIGERANT DRUM UPRIGHT, CONNECT LINESFOR GAS CHARGING THROUGH LOW SIDE MANIFOLDVALVE. PURGE CHARGING LINES BY LOOSELY CON-NECTING LINE AT DRUM VALVE AND SLIGHTLY OPEN-ING AIR CONDITIONER CHARGING VALVES. TIGHTENLINE AT DRUM VALVE. OPERATE AIR CONDITIONERWITH CONTROLS SET FOR MAXIMUM COOLING. OPENREFRIGERANT DRUM VALVE, LOW SIDE MANIFOLDVALVE, AND LOW PRESSURE CHARGING VALVE ON AIRCONDITIONER. CONTINUE OPERATION UNTIL BUBBLESNO LONGER APPEAR IN SIGHT INDICATOR. THEN CLOSELOW PRESSURE CHARGING VALVE ON AIR CONDI-TIONER. REPEAT CHARGING IF BUBBLES REAPPEAR INSIGHT INDICATOR. WHEN BUBBLES DO NOT REAPPEARAFTER 15 MINUTES OF OPERATION, THE SYSTEM ISFULLY CHARGED. CLOSE CHARGING VALVES AND DIS-CONNECT LINES.

Figure 6-2. Charging refrigerant system (Sheet 2 of 2)

6-5

TM 5-4120-361-14

b. Repair. Repair any leaks.Straighten bent fins. Repair or replacedamaged tubing if possible. Replacecoil if repair is not practical.

6-7. Solenoid Valve.

a. General. Replaceable parts arethe coil bonnet assembly, diaphragm andthe preformed packing. See figure 6-3.

b. Coil Replacement. Replace coilas follows:

(1) Remove electrical connectorfrom solenoid valve leads.

(2) Remove nut on top ofhousing. Lifting housing andsembly from bonnet assembly.

valvecoil as-

(3) Remove coil from housing.

(4) Install coil bottom plate withedge upward.

(5) Install lower coil sleeve withflange at bottom. Install coil withlead exits at bottom.

(6) Install coil spring with flatedges upward and upper coil sleeve with

Figure 6-3. Solenoid valve, exploded view

6-6

Figure 6-4.

TM 5-4120-361-14

flange at top. Sleeve passes throughthe coil spring.

(1) Remove four screws (1). Re-move end bell (2).

(7) Install coil housing, data (2)plate, and nut.

(3)6-8. Fan Motors.

(4)a. General. Except for the shaft on move end

the rotor, the condenser fan motors and

Remove end bell bearing (3).

Remove rotor (4).

Remove four screws (5). Re-bell (6) from stator (7).

the evaporator fan motor are identical, (5) Remove screw (8) and loop clamptherefore, the following instructions (9). Remove screws (10) and removeapply equally to either motor. cable (11) from motor.

b. Disassembly. Refer to figure 6-4 (6) Remove bearing (12) and spacerand disassemble motor as follows: (13) from end bell (6).

1

6-7

TM 5-4120-361-14

(7) Refer to paragraph 4-20 and 4-22 and remove screws (14), thermal pro-tectors (15) and housing (16).

c. Cleaning, Inspection and Repair.Clean, inspect and repair parts as fol-lows :

Dry cleaning solvent, P-D-680,used to clean parts, is poten-tially dangerous to personneland property. Avoid repeatedand prolonged skin contact.Do not use near open flame orexcessive heat. Flash pointof solvent is 100° - 138°F(38° - 59°C).

(1) Clean metal parts with clean-ing solvent (Fed. Spec. P-D-680). Wipeoff electrical parts with a cleancloth.

(2) Inspect wiring for damaged in-sulation and broken wiring. Repair dam-aged insulation.

(3) Inspect connector for damage.

(4) Inspect bearing for wear, gal-ling or flat spots. Replace defectivebearings.

(5) Inspect shaft for gouges orworn bearing surface. Repair minor de-fects.

(6) Inspect stator for damaged,broken or shorted wiring.

d. Assembly. Refer to figure 6-4and assemble motor as follows:

(1) Install thermal protectors(15), housing (16), and screws (14), asdescribed in paragraph 4-20 and 4-22.

(2) Install spacer (13) and bear-ing (12) in end

(3) Install(10).

(4) Attach(7) with screws

(5) Attach

bell (6).

cable ends using screws

end bell (6) to stator(5).

cable (11) to stator (7)with clamp (9) and screws” (8).

(6) Install rotor (4) in motor.

(7) Install bearing (3) in end bell(2).

(8) Attach end bell (2) with screws(1).

6-8

A-1 . Fire Protection.

TB 5-4200-200-10

A-2 . Lubrication.

C91OOIL

A-3 . Painting.

TM 9-213

A-4 . Maintenance.

TM 5-4120-361-24P

TM 38-750

TM 750-244-3

Fed. Spec. P-D-680

TM 5-4120-361-14

APPENDIX A

REFERENCES

Hand Portable Fire Extinguisher for Army Users

Fuels, Lubricants, Oils and Waxes

Painting Instructions for Field Use

Organizational, Direct and General Support MaintenanceRepair Parts and Special Tool List for Air Conditioner,Horizontal, Compact, 36,000 BTUH

Army Maintenance Management System

Procedures for Destruction of Equipment to PreventEnemy Use

Dry Cleaning Solvent

A-5. Shipment and Storage.

TM 740-90-1 Administration Storage of Equipment

A-1/(A-2 blank)

TM 5-4120-361-14

APPENDIX B

COMPONENTS OF END ITEM LIST

Section I.

1. Scope.

This appendix lists integral compo-nents of and basic issue items for theair conditioner to help you inventoryitems required for safe and efficientoperation.

2. General.

This Component of End Item List isdivided into the following sections:

a. Section II. Integral Compo-nents of the End Item. These items,when assembled, comprise the air condi-tioner and must accompany it whenever itis transferred or turned in. The il-lustrations will help you identify theseitems.

b. Section III. Basic IssueItems. These are the minimum essentialitems required to place the air condi-tioner in operation, to operate it, andto perform emergency repairs. Althoughshipped separately packed, they must ac-company the air conditioner during oper-ation and whenever it is transferred be-tween accountable officers. The il-lustrations will assist you with hard-to-identify items. This manual is yourauthority to requisition replacementB11, based on TOE/MTOE authorization ofthe end item.

3. Explanation of Columns.

a. Illustration. This column isdivided as follows:

(1) Figure Number. Indicatesthe figure number of the illustration onwhich the item is shown.

(2) Item Number. The numberused to identify item called out in theillustration.

INTRODUCTION

b. National Stock Number. Indi-cates the National stock number assignedto the item and which will be used forrequisitioning.

c. Part Number. Indicates theprimary number used by the manufacturer,which controls the design and character-istics of the item by means of its en-gineering drawings, specifications,standards, and inspection requirementsto identify an item or range of items.

d. Description. Indicates theFederal item name and, if required, aminumum description to identify theitem.

e. Location. The physical loca-tion of each item listed is given inthis column. The lists are designed toinventory all items in one area of themajor item before moving on to an adja-cent area.

f. Usable on Code. “USABLE ON”codes are included to help you identifywhich component items are used on thedifferent models. Identification of thecodes in these lists are:

Code Used On

DBK Model CH436-1DBJ Model CH636-1

g. Quantity Required (Qty Reqd).This column lists the quantity of eachitem required for a complete majoritem.

h. Quantity. This column is leftblank for use during an inventory.Under the Recv’d column, list the quan-tity you actually receive on your majoritem. The Date columns are for your usewhen you inventory the major item at alater date; such as for shipment to an-other site.

B-1

Section II.

Section III.

TM

5-4120-361-14T

M 5-4120-361-24P

TM 5-4120-361-14

Appendix B

B-2

TM 5-4120-361-14

APPENDIX C

ADDITIONAL AUTHORIZATION LIST

Section I. INTRODUCTION

1. Scope. equipment. If item required differsfor different models of this equip-

This appendix lists additional ment, the model is shown under theitems you are authorized for the sup- “Usable on” heading in the descriptionport of the air conditioner. column. These codes are identified as:

2. General.Code

This list identifies items that doUsed On

not have to accompany the air condition- DBK Modeler and that do not have to be turned in DBJ Modelwith it. These items are all author-ized to you by CTA, MTOE, TDA, or JTA. (1) (2)

3. Explanation of Listing. DESCRIPTIONNATIONAL

CH436-1CH636-1

(3)

National stock numbers, descrip- STOCK PART NUMBER USABLE U/Mtions, and quantities are provided to NUMBERhelp you identify and request the addi-tional items you require to support this

& FSCM ON CODE

NONE

(4)

QTYAUTH

C-1/(C-2 blank)

TM 5-4120-361-14

APPENDIX D

MAINTENANCE ALLOCATION CHART

Section I.

D-1. General.

a. This section provides a generalexplanation of all maintenance and re-pair functions authorized at variousmaintenance levels.

b. The Maintenance Allocation Chart(MAC) in Section II designates overallresponsibility for the performance ofmaintenance functions on the identifiedend item or component. The implemen-tation of the maintenance functions uponthe end item or component will be con-sistent with the assigned maintenancefunctions.

c. Section III lists the specialtools and test equipment required foreach maintenance function as referencedfrom Section II.

d. Section IV contains supplementalinstructions on explanatory notes for aparticular maintenance function.

D-2 . Maintenance Functions.

a. Inspect. To determine the ser-viceability of an item by comparing itsphysical, mechanical and/or electricalcharacteristics with established stan-dards through examination.

b. Test. To verify serviceabilityand detect incipient failure by measur-ing the mechanical or electrical char-acteristics of an item and comparingthose characteristics with prescribedstandards.

c. Service. Operations required per-iodically to keep an item in properoperating condition, i.e., to clean (de-contaminate), to preserve, to drain, topaint, or to replenish fuel, lubricants,hydraulic fluids, or compressed airsupplies.

d. Adjust. To maintain, within pre-scribed limits, by bringing into properor exact position, or by setting the op-erating characteristics to specifiedparameters.

Introduction

e. Align. To adjust specified vari-able elements of an item to bring aboutoptimum or desired performance.

f. Calibrate. To determine and causecorrections to be made or to be adjustedon instruments or test measuring and di-agnostic equipments used in precisionmeasurement. Consists of comparisons oftwo instruments, one of which is a cer-tified standard of known accuracy, todetect and adjust any discrepancy in theaccuracy of the instrument being com-pared.

g. Install. The act of emplacing,seating, or fixing into position anitem, part, or module (component or as-sembly) in a manner to allow the properfunctioning of an equipment or system.

h. Replace. The act of substitutinga serviceable like type part, subassem-bly, or module (component or assembly)for an unserviceable counterpart.

i. Repair. The application of main-tenance services (inspect, test, ser-vice, adjust, align, calibrate, or re-place) or other maintenance actions(welding, grinding, riveting, straight-eing, facing, remachining, or resurfac-ing) to restore serviceability to anitem by correcting specific damage,fault, malfunction, or failure in apart, subassembly, module (component orassembly), and item, or system.

j. Overhaul. That maintenance effort(services actions) necessary to restorean item to a completely serviceable/op-erational condition as prescribed bymaintenance standards (i.e., DMWR) in ap-propriate technical publications. Over-haul is normally the highest degree ofmaintenance performed by the Army.Overhaul does not normally return anitem to like new condition.

k. Rebuild. Consists of those ser-vices/actions necessary for the restora-tion of unserviceable equipment to alike new condition in accordance withoriginal manufacturing standards. Re-build is the highest degree of materiel

D-1

TM 5-4120-361-14

APPENDIX D (Continued)

maintenance applied to Army equipment.The rebuild operation includes the actof returning to zero those age measure-ments (hours/miles, etc.) considered inclassifying Army equipments/components.

D-3 . Column Entires Used in the MAC.

a. Column 1, Group Number. Column 1lists group numbers, the purpose ofwhich is to identify components, assem-blies, subassemblies, and modules withthe next higher assembly.

b. Column 2, component/ Assembly.Column 2 contains the names of compo-nents, assemblies, subassemblies, andmodules for which maintenance is author-ized.

c. Column 3, Maintenance Functions.Column 3 lists the functions to be per-formed on the item listed in column 2.(For detailed explanation of these func-tions, see paragraph B-2.)

d. Column 4, Maintenance Level. col-umn 4 specifies, by the listing of awork time figure in the appropriate sub-column(s), the lowest level of mainte-nance authorized to perform the functionlisted in column 3. This figure repre-sents the active time required to per-form the maintenance function at the in-dicated level of maintenance. If thenumber or complexity of the tasks withinthe listed maintenance function vary atdifferent maintenance levels, appropri-ate work time figures will be shown foreach level. The number of man-hoursspecified by the work time figure repre-sents the average time required to re-store an item (assembly, subassembly,component, module, end item, or system)to a serviceable condition. The symboldesignations for the various maintenancelevels are as follows:

c . . . . . Operator or crew

o . . . . . Organization maintenance

F . . . . . Direct support maintenance

H. . . . . General support maintenance

D . . . . . Depot maintenance

e. Column 5, Tools and Equipment.Column 5 specifies, by code, those com-mon tool sets (not individual tools) andspecial tools, test, and support equip-ment required to perform the designatedfunction.

f. Column 6, Remarks. This columnshall contain a letter code in alpha-betical order which shall be keyed tothe remarks contained in Section IV.

D-4 . Column Entries Used in Tool andTest Equipment Requirements.

a. Column 1, Tool or Test EquipmentReference Code. The tool and testequipment reference code correlates witha maintenance function on the identifiedend item or component.

b. Column 2, Maintenance Level. Thelowest level of maintenance authorizedto use the tool or test equipment.

c. Column 3, Nomenclature. Name oridentification of the tool or testequipment.

d. Column 4, National/NATO StockNumber. The National or NATO stock num-ber of the tool or test equipment.

e. Column 5, Tool Number.facturer’s part number.

D-5. Explanation of ColumnsIV.

The manu-

in Section

a. Reference Code. The code schemerecorded in column 6, Section II.

b. Remarks. This column lists infor-mation pertinent to the maintenancefunction being performed as indicatedon the MAC, Section II.

D-2

TM 5-4120-361-14

Section II. MAINTENANCE ALLOCATION CHART

36,000 BTU/HR Air Conditioner, Compact, Horizontal

(1) (2) (3) (4)Group

(5) (6)Component/Assembly Maintenance Maintenance Level Tools & Remarks

Num- Functions Equipmentber C O F H D

Air Conditioner Inspect .10Service .20Install .75

01 TOP Covers andFront Louvers

Metal Covers Inspect .10Service .10Repair .25Replace .20

Cover Gaskets Inspect .10Replace .25

Cover Insulation Inspect .10Replace .25

Information Inspect .10Plates Service .10

Replace .25

Front Louvers Inspect .10Service .10Adjust .10Replace .20

Air Conditioning Inspect .10Filter Service .40

Replace .20

02 Condenser Guard,Covers,Ventilation AirFilter, & LiftingRing

Condenser Guard Inspect .10Service .10Replace .20

. SUBCOLOUMNS ARE AS FOLLOWS: C - OPERATOR/CREW O - ORGANIZATIONALF - DIRECT SUPPORT H - GENERAL SUPPORT D - DEPOT

. . INDICATES WT/MH REQUIRED.

D-3

TM 5-4120-361-14

Section II. MAINTENANCE ALLOCATION CHART (CONT)


(1)GroupNum-ber

03

04

05

(2)Component/Assembly

Fabric Cover

Ventilation AirFilter

Lifting Ring &Clip

Condenser FansMotor SupportAssembly

Axial Fans

&

Motor Supports

Condenser FanMotor

EvaporatorImpeller, Housingand Related Parts

Impeller

. SUBCOLOUMNS AREF - DIRECT

. . INDICATES WT/MH

(3)MaintenanceFunctions

InspectServiceRepairReplace

InspectServiceReplace

InspectReplace

InspectServiceAlignReplace

InspectReplace

InspectServiceTestRepairReplace

InspectServiceAlignReplace

(4)Maintenance Level

C O F H D

.10

.10.10.20

.10.35.30

.101.0

.10

.15

.252.0

2.03.0

.10

.151.0

4.02.0

.10

.15

.252.0

(5)Tools &

Equipment

AS FOLLOWS: C - OPERATOR/CREW O - ORGANIZATIONALSUPPORT H - GENERAL SUPPORT D - DEPOTREQUIRED.

(6)Remark

D-4

06

07

08

09

TM 5-4120-361-14


(1)GroupNum-ber



Housing &Mounting BaseAssemblies

Evaporator Motor

Ventilation Damperand Actuator

Condenser LouverActuator & ControlAssembly

Louver ControlCables

Cable Actuator

Refrigerant Valvesand Related Tubing

Expansion Valves

Solenoid Valves

PressureRegulating Valve


InspectReplace

InspectServiceTestRepairReplace

InspectServiceAdjustReplace

InspectServiceAdjustReplace

InspectReplace

InspectTestReplace

InspectTestReplace

InspectTestReplace


C O F H D

.102.0

.10

.151.0

4.01.5

.10

.20

.501.0

.15

.25

.35

.50

.158.0

.15

.504.0

.15

.254.0

.15

.504.0

(5)Tools &Equipment

(6)Remarks


.. INDICATES WT/MH REQUIRED.

D-5

TM 5-4120-361-14



(1)GroupNum-ber

10

11

12


Tubing & Fittings

Dehydrator &Related Tubing

Dehydrator

Tubing & Fittings

Pressure Switches,Liquid Receiver,Sight Indicator,Charging Valves &Related Tubing

Receiver

Sight Indicator

Charging Valves

Tubing & Fittings

Pressure Switches

Compressor,Accumulator, &Related Parts

Compressor


. . INDICATES WT/MH

(3)maintenanceFunctions

InspectReplace

InspectReplace

InspectReplace

InspectReplace


InspectReplace

InspectReplace

InspectTestReplace

InspectTestReplace


C O F H D

.104.0

.104.0

.104.0

.5012.0

.05

.0512.0

.104.0

.104.0

.10

.254.0

.10

.1512.0

(5)Tools &Equipment


(6)Remark

D-6

TM 5-4120-361-14



(1)GroupNum-ber

13

14

15


Accumulator

Evaporator & Con-denser Coils &Related CompartmentParts

Mist Eliminator

Coils

Tubing & Fittings

CompartmentInsulation

Junction Box &Control Module Assy

Control ModuleElectricalComponentsReplace

Junction BoxElectricalComponents

Wiring Harness





InspectReplace



InspectServiceTest

InspectServiceTestReplace

InspectTestRepairReplace


C O F H D

.10

.1012.0

.10

.50

.10

.10

.158.0

.104.0

.10

.152.0

.10

.25

.10

.10

.25

.501.0

.10

.25

.301.0

.25

.401.08.0

(5)Tools &Equipment

(6)Remark



D-7

TM 5-4120-361-14



(1)GroupNum-ber

16

17


Ambient Thermostat,Auxiliary PowerInlet, and Con-densate DrainAssembly

AmbientThermostatSwitchAssembly

Inlet PwrConnector Assy

Heater, Trans-former, Rectifierand Related Parts

Heater Element

ThermostaticSwitch

Rectifier

Transformer

Capacitor


. . INDICATES WT/MH


InspectTestReplace

InspectRepairReplace

InspectTestReplace

InspectTestReplace

InspectTestReplace

InspectTestReplace

InspectTestReplace


C O F H D

.10

.508.0

.108.08.0

.10

.251.0

.10

.25

.50

.10

.25

.50

.10

.501.0

.10

.25

.25

(5) (6)Tools & RemarkEquipment


D-8

TM 5-4120-361-14




18 Louver & CondenserFan Housing Assy

Louver Assy

Fan Housing

1 9 Housing Assembly


InspectServiceAdjustRepairReplace


Housing RepairReplace


C O F H D

.15

.25.5O

.501.0

(5)Tools &

Equipment

(6)Remark

. SUBCOLOUNNS ARE AS FOLLOWS: C - OPERATOR/CREW O - ORGANIZATIONALF - DIRECT SUPPORT H - GENERAL SUPPORT D - DEPOT


D-9

TM 5-4120-361-14

Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS

(1) (2) (3) (4) (5)

Refer- Mainte-ence nance Nomenclature National/NATO ToolCode Level Stock Number Number

F Recovery and Recycling Unit. 4130-01-338-2707 (07295)Refrigerant 17500B

Tool Kit. Service, 5180-00-597-1474Refrigeration Unit(SC 5180-90-CL-N18)

Soldering Gun Kit 3439-00-930-1638

REFERENCECODE

Section IV. MAINTENANCE ALLOCATION CHART

REMARKS

No supplemental instructions or explanatory remarks for a particularmaintenance function listed in Section II are required. All functions aresufficiently defined in Section I. Due to various methods of installing theair conditioner, all active time listed for maintenance tasks are with the airconditioner in the off-equipment position at organizational user level or ina repair shop facility.

D-10 Change 4

TM 5-4120-361-14

APPENDIX E

REPAIR PARTS AND SPECIAL TOOLS LIST

See TM 5-4120-361-24P

E-1/(E-2 blank)

TM 5-4120-361-14

APPENDIX F

Section I.

1. Scope.

This appendix lists expendable supplies and materialsyou will need to operate and maintain the air conditioner.These items are authorized to you by CTA 50-970, Expend-able Items (Except Medical, Class V, Repair Parts, andHeraldic Items).

2. Explanation of Columns.

a. Column 1- Item number. This number isassigned to the entry in the listing and is referenced in thenarrative instructions to identify the material (e.g., “Usecleaning compound, item 5, App. D”).

b. Column 2- Level. This column identifies the low-est level of maintenance that requires the listed item.

O- Organizational Maintenance

National stock number assigned to the item; use it to requestor requisition the item.

d. Column 4 - Description. Indicates the Federalitem name and, if required, a description to identify theitem. The last line for each item indicates the part numberfollowed by the Federal Supply Code for Manufacturer(FSCM) in parentheses, if applicable.

e. Column 5- Unit of Measure (U/M). Indicates themeasure used in performing the actual maintenance func-tion. This measure is expressed by a two-character alphabet-ical abbreviation (e.g. ea, in, pr). If the unit of measurediffers from the unit of issue, requisition the lowest unit ofissue that will satisfy your requirements.

F- Direct Support Maintenance

(1)

ITEMNUMBER

1

(5)

STOCKLEVEL NUMBER DESCRIPTION U/M

O 4130-00-860-0042 Dust Collecting Adhesive pt

NOTE

Whenever available, use recycledrefrigerant for charging therefrigeration system.

F 6830-00-106-1659 R-22 (monochlorodifluoro-methane, CHC1F2)

Change 4 F-1/(F-2 blank)

PIN: 046441-004

A L P H A B E T I C A L I N D E X

A

Accumulator, Removal and Installation. . . . . . .Adjustment:

Condenser Louver Control . . . . . . . . . . . .Vent Damper Actuator . . . . . . . . . . . . . .

B

Base Mounting Hole Dimensions. . . . . . . . . . .Brazing. . . . . . . . . . . . . . . . . . . . . .

2 - 65 - 2

c

Capacitors, Removal and Installation . . . . . . .Coils, Evaporator and Condenser. . . . . . . . . .Compressors:

Removal and Installation . . . . . . . . . . . .Test. . . . . . . . . . . . . . . . . . . . . .

Compressor Circuit Breaker, Removal andInstallation. . . . . . . . . . . . . . . . . .

Compressor Relay, Removal and Installation . . . .Condensate Water Drain Tubes, Removal and

Installation. . . . . . . . . . . . . . . . . .Condenser Coil:

Removal and Installation . . . . . . . . . . . .Repair. . . . . . . . . . . . . . . . . . . . .Servicing. . . . . . . . . . . . . . . . . . . .

Condenser Fabric Cover . . . . . . . . . . . . . .Condenser Fan and Motor Assembly, Removal and

Installation. . . . . . . . . . . . . . . . . .Condenser Fan Motor High Speed Relay, Removal

and Installation . . . . . . . . . . . . . . . .Condenser Fan Motor Low Speed Relay, Removal and

Installation. . . . . . . . . . . . . . . . . .Condenser Fan Motor Thermal Protector, Removal

and Installation . . . . . . . . . . . . . . . .Condenser Guard, Removal and Installation. . . . .Condenser Louver Actuator and Control, Removal

and Installation . . . . . . . . . . . . . . . .Control Circuit, Troubleshooting . . . . . . . . .Control Circuit Breaker, Removal and Installation.Control Module, Removal and Installation . . . . .Control System Schematic Diagram . . . . . . . . .Controls and Instruments . . . . . . . . . . . . .Cooling Operation.. .. . . . . . . . . . . . . .Cover, Condenser, Removal and Installation . . . .Covers, Top, Removal and Installation. . . . . . .Cycling Heater Relay, Removal and Installation . .

4-3

D

Daily Preventive Maintenance Service . . . . . . .Damaged Threads, Repairing . . . . . . . . . . . .Damper Door Vent Screen and Fresh Air Filter,

Removal and Installation . . . . . . . . . . . .

TM 5-4120-361-14

Paragraph Page

5-27

5-204-39

2-9c5-6c

4-296-6

5-174-34

4-264-27

4-35

5-196-64-53-6, 4-6

4-23

4-27

4-27

4-244-4

5-204-19b4-264-251-92-22-104-64-6

2-45-11

4-8

5-20

5-124-34

4-276-5

5-84-31

4-214-26

4-31

5-116-5

3-1; 4-4

4-17

4-26

4-26

4-174-3

5-124-84-214-181-52-12-94-44-25

2-45-7

4-5

I-1

TM 5-4120-361-14

ALPHABETICAL INDEX (Continued)

Paragraph Page

D

Dehydrator, Removal and Installation . . . . . . .Description:

Air Conditioner. . . . . . . . . . . . . . . . .Refrigeration System . . . . . . . . . . . . . .

Difference Between Models. . . . . . . . . . . . .Dismantling For Movement . . . . . . . . . . . . .Drain Tubes:Operator’s Maintenance . . . . . . . . . . . . .Tubing Replacement . . . . . . . . . . . . . . .

5-24 5-18

1-56-11-72-13

1-26-11-42-15

3-74-35

3-14-31

E

Electrical System Maintenance. . . . . . . . . . .Equipment Purpose, Capabilities and Features . . .Equipment and Serviceability Criteria. . . . . . .Equipment Purpose, Capabilities and Features . . .Evaporator Air Inlet and Outlet Louvers,

Removal and Installation . . . . . . . . . . . .Evaporator Coil, Servicing . . . . . . . . . . . .Evaporator Coil and Mist Eliminator Holder,

Removal and Installation . . . . . . . . . . . .Evaporator Fan and Motor Assembly, Removal and

Installation. . . . . . . . . . . . . . . . . .Evaporator Fan Motor High Speed Relay, Removal

and Installation . . . . . . . . . . . . . . . .Evaporator Fan Motor Low Speed Relay, Removal

and Installation . . . . . . . . . . . . . . . .Evaporator Fan Motor Thermal Protector, Removal

and Installation . . . . . . . . . . . . . . . .Evaporator Fan Speed Switch, Removal and

Installation. . . . . . . . . . . . . . . . . .Expansion Valves:

Primary Expansion Valve:Inspection and Test. . . . . . . . . . . . . .Removal and Installation . . . . . . . . . . .

Quench Valve, Removal and Installation . . . . .

4-201-31-41-5

4-151-21-21-2

4-74-5

4-44-3

5-18 5-9

4-21 4-15

4-27 4-25

4-27 4-23

4-22 4-16

4-26 4-21

4-385-295-30

4-335-245-25

F

Fan Motors, Disassembly and Reassembly . . . . . .Filter, Return Air, Servicing. . . . . . . . . . .Fittings and Tubes . . . . . . . . . . . . . . . .Fixed Heater Relay, Removal and Installation . . .Fluid Pressure Regulating Valve, Removal and

Installation. . . . . . . . . . . . . . . . . .

6-84-35-144-27

6-74-15-74-24

5-31 5-27

G

5-82-9

5-72-8

Gaskets. . . . . . . . . . . . . . . . . . . . . .Ground Wire Installation . . . . . . . . . . . . .

I-2

TM 5-4120-361-14


Paragraph PageH

Hardware. . . . . . . . . . . . . . . . . . . . .Heater Cutout Switch, Removal and Installation . .Heater Elements, Removal and Installation. . . . .Heater Relay, Removal and Installation . . . . . .High Pressure Cutout Switch, Removal and

Installation. . . . . . . . . . . . . . . . . .Housing Covers, Removal and Installation . . . . .

5-94-304-304-27

5-74-284-284-24

5-224-6

5-144-4

I

Identification and Information Plates. . . . . . .Inspecting and Servicing EquipmentOperator’s Inspecting and Servicing. . . . . . .Organizational Inspecting and Servicing. . . . .

Installation, Air Conditioner. . . . . . . . . . .Insulation and Gaskets . . . . . . . . . . . . . .

2-15 2-15

2-84-22-9, 4-105-8

2-64-1

2-6, 4-65-7

J

Junction Box, Removal and Installation . . . . . .Junction Box Components, Removal and Installation.

4-254-27

4-184-22

L

Liquid Line Solenoid Valve:Disassembly and Parts Replacement. . . . . . . .Inspection and Test. . . . . . . . . . . . . . .Removal and Installation . . . . . . . . . . . .

Liquid Sight Indicator:Operator’s Maintenance . . . . . . . . . . . . .Removal and Installation . . . . . . . . . . . .

Location and Description of Major Components . . .Low Pressure Cutout Switch, Removal and

Installation. . . . . . . . . . . . . . . . . .Lubrication Instructions

Compressor. . . . . . . . . . . . . . . . . . .Fan Motor.. . . . . . . . . . . . . . . . . . .

6-74-365-25

6-64-325-18

3-85-281-6

3-15-221-2

5-22 5-14

3-2, 4-153-1, 4-14

3-13-1

M

Machined and Polished Surfaces, Damaged,Repairing. . . . . . . . . . . . . . . . . . . .

Maintenance Forms and Records. . . . . . . . . . .Maintenance Repair Parts

Direct Support. . . . . . . . . . . . . . . . .Organizational Support . . . . . . . . . . . . .

Mist Eliminator, Removal and Installation. . . . .Mode Selector Switch, Removal and Installation . .Model Numbers. . . . . . . . . . . . . . . . . . .Movement to a New Worksite . . . . . . . . . . . .

5-121-2

5-71-1

5-14-64-54-211-12-15

5-34-134-94-261-12-12

I-3

TM 5-4120-361-14


Paragraph Page

2-15

N

Nameplate, Location. . . . . . . . . . . . . . . . 2-15

0

Operating Controls . . . . . . . . . . . . . . . .Operation:

In Dusty or Sandy Areas. . . . . . . . . . . . .In Extreme Cold. . . . . . . . . . . . . . . . .In Extreme Heat. . . . . . . . . . . . . . . . .In Salt Water Areas. . . . . . . . . . . . . . .Operating under Rainy or Humid Conditions. . . .Starting and Operating Instructions:

For Cooling. . . . . . . . . . . . . . . . . .For Heating. . . . . . . . . . . . . . . . . .For Ventilation. . . . . . . . . . . . . . . .

Stopping Instructions. . . . . . . . . . . . . .Operator’s Maintenance:

Condenser Fabric Cover . . . . . . . . . . . . .Drains. . . . . . . . . . . . . . . . . . . . .liquid Sight Indicator . . . . . . . . . . . . .

Operator’s Troubleshooting Chart . . . . . . . . .Organizational Troubleshooting Chart . . . . . . .

2-2 2-1

2-182-162-172-202-19

2-162-162-162-172-16

2-10b2-10d2-10f2-11

2-92-112-132-14

3-63-73-83-44-19

3-13-13-13-14-8

P

Performance Data. . . . . . . . . . . . . . . . .Preparation for Movement . . . . . . . . . . . . .Pressure Equalizing Solenoid Valve . . . . . . . .Pressure Relief Valve, Removal and Installation. .Pressure Switches, Removal and Installation. . . .Pressure Testing the Refrigeration System. . . . .Preventive Maintenance Checks and Services:Operator’s Daily . . . . . . . . . . . . . . . .Organizational. . . . . . . . . . . . . . . . .

Primary Thermal Expansion Valve, Removal EndInstallation. . . . . . . . . . . . . . . . . .

1-82-124-375-235-226-2

1-42-154-325-165-146-1

2-44-17

2-44-7

5-29 5-24

Q

4-175-30

4-75-25

Quarterly Preventive Maintenance Services. . . . .Quench Expansion Valve, Removal and Installation .

R

Receiver, Removal and Installation . . . . . . . .Rectifier and Capacitors, Removal and

Installation. . . . . . . . . . . . . . . . . .

5-26

4-29

5-19

4-27

I-4

TM 5-4120-361-14


R

Refrigerant System:Brazing. . . . . . . . . . . . . . . . . . . . .Charging. . . . . . . . . . . . . . . . . . . .Decontamination. . . . . . . . . . . . . . . . .Discharging. . . . . . . . . . . . . . . . . . .General Description. . . . . . . . . . . . . . .Leak Testing. . . . . . . . . . . . . . . . . .Opening System. . . . . . . . . . . . . . . . .Pressure Testing . . . . . . . . . . . . . . . .Purging. . . . . . . . . . . . . . . . . . . . .Removal of Parts. . . . . . . . . . . . . . . .Repairing. . . . . . . . . . . . . . . . . . . .Servicing. . . . . . . . . . . . . . . . . . . .

Refrigeration Flow Diagram . . . . . . . . . . . .Reinstallation After Movement. . . . . . . . . . .Repair of Damaged Machined and Polished Surfaces .Repairing Damaged Threads. . . . . . . . . . . . .Repairing Refrigerant Leaks. . . . . . . . . . . .Reporting of Equipment Improvements. . . . . . . .Reporting of Errors. . . . . . . . . . . . . . . .Resistor, Removal and Installation . . . . . . . .Return Air Filter, Removal and Installation. . . .Rust and Corrosion, Removal. . . . . . . . . . . .

S

Schematic Diagram. . . . . . . . . . . . . . . . .Service Valves, Removal and Installation . . . . .Shims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Valves:

Removal and Installation . . . . . . . . . . . .Repair. . . . . . . . . . . . . . . . . . . . .

Special Tools and Equipment:Direct and General Support . . . . . . . . . . .Organizational. . . . . . . . . . . . . . . . .

Starting and Operating Instructions. . . . . . . .Stopping Instructions. . . . . . . . . . . . . . .

T

Technical Principles of Operation. . . . . . . . .Terminal Boards, Removal and Installation. . . . .Temperature Control Switch, Removal and

Installation. . . . . . . . . . . . . . . . . .Testing Refrigerant System:

Leak Test. . . . . . . . . . . . . . . . . . . .Pressure Test. . . . . . . . . . . . . . . . . .

Paragraph

5-7C6-3e6-56-3b6-15-65-7a6-26-3d5-7b6-46-35-42-145-125-116-41-3Title Page4-284-35-13

1-95-215-10

5-256-7

5-24-122-102-11

1-94-27

4-26

5-66-2

Page

5-76-46-26-26-15-65-66-16-25-66-26-25-22-155-75-76-21-1i4-264-15-7

1-55-145-7

5-186-6

5-14-62-82-14

1-44-26

4-21

5-66-1

I-5

TM 5-4120-361-14


Paragraph

T

Thermostatic Switches:

Condenser Fan Motor. . . . . . . . . . .Heater. . . . . . . . . . . . . . . . .

Thermal Expansion Valves:Primary. . . . . . . . . . . . . . . .Quench. . . . . . . . . . . . . . . . .

Time Delay Relay, Removal and InstallationToggle Switch

Control Circuit Breaker. . . . . . . . .Evaporator Fan Speed . . . . . . . . . .

Top Covers, Removal and Installation . . .Transformer, Removal and Installation. . .Troubleshooting

Direct and General Support . . . . . . .Operator's. . . . . . . . . . . . . . .Organizational . . . . . . . . . . . . .

Tubes and Fittings . . . . . . . . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

U

Unloading Equipment. . . . . . . . . . . . . . . .Unpacking Equipment. . . . . . . . . . . . . . . .

V

Valves. . . . . . . . . . . . . . . . . . . . . .Vent Damper Actuator, Removal and Installation . .Ventilation Operation. . . . . . . . . . . . . . .

W

Wiring. . . . . . . . . . . . . . . . . . . . . .Wiring Diagrams. . . . . . . . . . . . . . . . . .

4-314-30

5-295-304-27

4-264-264-64-28

5-43-34-185-14

2-62-7

5-154-392-10f

4-321-9

Page

4-284-28

5-245-254-22

4-214-214-44-26

5-13-24-95-7

2-62-6

5-74-342-13

4-291-5

I-6

By Order of the Secretary of the Army:

TM 5-4120-361-14

Official:

J. C. PENNINGTONMqjor General, United States Army

The Adjutant General

DISTRIBUTION:To be distributed in accordance with DA Form

maintenance requirements for Air Conditioners,12-25C Operator36,000 BTU

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