TM-9-4110-254-14 Refrigeration Unit Mechanical 5K BTU Electric Model F5000RE (4110-01-389-9180) Manual

Figure 1-0. Refrigeration Unit - TM-9-4110-254-140018
CHAPTER 1 INTRODUCTION - TM-9-4110-254-140019
CORROSION PREVENTION AND CONTROL - TM-9-4110-254-140020
SECTION II EQUIPMENT DESCRIPTION - TM-9-4110-254-140021
Figure 1-1. Major Components - TM-9-4110-254-140022
EQUIPMENT DATA. - TM-9-4110-254-140023
SECTION III PRINCIPLES OF OPERATION - TM-9-4110-254-140024
Figure 1-3. Electrical Schematic - TM-9-4110-254-140025
Figure 1-4. Electrical Wiring Diagram (Sheet 1 of 2) - TM-9-4110-254-140026
REFRIGERATION SYSTEM. - TM-9-4110-254-140027
Figure 1-5. Refrigeration System - TM-9-4110-254-140028
Figure 1-6. Refrigeration Schematic - TM-9-4110-254-140029
AIR HANDLING SYSTEM
CHAPTER 2 OPERATING INSTRUCTIONS - TM-9-4110-254-140031
OPERATING CONTROLS AND INDICATORS. - TM-9-4110-254-140032
Figure 2-1. Operating Controls and Indicators - TM-9-4110-254-140033
FAULT CONTROLS AND INDICATORS
Figure 2-2. Fault Controls and Indicators - TM-9-4110-254-140035
SECTION II OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-4110-254-140036
Figure 2-3. Operator' PMCS Routing Diagram
Table 2-1. Operator Preventive Maintenance Checks and Services - TM-9-4110-254-140038
Table 2-1. Operator Preventive Maintenance Checks and Services - Continued - TM-9-4110-254-140039
Table 2-1. Operator Preventive Maintenance Checks and Services - Continued - TM-9-4110-254-140040
Table 2-1. Operator Preventive Maintenance Checks and Services - Continued - TM-9-4110-254-140041
Table 2-1. Operator Preventive Maintenance Checks and Services - Continued - TM-9-4110-254-140042
Table 2-1. Operator Preventive Maintenance Checks and Services - Continued - TM-9-4110-254-140043
Table 2-1. Operator Preventive Maintenance Checks and Services - Continued - TM-9-4110-254-140044
Table 2-1. Operator Preventive Maintenance Checks and Services - Continued - TM-9-4110-254-140045
Table 2-1. Operator Preventive Maintenance Checks and Services - Continued - TM-9-4110-254-140046
SECTION III OPERATION UNDER USUAL CONDITIONS - TM-9-4110-254-140047
Figure 2-4. Operating Controls and Indicators - TM-9-4110-254-140048
OPERATOR CHECKS. - TM-9-4110-254-140049
Figure 2-5. Decals and Instruction Plates (Sheet 1 of 2) - TM-9-4110-254-140050
Figure 2-5. Decals and Instruction Plates (Sheet 2 of 2) - TM-9-4110-254-140051
SECTION IV OPERATION UNDER UNUSUAL CONDITIONS - TM-9-4110-254-140052
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS - TM-9-4110-254-140053
SECTION II TROUBLESHOOTING PROCEDURES - TM-9-4110-254-140054
TROUBLESHOOTING. - TM-9-4110-254-140055
TROUBLESHOOTING. (Cont)
SECTION III OPERATOR'S MAINTENANCE PROCEDURES - TM-9-4110-254-140057
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS - TM-9-4110-254-140059
SERVICE UPON RECEIPT OF MATERIAL. - TM-9-4110-254-140060
Figure 4-2. Installation - TM-9-4110-254-140061
Power Connection - TM-9-4110-254-140062
Figure 4-3. Input Power Connection - TM-9-4110-254-140063
PRELIMINARY SERVICING OF EQUIPMENT. - TM-9-4110-254-140064
PRELIMINARY ADJUSTMENT OF EQUIPMENT. - TM-9-4110-254-140065
Figure 4-6. Preliminary Adjustment - TM-9-4110-254-140066
PRELIMINARY ADJUSTMENT OF EQUIPMENT. - TM-9-4110-254-140067
SECTION III UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-4110-254-140068
Figure 4-7. Lubrication - TM-9-4110-254-140069
GENERAL - TM-9-4110-254-140070
Table 4-1. Unit Preventive Maintenance Checks and Services for Model F5000RE
Table 4-1. Unit Preventive Maintenance Checks and Services for Model F5000RE - Continued - TM-9-4110-254-140072
Table 4-1. Unit Preventive Maintenance Checks and Services for Model F5000RE - Continued - TM-9-4110-254-140073
Table 4-1. Unit Preventive Maintenance Checks and Services for Model F5000RE - Continued - TM-9-4110-254-140074
Table 4-1. Unit Preventive Maintenance Checks and Services for Model F5000RE - Continued - TM-9-4110-254-140075
Table 4-1. Unit Preventive Maintenance Checks and Services for Model F5000RE - Continued - TM-9-4110-254-140076
Table 4-1. Unit Preventive Maintenance Checks and Services for Model F5000RE - Continued - TM-9-4110-254-140077
Table 4-1. Unit Preventive Maintenance Checks and Services for Model F5000RE - Continued - TM-9-4110-254-140078
Table 4-1. Unit Preventive Maintenance Checks and Services for Model F5000RE - Continued - TM-9-4110-254-140079
Table 4-1. Unit Preventive Maintenance Checks and Services for Model F5000RE - Continued - TM-9-4110-254-140080
Table 4-2. Monthly Mandatory Replacement Parts
SECTION IV UNIT TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING. - TM-9-4110-254-140083
TROUBLESHOOTING. - Continued - TM-9-4110-254-140084
TROUBLESHOOTING. - Continued - TM-9-4110-254-140085
TROUBLESHOOTING. - Continued - TM-9-4110-254-140086
SECTION V UNIT MAINTENANCE PROCEDURES - TM-9-4110-254-140087
Figure 4-8. Barrel Bolts
TOP ACCESS PANEL REPLACEMENT.
ACCESS PANEL REPLACEMENT. - TM-9-4110-254-140090
COVER PANEL (COIL GUARD REAR) REPLACEMENT.
COIL GUARD FRONT PANEL REPLACEMENT.
UNIT MOUNTING BOLT ASSEMBLY REPLACEMENT.
Figure 4-13. Unit Mounting Bolt Assembly
CONTROL BOX ASSEMBLY REPLACEMENT. - TM-9-4110-254-140095
Figure 4-14. Control Box Assembly - TM-9-4110-254-140096
Installation. - TM-9-4110-254-140097
WIRES, CABLES, AND HARNESSES TESTING, REPAIR, AND REPLACEMENT. - TM-9-4110-254-140098
Figure 4-15. Wires Cables and Harnesses - TM-9-4110-254-140099
Repair - TM-9-4110-254-140100
Table 4-3. Wire List - TM-9-4110-254-140101
Table 4-3. Wire List - Cont
Installation. - TM-9-4110-254-140103
CIRCUIT BREAKER CB1 TESTING AND REPLACEMENT. - TM-9-4110-254-140104
Figure 4-16. Circuit Breaker
RESISTOR R1 ASSEMBLY TESTING AND REPLACEMENT
Installation. - TM-9-4110-254-140107
LAMP DS1 ASSEMBLY TESTING AND REPLACEMENT.
Figure 4-18. Lamp DS1 Assembly
FUSES Fl AND F2 TESTING AND REPLACEMENT.
Installation. - TM-9-4110-254-140111
MOTOR STARTER K1 TESTING, REPAIR, AND REPLACEMENT.
Repair. - TM-9-4110-254-140113
Installation. - TM-9-4110-254-140114
CONTACTOR K2 TESTING AND REPLACEMENT.
Removal. - TM-9-4110-254-140116
CONTROL RELAYS K3 AND K4 TESTING AND REPLACEMENT. - TM-9-4110-254-140117
Removal. - TM-9-4110-254-140118
Figure 4-22. Control Relays
HOUR METER M1 TESTING AND REPLACEMENT. - TM-9-4110-254-140120
Figure 4-23. Hourmeter
TOGGLE SWITCH S1 TESTING AND REPLACEMENT. - TM-9-4110-254-140122
Installation. - TM-9-4110-254-140123
REPEAT CYCLE TIMER TM1 TESTING AND REPLACEMENT. - TM-9-4110-254-140124
Figure 4-25. Repeat Cycle Timer
Installation - TM-9-4110-254-140126
REMOTE BULB THERMOSTAT S3 TESTING AND REPLACEMENT. - TM-9-4110-254-140127
Figure 4-26. Remote Bulb Thermostat (Temperature Control)
Removal - TM-9-4110-254-140129
REMOTE BULB THERMOSTAT S3 TESTING AND REPLACEMENT. - Continued
TERMINAL BOARD TB1 REPLACEMENT.
Figure 4-27. Terminal Board TB1
GROUND STRAP (CONTROL BOX ASSEMBLY) REPLACEMENT.
Figure 4-28. Ground Strap (Control Panel)
DUMMY STOWAGE CONNECTOR AND COVER REPLACEMENT.
Installation. - TM-9-4110-254-140136
RESET BUTTON REPLACEMENT.
Installation. - TM-9-4110-254-140138
POWER DISTRIBUTION BLOCK TB2 REPLACEMENT.
Figure 4-31. Power Distribution Block
PUSH SWITCHES S6 AND S7 TESTING AND REPLACEMENT. - TM-9-4110-254-140141
Removal - TM-9-4110-254-140142
V-BELT REPLACEMENT AND ADJUSTMENT. - TM-9-4110-254-140143
Figure 4-33. V-Belt
PULLEY REPLACEMENT. - TM-9-4110-254-140145
GROUND STRAP (MOTOR) REPLACEMENT.
AC MOTOR B2 TESTING AND REPLACEMENT. - TM-9-4110-254-140147
Installation - TM-9-4110-254-140148
Installation - TM-9-4110-254-140149
CONDENSER FAN REPLACEMENT. - TM-9-4110-254-140150
Figure 4-37. Condenser Fan
EVAPORATOR FAN REPLACEMENT. - TM-9-4110-254-140152
PULLEY (SHEAVE AND BUSHING) REPLACEMENT.
FLANGE BEARING (EVAPORATOR FAN) REPLACEMENT.
Figure 4-40. Flange Bearing (Evaporator Fan)
FLANGE BEARING (CONDENSER FAN) REPLACEMENT
SOLENOID VALVE L1 (LIOUID LINE) TESTING AND REPAIR.
Figure 4-42. Solenoid Valve (Liquid Line)
SOLENOID VALVE L2 (DEFROST LINE) TESTING AND REPAIR
SOLENOID VALVE L2 (DEFROST LINE) TESTING AND REPAIR. - Continued
THERMOMETER TESTING AND REPLACEMENT
Figure 4-44. Refrigeration Temperature Gage (Thermometer)
Removal. - TM-9-4110-254-140163
GREASE FITTING EXTENSION REPLACEMENT.
Installation. - TM-9-4110-254-140165
DEFROST TERMINATION THERMOSTAT S4 TESTING AND REPLACEMENT
Installation - TM-9-4110-254-140167
GROUND STRAP (COMPRESSOR) REPLACEMENT.
HEAT SHIELD GASKETS REPLACEMENT
Figure 4-48. Heat Shield Gaskets
SECTION VI PREPARATION FOR STORAGE OR SHIPMENT - TM-9-4110-254-140171
Figure 4-49. Refrigeration System Pump Down
LONG TERM STORAGE OR SHIPMENT. - TM-9-4110-254-140173
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-4110-254-140175
TROUBLESHOOTING.
SECTION II DIRECT SUPPORT MAINTENANCE PROCEDURES - TM-9-4110-254-140177
Figure 5-1. Circuit Breaker Cover
CONTROL PANEL REPAIR.
Figure 5-2. Control Panel and Operating Instruction Plate
FAN DRIVE SHAFT REPLACEMENT. - TM-9-4110-254-140181
REFRIGERATION SYSTEM REPAIRS. - TM-9-4110-254-140182
Figure 5-4. Service Manifold Installation - TM-9-4110-254-140183
Installation. - TM-9-4110-254-140184
Removal. - TM-9-4110-254-140185
DISCHARGING THE REFRIGERANT SYSTEM.
Figure 5-5. Discharging Refrigerant - TM-9-4110-254-140187
PURGING THE REFRIGERANT SYSTEM. - TM-9-4110-254-140188
Figure 5-6. Nitrogen Tank Connection - TM-9-4110-254-140189
BRAZING/DEBRAZE PROCEDURE. - TM-9-4110-254-140190
Braze. - TM-9-4110-254-140191
LEAK TESTING THE REFRIGERANT SYSTEM. - TM-9-4110-254-140192
Testing. - TM-9-4110-254-140193
EVACUATING THE REFRIGERANT SYSTEM. - TM-9-4110-254-140194
Evacuate - TM-9-4110-254-140195
CHARGING THE REFRIGERANT SYSTEM. - TM-9-4110-254-140196
Figure 5-8. Refrigerant Charging (Total System) - TM-9-4110-254-140197
Partial Charge. - TM-9-4110-254-140198
Figure 5-9. Refrigerant Charging (Partial System /Small Quantity Charge)
Partial Charge. - TM-9-4110-254-140200
REFRIGERANT SYSTEM PRESSURE CHECK. - TM-9-4110-254-140201
Table 5-1. Pressure Temperature Relationship of Saturated Refrigerant R-134a - TM-9-4110-254-140202
Table 5-2. Nominal Operating Pressure At Suction And Discharge Shut Off Valves - TM-9-4110-254-140203
DEHYDRATOR REPLACEMENT. - TM-9-4110-254-140204
Installation. - TM-9-4110-254-140205
STRAINER REPLACEMENT. - TM-9-4110-254-140206
Installation. - TM-9-4110-254-140207
ISOLATION VALVES REPLACEMENT. - TM-9-4110-254-140208
Installation. - TM-9-4110-254-140209
RECEIVER AND FUSIBLE PLUG REPLACEMENT.
Installation. - TM-9-4110-254-140211
CONDENSER COIL REPLACEMENT. - TM-9-4110-254-140212
Figure 5-14. Condenser Coil
PRESSURE REGULATOR VALVE (DISCHARGE) REPLACEMENT. - TM-9-4110-254-140214
Installation - TM-9-4110-254-140215
METAL HOSE ASSEMBLY (DISCHARGE) REPLACEMENT. - TM-9-4110-254-140216
PRESSURE REGULATOR VALVE (SUCTION) REPLACEMENT
Installation. - TM-9-4110-254-140218
METAL HOSE ASSEMBLY (SUCTION) REPLACEMENT. - TM-9-4110-254-140219
Installation. - TM-9-4110-254-140220
ACCUMULATOR REPLACEMENT.
Figure 5-19. Accumulator - TM-9-4110-254-140222
SOLENOID VALVE L1 (LIOUID LINE) REPLACEMENT.
Installation. - TM-9-4110-254-140224
SOLENOID VALVE L2 (DEFROST LINE) REPLACEMENT
Installation. - TM-9-4110-254-140226
STOP VALVE (LIQUID LINE) REPLACEMENT. - TM-9-4110-254-140227
Installation. - TM-9-4110-254-140228
STOP VALVE (DEFROST LINE) REPLACEMENT. - TM-9-4110-254-140229
Installation. - TM-9-4110-254-140230
SIGHT INDICATOR REPLACEMENT. - TM-9-4110-254-140231
DIFFERENTIAL OIL PRESSURE SWITCH S5 REPLACEMENT. - TM-9-4110-254-140232
Figure 5-25. Differential Oil Pressure Switch S5
Installation. - TM-9-4110-254-140234
DUAL PRESSURE CONTROL SWITCH S2 REPLACEMENT. - TM-9-4110-254-140235
Figure 5-26. Dual Pressure Control Switch
Figure 5-27. Dual Pressure Control Switch Settings
COMPOUND GAGE (SUCTION PRESSURE) REPLACEMENT
Installation. - TM-9-4110-254-140239
PRESSURE GAGE (DISCHARGE PRESSURE) REPLACEMENT
Installation - TM-9-4110-254-140241
HEAT EXCHANGER REPLACEMENT. - TM-9-4110-254-140242
Installation. - TM-9-4110-254-140243
EXPANSION VALVE REPLACEMENT. - TM-9-4110-254-140244
Installation - TM-9-4110-254-140245
EVAPORATOR COIL REPLACEMENT. - TM-9-4110-254-140246
Installation. - TM-9-4110-254-140247
Figure 5-32. Evaporator Coil
COMPRESSOR B1 TESTING, REPAIR, AND REPLACEMENT.
Figure 5-33. Compressor (Sheet 1 of 2)
Figure 5-33. Compressor (Sheet 2 of 2)
Testing - TM-9-4110-254-140252
Disassembly. - TM-9-4110-254-140253
Assembly. - TM-9-4110-254-140254
Installation - TM-9-4110-254-140255
TUBING AND FITTINGS TESTING, REPAIR, AND REPLACEMENT.
Figure 5-34. Tubing And Fittings
Installation. - TM-9-4110-254-140258
PLATES (DATA) REPLACEMENT.
LEFT AND RIGHT SIDE DOOR REPLACEMENT.
Figure 5-35. Left and Right Side Doors
FRONT BOTTOM DOOR REPLACEMENT
Figure 5-36. Front Bottom Door
FRONT TOP DOOR REPLACEMENT
Figure 5-37. Front Top Door
CONTROL BOX COVER REPAIR AND REPLACEMENT
Installation. - TM-9-4110-254-140267
FRAME REPAIR - TM-9-4110-254-140268
CHAPTER 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-4110-254-140269
APPENDIX A REFERENCES - TM-9-4110-254-140271
APPENDIX B - TM-9-4110-254-140273
Maintenance Functions - TM-9-4110-254-140274
Explanation of Columns in the MAC - TM-9-4110-254-140275
Explanation of Columns in Remarks - TM-9-4110-254-140276
Section II. MAINTENANCE ALLOCATION CHART (MAC) FOR 5K BTU REFRIGERATOR
Section II. MAC FOR 5K BTU REFRIGERATOR, Continued - TM-9-4110-254-140278
Section II. MAC FOR 5K BTU REFRIGERATOR, Continued - TM-9-4110-254-140279
Section II. MAC FOR 5K BTU REFRIGERATOR, Continued - TM-9-4110-254-140280
Section II. MAC FOR 5K BTU REFRIGERATOR, Continued - TM-9-4110-254-140281
Section III. TOOLS AND TEST EQUIPMENT FOR MAC FOR 5K BTU REFRIGERATOR
APPENDIX C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS LIST - TM-9-4110-254-140283
SECTION III. BASIC ISSUE ITEMS LIST - TM-9-4110-254-140284
APPENDIX A ADDITIONAL AUTHORIZATION LIST
APPENDIX E EXPENDABLE AND DURABLE ITEMS LIST - TM-9-4110-254-140287
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST - TM-9-4110-254-140288
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST - CONT
APPENDIX F ILLUSTRATED LIST OF MANUFACTURED ITEMS - TM-9-4110-254-140291
MANUFACTURED ITEMS PART NUMBER LIST. -Continued - TM-9-4110-254-140292
MANUFACTURED ITEMS PART NUMBER LIST. -Continued - TM-9-4110-254-140293
Figure F-1. Tube, Copper Straight, Various - TM-9-4110-254-140294
Figure F-3. Insulation Sleeving
Figure F-6. Chain, Sash, Part Number 12290-8-8000
Figure F-7. Gasket, Top/Bottom, Part Number 148K0143
Figure F-9. Tube, Coil to Heat Exchanger, Part Number 148K0168
Figure F-11. Tube, Expansion Valve Bypass, Part Number 148K0171
Figure F-13. Tube, Heat Exchanger to 0.375 Elbow, Part Number 148K0174
Figure F-15. Insulation Sound and Temperature, Part Number 149K0000-1/162
Figure F-17. Tube Assembly Inlet, Receiver, Part Number 149K0052-1/T
Figure F-19. Tube, Elbow to Elbow, Sight Glass Outlet, Part Number 149K0074
Figure F-21. Tube, Outlet, Suction Pressure Regulator Valve, Part Number 149K0058
Figure F-23. Tube, Outlet, Condenser Coil, Part Number 149K0075
Figure F-25. Tube Assembly, Outlet Strainer, Part Number 149K0063-1/T
Figure F-27. Tube, Inlet, Shut-off Valve, Part Number 149K0065
Figure F-29. Gasket, Circuit Breaker Panel, Part Number 151K0031
APPENDIX G MANDATORY REPLACEMENT PARTS - TM-9-4110-254-140309
APPENDIX G MANDATORY REPLACEMENT PARTS - CONT - TM-9-4110-254-140310
TM-9-4110-254-14 Refrigeration Unit Mechanical 5K BTU Electric Model F5000RE (4110-01-389-9180) Manual

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