Figure 1-1. Air Conditioner - TM-9-4120-402-140010CHAPTER 1 INTRODUCTION - TM-9-4120-402-140011Section II EQUIPMENT DESCRIPTION - TM-9-4120-402-140012Figure 1-2. Location of Major Components - TM-9-4120-402-140013LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-9-4120-402-140014EQUIPMENT DATA.ISection III TECHNICAL PRINCIPLES OF OPERATION - TM-9-4120-402-140016Figure 1-3. Refrigeration Schematic - TM-9-4120-402-140017HEATING. - TM-9-4120-402-140018CHAPTER 2 OPERATING INSTRUCTIONS - TM-9-4120-402-140019Figure 2-1. Operator's Controls Front - TM-9-4120-402-140020Figure 2-2. Operator's Controls Rear - TM-9-4120-402-140021INDICATORS - TM-9-4120-402-140022Section II OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-4120-402-140023Table 2-1. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-9-4120-402-140024Table 2-1. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT) - TM-9-4120-402-140025Table 2-1. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT) - TM-9-4120-402-140026Table 2-1. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT) - TM-9-4120-402-140027Table 2-1. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT) - TM-9-4120-402-140028GENERAL OPERATING PROCEDURES. - TM-9-4120-402-140029Figure 2-4. Air Openings and Drains - TM-9-4120-402-140030Table 2-2. INITIAL OPERATOR CONTROL SETTINGS - TM-9-4120-402-140031OPERATION IN VENTILATE MODE (NO HEATING OR COOLING NEEDED) - TM-9-4120-402-140032OPERATION IN HEAT MODE - TM-9-4120-402-140033Figure 2-9. Fresh Air Damper (Door) Adjustment - TM-9-4120-402-140034Figure 2-11. Fabric CoverOPERATION IN COOL MODE. - TM-9-4120-402-140036Figure 2-14. Fresh Air Damper (Door) AdjustmentFigure 2-16. OFF/RESET Control SettingFigure 2-17. Information PlatesSection IV OPERATION UNDER UNUSUAL CONDITIONS - TM-9-4120-402-140040OPERATION INDUSTY OR SANDY CONDITIONS.OPERATION UNDER EMERGENCY CONDITIONS. - TM-9-4120-402-140042CHAPTER 3 OPERATOR'S MAINTENANCE INSTRUCTIONS - TM-9-4120-402-140043AIR CONDITIONER DOES NOT START IN ANY MODE. - TM-9-4120-402-140044COMPRESSOR DOES NOT START IN COOL MODE. - TM-9-4120-402-140045REDUCED COOLING CAPACITY. - TM-9-4120-402-140046REDUCED COOLING CAPACITY. - continued - TM-9-4120-402-140047REDUCED HEATING CAPACITY. - TM-9-4120-402-140048Section III MAINTENANCE PROCEDURES - TM-9-4120-402-140049CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS - TM-9-4120-402-140050Section I LUBRICATION INSTRUCTIONS - TM-9-4120-402-140051Section III SERVICE UPON RECEIPT OF EQUIPMENT - TM-9-4120-402-140052Figure 4-1. Installation Dimensions (Sheet 1 of 6)Figure 4-1. Installation Dimensions (Sheet 2 of 6)Figure 4-1. Installation Dimensions (Sheet 3 of 6)Figure 4-1. Installation Dimensions (Sheet 4 of 6)Figure 4-1. Installation Dimensions (Sheet 5 of 6)Figure 4-1. Installation Dimensions (Sheet 6 of 6)SERVICE UPON RECEIPT OF MATERIAL. - TM-9-4120-402-140059SERVICE UPON RECEIPT OF MATERIAL. - continuedINSTALLATION INSTRUCTIONS. - TM-9-4120-402-140061INSTALLATION INSTRUCTIONS. - continued - TM-9-4120-402-140062Figure 4-5. Control Panel RemovalFigure 4-6. Fabric Cover RemovalFigure 4-7. Blast DamperFigure 4-9. Blast Damper Maintenance ItemsConnect power cable to a 208 volt, 3 phase, 50/60/400 hertz power source.Table 4-1. Connector (P4)Figure 4-10. Wiring Diagram (Sheet 1 of 2)Figure 4-10. Wiring Diagram (Sheet 2 of 2)Figure 4-11. Electrical SchematicSection IV UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-4120-402-140072Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly ScheduleTable 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140074Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140075Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140076OTable 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONTTable 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140078Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140079Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140080Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140081Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140082Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140083Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140084Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) Quarterly Schedule - CONT - TM-9-4120-402-140085Section V UNIT TROUBLESHOOTING - TM-9-4120-402-140086AIR CONDITIONER DOES NOT START IN ANY MODE. - TM-9-4120-402-140087AIR CONDITIONER DOES NOT START IN ANY MODE. - continued FAN RUNS, BUT COMPRESSOR DOES NOT START.COMPRESSOR STARTS NORMALLY, BUT SOON STOPS.COMPRESSOR STARTS NORMALLY, BUT HIGH PRESSURE CUTOUT SWITCH TRIPS. - TM-9-4120-402-140091COMPRESSOR STARTS NORMALLY, BUT HIGH PRESSURE CUTOUT SWITCH TRIPS. - CONTREDUCED COOLING CAPACITY. - TM-9-4120-402-140093REDUCED COOLING CAPACITY. - continued - TM-9-4120-402-140094REDUCED COOLING CAPACITY. - continued - TM-9-4120-402-140095REDUCED HEATING CAPACITY. - TM-9-4120-402-140096REDUCED HEATING CAPACITY. - continuedNO HEAT IN HEAT MODE. - TM-9-4120-402-140098FAN MOTOR DOES NOT OPERATE.Section VI UNIT MAINTENANCE PROCEDURES - TM-9-4120-402-140100FABRIC COVER. - TM-9-4120-402-140101FABRIC COVER. - continuedCBR (CHEMICAL, BIOLOGICAL, RADIOLOGICAL) DUCT COVER. - TM-9-4120-402-140103ACCESS (SERVICE VALVES) COVER. - TM-9-4120-402-140104Figure 4-14. Access (Service Valves) CoverCONNECTOR COVER PLATES. - TM-9-4120-402-140106CONDITIONED AIR DISCHARGE (OUTLET) GRILLE ASSEMBLY. - TM-9-4120-402-140107CONDITIONED AIR DISCHARGE (OUTLET) GRILLE ASSEMBLY. - continuedCONDITIONED AIR INTAKE GRILLE ASSEMBLY. - TM-9-4120-402-140109CONDITIONED AIR INTAKE GRILLE ASSEMBLY. - continuedCONDENSER (FAN) GUARD. - TM-9-4120-402-140111CONDENSER (FAN) GUARD. - continuedCONDENSER COIL GUARD. - TM-9-4120-402-140113CONDENSER COIL GUARD. - continuedFRESH AIR (INLET) SCREEN OR COVER. FRESH AIR (INLET) SCREEN OR COVER. - continuedTOP PANEL. - TM-9-4120-402-140117TOP PANEL.- continuedLOWER FRONT COVER.LOWER FRONT COVER.- continuedFILTER (RADIO. FREQUENCY) MOUNTING PLATE.FILTER (RADIO FREQUENCY) MOUNTING PLATE. - continuedREAR PANEL.Figure 4-24. Rear PanelREAR PANEL.- continuedCONDITIONED AIR FILTER .CONDITIONED AIR FILTER. - continuedFRESH AIR FILTER.FRESH AIR FILTER.- continuedMIST ELIMINATOR. - TM-9-4120-402-140130MIST ELIMINATOR. - continued - TM-9-4120-402-140131ELECTRICAL WIRING REPAIR - GENERAL. - TM-9-4120-402-140132Table 4-4. WIRE LIST - TM-9-4120-402-140133Table 4-4. WIRE LIST - continued - TM-9-4120-402-140134Table 4-4. WIRE LIST - continued - TM-9-4120-402-140135Table 4-4. WIRE LIST - continued - TM-9-4120-402-140136Table 4-4. WIRE LIST - continued - TM-9-4120-402-140137Table 4-4. WIRE LIST - continued - TM-9-4120-402-140138CONTROL PANEL. - TM-9-4120-402-140139WIRING HARNESS, CONTROL PANEL. - TM-9-4120-402-140140Figure 4-29. Wiring Harness, Control Panel WIRING HARNESS, CONTROL PANEL.-continuedPOTENTIOMETER (TEMPERATURE CONTROL) (R1). - TM-9-4120-402-140143POTENTIOMETER (TEMPERATURE CONTROL) (R1).-continuedMODE SELECTOR ROTARY SWITCH (S1). - TM-9-4120-402-140145MODE SELECTOR ROTARY SWITCH (S1). - continuedFAULT INDICATOR, LIGHT EMITTING DIODE (DS1, DS2, DS3, AND DS4). - TM-9-4120-402-140147Figure 4-32. Light Emitting Diodes (DS1, DS2, DS3, & DS4)ELECTROMAGNETIC INTERFERENCE FILTER (FL1). - TM-9-4120-402-140149Table 4-5. Electromagnetic Interference Filter (FL1) Test Points.ELECTROMAGNETIC INTERFERENCE FILTER (FL1). - continuedCOIL FROST SWITCH (S2). - TM-9-4120-402-140152COIL FROST SWITCH (S2). - continuedCONTROL ASSEMBLYCONTROL ASSEMBLY. - continuedCONTROL ASSEMBLY WIRING HARNESSES.Figure 4-36. Control Assembly Wiring HarnessesLOGIC BOX ASSEMBLY (LGC1). - TM-9-4120-402-140158LOGIC BOX ASSEMBLY (LGC1). - continued - TM-9-4120-402-140159MOTOR CONTROLLER ASSEMBLYFigure 4-38. Motor Controller Assembly (MC1) RECTIFIER (CR1) AND CAPACITORS (C1 AND C2).Figure 4-39. Rectifier (CR1) and Capacitors (C1 and C2)RECTIFIER (CR1) AND CAPACITORS (C1 AND C2). - continuedTRANSFORMER (T1). - TM-9-4120-402-140165Figure 4-40. Transformer (T1)COMPRESSOR START RELAY (K2), DIODE (CR3), AND SURGE ARRESTOR (SA1). - TM-9-4120-402-140167Figure 4-41. Compressor Start Relay (K2), Diode (CR3), and Surge Arrestor (SA1)COMPRESSOR START RELAY (K2), DIODE (CR3), AND SURGE ARRESTOR (SA1) - continuedHEATER RELAY (K1) AND DIODE (CR2). - TM-9-4120-402-140170Figure 4-42. Heater Relay (K1) and Diode (CR2)HEATER RELAY (K1) AND DIODE (CR2). - continuedRECTIFIER (CR4). - TM-9-4120-402-140173RECTIFIER (CR4). - continuedCIRCUIT BREAKER (CB1). - TM-9-4120-402-140175CIRCUIT BREAKER (CB1). - continuedELECTRIC HEATER ELEMENTS (HR1 THROUGH HR6).ELECTRIC HEATER ELEMENTS (HR1 THROUGH HR6). - continuedHEATER CUTOUT (THERMOSTAT) SWITCH (S4).HEATER CUTOUT (THERMOSTAT) SWITCH (S4). - continuedEVAPORATOR FAN. - TM-9-4120-402-140181Figure 4-47. Evaporator Fan and Inlet BellEVAPORATOR FAN. - continuedEVAPORATOR AND CONDENSER FAN MOTOR (B2) AND CONDENSER FAN.Figure 4-48. Evaporator and Condenser Fan Motor and Condenser FanEVAPORATOR AND CONDENSER FAN MOTOR (B2) AND CONDENSER FAN. - continued - TM-9-4120-402-140186EVAPORATOR AND CONDENSER FAN MOTOR (B2) AND CONDENSER FAN. - continued - TM-9-4120-402-140187EVAPORATOR AND CONDENSER FAN MOTOR (B2) AND CONDENSER FAN. - continued - TM-9-4120-402-140188CONDENSER COIL CLEANING. - TM-9-4120-402-140189SOLENOID VALVE (L1) COIL. - TM-9-4120-402-140190Figure 4-50. Solenoid Valve (L1) CoilEVAPORATOR COIL CLEANING. - TM-9-4120-402-140192CONDENSATE DRAIN TRAPS.Figure 4-52. Condensate Drain TrapsCONDENSATE DRAIN TRAPS. - continuedSECTION VII PREPARATION FOR STORAGE OR SHIPMENT - TM-9-4120-402-140196chapter 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-4120-402-140197Section I REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE), AND SUPPORT EQUIPMENTSection II DIRECT SUPPORT TROUBLESHOOTINGSYMPTOM INDEX - TM-9-4120-402-140200INSUFFICIENT COOLING ACTION. - TM-9-4120-402-140201INSUFFICIENT COOLING ACTION. - continuedREFRIGERANT SYSTEM CONTINUOUSLY LOSING REFRIGERANT. - TM-9-4120-402-140203SIGHT GLASS APPEARS YELLOW INSTEAD OF GREEN. - TM-9-4120-402-140204Section III MAINTENANCE PROCEDURES - TM-9-4120-402-140205OUTSIDE COVERS AND PANELS.SCREENS, GUARDS, AND GRILLES. INFORMATION PLATES. - TM-9-4120-402-140208 LOGIC BOX ASSEMBLY (LGC1).Figure 5-1. Logic Box Test Fixture.LOGIC BOX ASSEMBLY (LGC1). - continued - TM-9-4120-402-140211LOGIC BOX ASSEMBLY (LGC1). - continued - TM-9-4120-402-140212LOGIC BOX ASSEMBLY (LGC1). - continued - TM-9-4120-402-140213LOGIC BOX ASSEMBLY (LGC1). - continued - TM-9-4120-402-140214LOGIC BOX ASSEMBLY (LGC1). - continued - TM-9-4120-402-140215LOGIC BOX ASSEMBLY (LGC1). - continued - TM-9-4120-402-140216LOGIC BOX ASSEMBLY (LGC1). - continued - TM-9-4120-402-140217LOGIC BOX ASSEMBLY (LGC1). - continued - TM-9-4120-402-140218EVAPORATOR AND CONDENSER FAN MOTOR (B2) REPAIR. - TM-9-4120-402-140219Figure 5-2. Evaporator and Condenser Fan Motor (Welco Industries Motor).EVAPORATOR AND CONDENSER FAN MOTOR (B2) REPAIR. - continued - TM-9-4120-402-140221IMC Magnetics motor.Figure 5-3. Evaporator and Condenser Fan Motor (IMC Magnetics Motor).EVAPORATOR AND CONDENSER FAN MOTOR (B2) REPAIR. - continued - TM-9-4120-402-140224Figure 5-4. Evaporator and Condenser Fan Motor (Keco Industries (Howell) Motor).EVAPORATOR AND CONDENSER FAN MOTOR (B2) REPAIR. - continued - TM-9-4120-402-140226EVAPORATOR AND CONDENSER FAN MOTOR (B2) REPAIR. - continued - TM-9-4120-402-140227SERVICE MANIFOLD INSTALLATION - TM-9-4120-402-140228Figure 5-5. Service Manifold Installation.DISCHARGING THE REFRIGERANT SYSTEM. - TM-9-4120-402-140230Discharge.PURGING THE REFRIGERANT SYSTEM. - TM-9-4120-402-140232Purge. - TM-9-4120-402-140233 BRAZING/DEBRAZE PROCEDURES.BRAZING/DEBRAZING PROCEDURES. - continued - TM-9-4120-402-140235BRAZING/DEBRAZING PROCEDURES. - continued - TM-9-4120-402-140236FLUSHING THE REFRIGERANT SYSTEM. - TM-9-4120-402-140237FLUSHING THE REFRIGERANT SYSTEM. - continued - TM-9-4120-402-140238LEAK TESTING THE REFRIGERANT SYSTEM. - TM-9-4120-402-140239Test. - TM-9-4120-402-140240EVACUATING THE REFRIGERANT SYSTEM. - TM-9-4120-402-140241EVACUATING THE REFRIGERANT SYSTEM. - continuedCHARGING THE REFRIGERANT SYSTEM. - TM-9-4120-402-140243CHARGING THE REFRIGERANT SYSTEM. - continued - TM-9-4120-402-140244Figure 5-10. Refrigerant Charging (Partial System/Small Quantity Charge) - TM-9-4120-402-140245CHARGING THE REFRIGERANT SYSTEM. - continued - TM-9-4120-402-140246Partial Charge. - TM-9-4120-402-140247Partial Charge (cont) - TM-9-4120-402-140248REFRIGERATION SYSTEM TROUBLESHOOTING. - TM-9-4120-402-140249OVERHEATING CHECKS. - TM-9-4120-402-140250REFRIGERANT SYSTEM PRESSURE CHECK. - TM-9-4120-402-140251Table 5-2. PRESSURE-TEMPERATURE RELATIONSHIP OF SATURATED REFRIGERANT-22 - TM-9-4120-402-140252 REFRIGERANT DESICCANT DEHYDRATOR (FILTER-DRIER).REFRIGERANT DESICCANT DEHYDRATOR (FILTER-DRIER). - continuedPRESSURE RELIEF VALVE. - TM-9-4120-402-140255CONDENSER COIL. - TM-9-4120-402-140256Figure 5-13. Condenser CoilCONDENSER COIL. - continued.RECEIVER. - TM-9-4120-402-140259HIGH PRESSURE SWITCH (S5).Test - TM-9-4120-402-140261LOW PRESSURE SWITCH (S3). IReplace. - TM-9-4120-402-140263SERVICE VALVES. - TM-9-4120-402-140264 SOLENOID VALVE (L1).Figure 5-18. Solenoid Valve (L1)LIQUID SIGHT INDICATOR (SIGHT GLASS). - TM-9-4120-402-140267EXPANSION VALVE. - TM-9-4120-402-140268Figure 5-20. Expansion ValveReplace. - TM-9-4120-402-140270Replace. - contEVAPORATOR COIL. - TM-9-4120-402-140272Replace. - TM-9-4120-402-140273Replace - contCOMPRESSOR (B1). - TM-9-4120-402-140275Test. - TM-9-4120-402-140276Figure 5-23. Compressor (B1) (Keco Industries, Inc.)Remove - TM-9-4120-402-140278Repair. - TM-9-4120-402-140279Connector replacement:Install. - TM-9-4120-402-140281TUBING AND FITTINGS. - TM-9-4120-402-140282FRESH AIR DAMPER. - TM-9-4120-402-140283Figure 5-26. Fresh Air DamperINSULATION.Replace. - TM-9-4120-402-140286BLAST DAMPER.Figure 5-28. Fresh Air Cover InstalledFigure 5-30. Blast Damper - Test/AdjustInspect. - TM-9-4120-402-140290Repair. - TM-9-4120-402-140291chapter 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-4120-402-140292Section II AUTHORIZED GENERAL SUPPORT MAINTENANCE ACTIONSRepair. - TM-9-4120-402-140294Figure 6-1. Lifting Handles - TM-9-4120-402-140295APPENDIX A REFERENCES - TM-9-4120-402-140296APPENDIX B MAINTENANCE ALLOCATION CHART - TM-9-4120-402-140297EXPLANATION OF COLUMNS IN THE MAC - TM-9-4120-402-140298EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-9-4120-402-140299SECTION II. MAINTENANCE ALLOCATION CHART - TM-9-4120-402-140300MAINTENANCE ALLOCATION CHART - continued - TM-9-4120-402-140301MAINTENANCE ALLOCATION CHART - continued - TM-9-4120-402-140302MAINTENANCE ALLOCATION CHART - continued - TM-9-4120-402-140303MAINTENANCE ALLOCATION CHART - continued - TM-9-4120-402-140304SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS FOR MAINTENANCE ALLOCATION CHARTSection IV REMARKS MAINTENANCE ALLOCATION CHART - TM-9-4120-402-140306APPENDIX C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (811) LISTSSection II COMPONENTS OF END ITEM - TM-9-4120-402-140308Section III BASIC ISSUE ITEMS - TM-9-4120-402-140309APPENDIX D ADDITIONAL AUTHORIZATION LIST (AAL) - TM-9-4120-402-140310APPENDIX E EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (EDSML) - TM-9-4120-402-140311Section II EXPENDABLE SUPPLIES AND MATERIALS LIST - continuedAPPENDIX F ILLUSTRATED LIST OF MANUFACTURED ITEMS - TM-9-4120-402-140313Manufactured Items Part Number Index - TM-9-4120-402-140314Figure F-1. Gasket, Part Numbers 13222E9996/2 and 13222E9996/5Figure F-4. GasketFigure F-7. GasketFigure F-10. Gasket, Part Number 13225E8115/2Figure F-13. Gasket, Part Number 13229E4250/44Figure F-16. Gasket, Part Number 13229E4243/8Figure F-17. Insulation, Part Number 13229E4243/14Figure F-20. Insulation, Part Number 13229E4243/10Figure F-22. Insulation, Part Number 13229E4246/19Figure F-24. Gasket, Part Number 13229E4246/22Figure F-27. Gasket, Part Number 13229E4246/8Figure F-30. Gasket, Part Number 13229E4242/10Figure F-33. Insulation, Part Number 13229E4251/57Figure F-35. Insulation, Part Number 13229E4251/67Figure F-37. Insulation, Part Number 13229E4251/62Figure F-39. Insulation, Part Number 13229E4251174Figure F-41. Insulation, Part Number 13229E4251/70Figure F-43. Insulation, Part Number 13229E4251/73Figure F-46. Gasket, Part Number 13226E0876Figure F-48. Extended Wiring Harness J4 to P15 DiagramFigure F-50. Input Power Cable DiagramFigure F-51. Logic Box Test Fixture SchematicSection I ABBREVIATIONSSection II DEFINITION OF UNUSUAL TERMS - TM-9-4120-402-140338TM-9-4120-402-14 Air Conditioner Vertical Compact 18 000 BTU/HR Model F18T-MPI 208 Volt Three Phase 50/60 or Hertz (4120-01-325-7062) Manual