Figure 1-1. Air Conditioner: Split Pack, 30,000 BTUH, 28VDC.CHAPTER 1 INTRODUCTION - TM-9-4120-408-140010Table 1-1. Nomenclature Cross-Reference Limit.SECTION II. EQUIPMENT DESCRIPTION - TM-9-4120-408-140012Table 1-2. Description of Major Components, Condenser Assembly. - TM-9-4120-408-140013Table 1-2. Description of Major Components, Condenser Assembly. - TM-9-4120-408-140014Table 1-3. Description of Major Components, Control Module.Table 1-4. Description of Major Components, Evaporator Assembly.Table 1-4. Description of, Major Components, Evaporator Assembly (Continued).SECTION III. PRINCIPLES OF OPERATION - TM-9-4120-408-140018Figure 1-5. Refrigerant Schematic.FUNCTIONAL DESCRIPTIONFigure 1-6. Electrical Schematic Diagram.Figure 1-7. System Interconnection Diagram.CHAPTER 2 OPERATING INSTRUCTIONS - TM-9-4120-408-140023SECTION II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-4120-408-140024PMCS PROCEDURES. - TM-9-4120-408-140025CLEANING AGENTS. - TM-9-4120-408-140026Figure 2-2. Operator's PMCS Routing Diagram (Sheet 1 of 3).Figure 2-2. Operator's PMCS Routing Diagram (Sheet 2 of 3).Figure 2-2. Operator's PMCS Routing Diagram (Sheet 3 of 3).Table 2-2. Operator Preventive Maintenance Checks and Services for Air Conditioner: Split Pack, 30,000 BTUH, 28VDCTable 2-2. Operator Preventive Maintenance Checks and Services for Air Conditioner: Split Pack, 30,000 BTUH, 28VDC (CONT) - TM-9-4120-408-140031Table 2-2. Operator Preventive Maintenance Checks and Services for Air Conditioner: Split Pack, 30,000 BTUH, 28VDC (CONT) - TM-9-4120-408-140032Table 2-2. Operator Preventive Maintenance Checks and Services for Air Conditioner: Split Pack, 30,000 BTUH, 28VDC (CONT) - TM-9-4120-408-140033Table 2-2. Operator Preventive Maintenance Checks and Services for Air Conditioner: Split Pack, 30,000 BTUH, 28VDC (CONT) - TM-9-4120-408-140034SECTION III. OPERATION UNDER USUAL CONDITIONS - TM-9-4120-408-140035Figure 2-3. Information Plate, Control Module.Figure 2-5. Schematic Diagram Plate.Figure 2-6. Refrigerant Fluid Diagram Plate.Figure 2-7. Identification Plate, Evaporator Assembly.SECTION IV. OPERATION UNDER UNUSUAL CONDITIONS - TM-9-4120-408-140040 UNUSUAL ENVIRONMENTAL/WEATHER. (Continued)EMERGENCY PROCEDURES. - TM-9-4120-408-140042CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS - TM-9-4120-408-140043SECTION III. OPERATOR TROUBLESHOOTING PROCEDURESTable 3-1. Operator Troubleshooting Table. (Continued)SECTION IV. OPERATOR MAINTENANCE PROCEDURESFigure 3-1. Return AirUNIT MAINTENANCE INSTRUCTIONS CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONSSECTION I. LUBRICATION INSTRUCTIONS - TM-9-4120-408-140049SECTION IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-4120-408-140050Table 4-1. Unit Preventive Maintenance Checks and Services for Control Module Assembly.Table 4-1. Unit Preventive Maintenance Checks and Services for Control Module Assembly. (CONT)Table 4-2. Unit Preventive Maintenance Checks and Services for Condenser Amply.SECTION V. UNIT TROUBLESHOOTING PROCEDURES - TM-9-4120-408-140054Table 4-4. Unit Troubleshooting Table Table 4-4. Unit Troubleshooting TableTable 4-4. Unit Troubleshooting Table. (continued) - TM-9-4120-408-140057Table 4-4. Unit Troubleshooting Table. (continued) - TM-9-4120-408-140058SECTION VI. UNIT MAINTENANCE PROCEDURES - TM-9-4120-408-140059Figure 4-4. Access Panel Maintenance.CONDENSER SIDE PANEL MAINTENANCEDATA PLATE AND SPRING CLIP REPLACEMENT.ROADSIDE LIFTING RING REPLACEMENT.Figure 4-7. Lifting Ring Replacement.CONDENSER FOOT REPLACEMENT.UPPER CONDENSER PROTECTIVE GRILLE AND EMI/RFI VENTILATION PANEL MAINTENANCE.UPPER CONDENSER PROTECTIVE GRILLE AND EMI/RFI VENTILATION PANEL MAINTENANCE. (CONT)CONDENSER WIRING HARNESS MAINTENANCE.Figure 4-10. Condenser Assembly Wiring Harness Maintenance.CONDENSER WIRING HARNESS MAINTENANCECONDENSER ELECTRICAL LEAD AND DIODE ASSEMBLIES MAINTENANCE.Figure 4-11. Electrical Lead Assembly Maintenance.50 AMP RELAY MAINTENANCE.Figure 4-12. 50 Amp Relay Maintenance.CONDENSER TERMINAL BOARD MAINTENANCEFigure 4-13. Terminal Board Maintenance.CONTROL MODULE TOP PANEL MAINTENANCEMODE SELECTOR SWITCH (S1) MAINTENANCETable 4-5. Mode Selector Switch (S1) Closed Contacts.LIGHT EMITTING DIODE (LED) ASSEMBLY MAINTENANCEFigure 4-16. LED Assembly.LIGHT EMITTING DIODE (LED) ASSEMBLY MAINTENANCE. (Continued)THERMOSTAT MAINTENANCEFigure 4-17. Thermostat MaintenanceTHERMOSTAT MAINTENANCE. (Continued)CONTROL MODULE WIRING HARNESS MAINTENANCE.CONTROL MODULE WIRING HARNESS MAINTENANCE. (Continued)CONTROL MODULE ELECTRICAL LEAD, DIODE, AND RESISTOR ASSEMBLIES MAINTENANCE.Figure 4-19. Resistor Assembly MaintenanceCONTROL MODULE ELECTRICAL LEAD, DIODE, AND RESISTOR ASSEMBLIES MAINTENANCE. (Continued)CONTROL MODULE BUS CONNECTOR AND SINGLE ROW TERMINAL BOARD MAINTENANCE CONTROL MODULE HOUSING MAINTENANCECONTROL MODULE HOUSING MAINTENANCE. (Continued) - TM-9-4120-408-140093CONTROL MODULE HOUSING MAINTENANCE. (Continued) - TM-9-4120-408-140094FRONT (AIR INLET) EVAPORATOR EMI/RFI VENTILATION PANEL MAINTENANCEDIFFERENTIAL PRESSURE SWITCH TESTSECTION VII. PREPARATION FOR STORAGE OR SHIPMENT - TM-9-4120-408-140097CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-4120-408-140098SECTION II. DIRECT SUPPORT TROUBLESHOOTING - TM-9-4120-408-140099Table 5-1. Direct Support Troubleshooting Table.Table 5-1. Direct Support Troubleshooting Table. (Continued) - TM-9-4120-408-140101Table 5-1. Direct Support Troubleshooting Table. (Continued) - TM-9-4120-408-140102SECTION III. DIRECT SUPPORT MAINTENANCE PROCEDURES - TM-9-4120-408-140103REFRIGERANT SERVICECharging the system. - TM-9-4120-408-140105LOWER CONDENSER PROTECTIVE GRILLE AND EMI/RFI VENTILATION PANEL MAINTENANCEFigure 5-1. Condenser EMI/RFI Ventilation Panels.CONDENSER VANVE AXIAL FAN MAINTENANCEFigure 5-2. Condenser Vane Axial Fan Maintenance.Test. - TM-9-4120-408-140110 Install.CURBSIDE LIFTING RING REPLACEMENT.Figure 5-3. Curbside Lifting Ring ReplacementCONDENDSER DATA PLATE AND SPRING CLIP REPLACEMENTFigure 5-4. Data Plate ReplacementCONDENSER PRESSURE SWITCH MAINTENANCE.CONDENSER PRESSURE SWITCH MAINTENANCEICONDENSER PRESSURE SWITCH MAINTENANCE. (Continued)CONDENSER PRESSURE SWITCH MAINTENANCE. (Continued) - TM-9-4120-408-140119CONDENSER PRESSURE SWITCH MAINTENANCE. (Continued) - TM-9-4120-408-140120SWIVEL TEE ACCESS VALVE AND FLARE TEE MAINTENANCE.SWIVEL TEE ACCESS VALVE AND FLARE TEE MAINTENANCE. (Continued)CONDENSER TUBING AND FITTINGS MAINTENANCE. - TM-9-4120-408-140123Figure 5-7. Condenser Tubing and Fittings maintenance.CONDENSER TUBING AND FITTINGS MAINTENANCE. - TM-9-4120-408-140125LIQUID LINE RECEIVER MAINTENANCE.Figure 5-8. Liquid Line Receiver Replacement.DEHYDRATOR MAINTENANCE.Install - TM-9-4120-408-140129CONDENSER COIL MAINTENANCE.Repair. - TM-9-4120-408-140131REAR (AIR DISCHARGE) EVAPORATOR EMI/RFI VENTILATION PANEL MAINTENANCE.REM (AIR DISCHARGE) EVAPORATOR EMI/RFI VENTILATION PANEL MAINTENANCE. (Continued)EVAPORATOR SIDE PANEL MAINTENANCE.Figure 5-12. Evaporator Side Panel Maintenance.EVAPORATOR FAN ASSEMBLY MAINTENANCE.Figure 5-13. Evaporator Fan Assembly Removal. EVAPORATOR FAN ASSEMBLY MAINTENANCE. (Continued) - TM-9-4120-408-140138Figure 5-14. Evaporator Fan Assembly. EVAPORATOR FAN ASSEMBLY MAINTENANCE. (Continued) - TM-9-4120-408-140140EMI ELECTRONIC FILTER REPLAC EMENT.Install - TM-9-4120-408-140142EVAPORATOR ELECTRICAL LEAD MAINTENANCE. - TM-9-4120-408-140143EVAPORATOR ELECTRICAL LEAD MAIRTENANCE. (Continued)DIFFERENTIAL PRESSURE SWITCH MAINTENANCE. This task covers:DIFFERENTIAL PRESSURE SWITCH MAINTENANCE. (Continued)Install. - TM-9-4120-408-140147EVAPORATOR ELECTRICAL LEAD MAINTENANCE. - TM-9-4120-408-140148EVAPORATOR WIIRING HARNESS, A106J1, MAINTENANCE. (Continued)EVAPORATOR HIRING HARNESS, A106J1,-MAINTENANCE. (Continued) EVAPORATOR LOW PRESSURE SWITCH MAINTENANCE. EVAPORATOR LOW PRESSURE SWITCH MAINTENANCE. (Continued) - TM-9-4120-408-140152 EVAPORATOR LOW PRESSURE SWITCH MAINTENANCE. (Continued) - TM-9-4120-408-140153EVAPORATOR SINGLE ROW TERMINAL BOARD MAINTENANCE.EVAPORATOR SINGLE ROW TERMINAL BOARD MAINTENANCE. (Continued) EQUALIZER LIKE TUBE ASSEMBLY - MAINTENANCE.Figure 5-21. Equalizer Line Tube Assembly Maintenance.THERMO EXPANSION VALVE (TEV) MAINTENANCETHERMO EXPANSION VALVE (TEV) MAINTENANCE. (Continued) - TM-9-4120-408-140159THERMO EXPANSION VALVE (TEV) MAINTENANCE. (Continued) - TM-9-4120-408-140160EVAPORATOR TUBING AND FITTINGS MAINTENANCEFigure 5-24. Evaporator Tubing and Fittings Maintenance. EVAPORATOR TUBING AND FITTINGS MAINTENANCE. (Continued)EVAPORATOR TUBING AND FITTINGS MAINTENANCE. (Continued)EVAPORATOR COIL MAINTENANCEFigure 5-25. Evaporator Coil Maintenance.EVAPORATOR COIL MAINTENANCE. (Continued)CONDENSATE LEVEL WARNING SWITCH MAINTENANCECONDENSATE LEVEL WARNING SWITCH MAINTENANCE. (Continued)CONDENSATE DRAIN PAN MAINTENANCESECTION IV. PREPARATION FOR STORAGE OR SHIPMENT - TM-9-4120-408-140171PACKING.CHAPTER 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-4120-408-140173SECTION II. GENERAL SUPPORT MAINTENANCE PROCEDURES - TM-9-4120-408-140174CONDENSER HOUSING MAINTENANCE. (Continued) - TM-9-4120-408-140175CONDENSER HOUSING MAINTENANCE. (Continued) - TM-9-4120-408-140176EVAPORATOR HOUSING MAINTENANCEEVAPORATOR HOUSING MAINTENANCE. (Continued) - TM-9-4120-408-140178EVAPORATOR HOUSING MAINTENANCE. (Continued) - TM-9-4120-408-140179APPENDIX A REFERENCES - TM-9-4120-408-140180APPENDIX B MAINTENANCE ALLOCATION CHART (MAC) - TM-9-4120-408-140181EXPLANATION OF COLUMNS IN THE MAC - TM-9-4120-408-140182EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-9-4120-408-140183SECTION II. MAINTENANCE ALLOCATION CHART - TM-9-4120-408-140184SECTION II. MAINTENANCE ALLOCATION CHART (CONT) - TM-9-4120-408-140185SECTION II. MAINTENANCE ALLOCATION CHART (CONT) - TM-9-4120-408-140186SECTION II. MAINTENANCE ALLOCATION CHART (CONT) - TM-9-4120-408-140187SECTION II. MAINTENANCE ALLOCATION CHART (CONT) - TM-9-4120-408-140188SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-9-4120-408-140189SECTION IV. REMARKS - TM-9-4120-408-140190APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS - TM-9-4120-408-140191SECTION II. COMPONENTS OF END ITEM - TM-9-4120-408-140192SECTION III. BASIC ISSUE ITEMS - TM-9-4120-408-140193APPENDIX D ADDITIONAL AUTHORIZATION LIST - TM-9-4120-408-140194APPENDIX E EXPENDABLE AND DURABLE ITEMS LIST - TM-9-4120-408-140195SECTION II. EXPENDABLE AND DURABLE ITEMS LIST - TM-9-4120-408-140196SECTION II. EXPENDABLE AND DURABLE ITEMS LIST (CONT) - TM-9-4120-408-140197APPENDIX F ILLUSTRATED LIST OF MANUFACTURED ITEMS - TM-9-4120-408-140198PROCEDURES: - TM-9-4120-408-140199Table F-1. Parts List for Wiring Harness A104J1.Figure F-2. Wiring Harness A10J102.Table F-3. Parts List for Wiring Harness A104J2.Table F-4. Wiring Harness A104J2 Wire Run List .Table F-5. Parts List for Electrical Lead Assemblies .Table F-6. Electrical Lead Assembly Wire u List.Table F-7. Parts List for Diode Assembly.Figure F-5. LED Assembly.Table F-8. Parts List for LED Assembly.PROCEDURES: - TM-9-4120-408-140209Table F-10. Parts List for Wiring Harness A105J1.Figure F-7. Wiring Harness A105J2.Table F-12. Parts List for Wiring Harness A105J2.Table F-14. Parts List for Resistor Assembly.PROCEDURES: - TM-9-4120-408-140214Table F-14. Parts List for Wiring Harness A104P3.PROCEDURES: - TM-9-4120-408-140216Table P-16. Parts List for Wiring Harness A104P4.Table F-18. Condenser Tubing.Table F-19. Rubber Sheets.Table F-21. Differential Pressure Switch Material.PROCEDURES: - TM-9-4120-408-140221Table F-22. Parts List for Wiring Harness A106J1.Table F-24. Parts for Equalizer Line Tube Assembly.Table F-25. Parts for TZV Outlet Tube Assembly.APPENDIX G MANDATORY REPLACEMENT PARTS - TM-9-4120-408-140225APPENDIX H WIRING DIAGRAMS AND WIRE RUN TABLESFigure H-1. Control Module Assembly Wiring Diagram.Table H-1. Control Module Assembly Component Reference.Figure H-2. Condenser Assembly Wiring Diagram.Table H-3. Condenser Assembly Component Reference.Figure H-3. Evaporator Assembly Wiring Diagram.Table H-5. Evaporator Assembly Component Reference.GLOSSARY - TM-9-4120-408-140233SECTION II. DEFINITION OF UNUSUAL TERMS - TM-9-4120-408-140234TM-9-4120-408-14 Air Conditioner: Split Pack 30 000 BTUH 28 VDC (NSN: 4120-01-377-7511) (EIC: FGJ) Manual
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