AG-180AO-MMM-000

AG-180AO- 15 May 1991

ORGAN! ERMEDIATE MAINTEN RATED PARTS

DISTRIBUTION STATEMENT C. Distribution authorized lo U.S. Government agencies and their contractors lo protect publications required for official use or for administrative or operationalpurposes only, 15 May 1990. Other requesfs for this document shall be referred to commanding officer, naval air technical sewicas facility, 700 Robbins Avenue, Philadelphia. PA 1911 l-5097.

DESTRUCTION NOTICE For unclassified. limited documents. destroy by any method that will prevent disclosure of contents or reconstruction of the document.

NATEC ELECTRONIC MANUAL

0819LP6662352

AG-180AO-MMM-000 15May1991 Page A

NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES/PAGES

originaI0 . . . . . . . . . . . 15 May91

Ody those work pa&ages assignsd to the menual arc listed in this index. Insert _ dated Dispose of superseded and deleted work packages/pages. Superseded and deleted classified work pacas shall ba destroyed in accordance with applicable regulations. If changed pages are issued to a work package, insert the changed pages in the applicable work package. The portion of text afTect.ed in a changed or revised work package is indicated by change bars or the change symbol ‘R’ in the outer margin of each column oftext Changes to iIk&rations are indicated by pointing hands or change bars, as applicable.

WP Number

WP Number Mle

liuc WA

IPDR-1

00100 all 01 MllU2

00200 00300 00400

an00 al600 00700

Numerical In&x of Effcctivc woIkpadrages/wges List of Technical Pablicatimu ===qReports- Al~bldcx Ntmerid Imlcx of Part Numbers NlllMXidbKlCXOfRCferenCe

Inmnlacdoll l+iaciplcs of Opcmtkm Reparation for use, storage sad sbipmcnt opcmingbwtNctions Testiag aad Troableshooting Servicing, Lubhatim. AdjwhneaI cleanup Atiex Compmsx Motor Burnout

00800

00900

01000

01100

01200

Removal and Instsllstion Instmc- tiOUS F’resm-c Switches sad Capillary lafmmstives Assembly sad Disasscm- bly lastmctioos Elcchicsl Controls Panel, Fuse Box, Illmomen1 F%mcl aad wig Assembly sad Disassembly Instrac- tiOOS Abilow contmuer Motor, Afler- cooler Module and I’recmlcr Module and Water Dmis Pump Assembly aad DisssscmbIy Instractions Refrigcmtioa Compressor Asscm- bly sad Compressor Cylinder Head Temperature Cutout (C’KO)

Tocal numbez of pages ia this msaosl is 298 consisting of tbe following:

WPmlg No. Change No. WPlPege No. Change No. WPlPage No. Change No.

lWC_. ................ .O A.. ................... . TPDR-1 ................ 0 TPDR-2Bkmk ......... .O 00100.. .............. .o

1-3 ................ .o 4Bbmk.. ............ .O

00101 ................ .o 1-6 ................ .O

00102.. ............... 0 l-2 ................ .o

00200.. ............... 0 l-3 ................ .o 4Blaok.. ............ .O

00300 ................. 0 l-9 ................ .o lOBlat&. ............ .O

11 ................... . 12Bbmk ............ ..O 13-17 .............. .o 18Blaak ............ ..O

CHMOO ................ .o l-4 ................ .o

00500.. .............. .o l-7 ................ .o 8Bbmk.. ............ .o

al6Ml.. .............. .o l-64 ............... .o

00700.. .............. .o l-28 ............... .o

00800.. .............. .o l-7 ................ .o 8Blaak.. ............ .o 9-41 ............... .o

42Blsak ............. .O 43-75 .............. .o 76Blaak.. ........... .O

00900 ................. 0 l-21 ............... .o 22Blaok.. ........... .O

01000.. .............. .o l-33 ............... .o 34Blaak.. ........... .O

01100.. .............. .o I-17 ............... .o 18Blsak.. ........... .o

01200.. .............. .o l-5 ................ .o 6Blank.. ............ .O

AC-1 80AO-MMM-000 15 May 1991 TPDR-l/(TPDR-2 Blank)

LIST OF TECHNICAL PUBLICATIONS I)EFICIENCY REI’OKTS INCOKPORATEI)

OKGANIZATIONAL AND 1NTEHMEI)IATE MAINTENANCE WITH IPB

AIR CONI)ITIONER. AIRCHAFT GROUND COOLING

A/M32C-21

PART NUMBER 1603ASlOO-1

Identification No./ QA Sequence No.

NAS NORFOLK 0064/03169

Identification No./ Location QA Sequence No. Location

(WP) 003 00 (Pg) 11 (F) 2

NAS NORFOLK 0061/03152

(WP) 010 00 Wg) 11 (F) 2

AG-180AO-MMM-000 15 May 1991

001 00 Page 1 of 4

ALPHABETICAL 1NDEX

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE

AIR CONDITIONER. AIRCRAFT GHOUND COOLING

A/M32C-21

Adjustment Brake Bypass Airflow Controller Fan Cycling Switch Head Pressure Regulator Valve (VI) Inlet Airflow Controller Low Pressure Cutout Switch (LPCO) .&in Service Circuit Breaker MotorStarter (Kl, K2, K3) Pressure Differential Switch (Open On Pressure Rise) (PS6) Pressure Differential Switch (Close On Pressure Rise) (PS4, PS5)

Aftercooler Module Air Conditioner, Aircraft Ground Cooling, A/M32C-21 Airflow Controller .Motor Airflow Control System Schematic Atmospheric Relief Valve (V2) Blower Airflow Delta Pressure Capillary Informative Blowerand Delivered Airflow Differential Pressure Switches (PSI, PS2, PS3) Blower Assembly Blower, Blower Motor, Precoolerand Aftercooler Assemblies Blower and Compressor Oil Servicing Blower Oil Servicing Brake Adjustment Brake Assembly Bypass Airflow Controller Adjustment Cable and Connector Assemblies Chassis and Wheel Assemblies Cleanup After Compressor Motor Burnout Component Locator Compressor Assembly Compressor and Receiver Assembly Compressor Cylinder Head Temperature Cutout (CTCO) Compressor Cylinder Head Temperature Cutout (CTCO) Testing Compressor Suction Pressure Capillary Informative Condenser Fan Condenser Fan Motor Condenser Fan and Motor Controls and Indicators Control Voltage Transformer (TRI l Description Differential Pressure Switch (PSI)

Number

007 00 007 00 007 00 007 00 007 00 007 00 007 00 007 00 007 00 007 00 00100 01000 008 00 01100 003 00 008 00 009 00 009 00 008 00 008 00 007 00 007 00 007 00 008 00 007 00 010 00 008 00 007 00 003 00 008 00 008 00 01200 006 00 00900 008 00 008 00 008 00 005 00 006 00 003 00 009 00

AG-180AO-MMM-000 00100 Page 2

Differential Pressure Switch (I’SZ, 1’53) Differential Pressure Switch (I’S61 Duct Storage Rack Drain Pan Assembly F:lectrical Controls Panel Electrical Phase Loss Relay (K.5) Electrical Schematic Evacuation and Charging Evaoorator Pressure Rewlator Valve Fan’Cycling Switch ~- Fan Cycling Switch (E‘SW), Low I’rcssurc Cutout Switch (LPCOI and

IIigh Pressure Cutout Switch (IlI’COl 00700 Filter Drier 00800 Front Wheel Assembly 00800 Fuse Box 01000 Fuse Testing 00600 Ilead Pressure Regulator Adjustment 00700 Head Pressure Regulator Valve 00800 lligh Pressure Switch 009 00 1tot Gas Bypass Valve 008 00 Inlet Airflow Controller Adjustment 00700 Instrument Panel 00800 Instrument Panel, Electrical Controls Panel and Delivery Duct 00500 Introduction 00200 Leading Particulars 00300 Low Pressure Switch 009 00 MainServiceCircuit Hreaker(CR1) Adjustment 00700 Main Service Circuit Breaker (CBl) Testing 00600' Motor 30 HP Blower 00800 Motor Starters (K I, K2, K3) Adjustment 00700 Oil Pressure Switch 009 00 Operating Instructions 00500 Panel and Door Assemblies 00800 Panel Assemblies and Duct Storage Rack 00800 Precooler Module 00800 Pressure Controls Panel 00800 Preparation for Shipment 00400 Preparation for Storage 00400 Preparation for Cse 00400 Preparalion For Use, Storage and Shipment 00400 Pressure Controls Testing 00600 Pressure Differential Switches (PS4, I’%, PS6) Adjustment 00700 Pressure Switches 009 00 Pressure Switches Testing 00600 Principles ofOperation 00300

Conditioned Airflow 003 00 Cooling Mode 00300 Dehumidification Mode 00300 tilectrical and Control Function 00300 Entering Airflow 00300 Refrigerant Function 00300 Ventilation Mod12 00300

WP Number

00900 009 00 00800 01100 00800 00600 00300 00700 00800 009 00

AG-18OAO-MMM-000

Title -

Quench Valve Kear Wheel Assemblies Receiver Assembly fMrigeration Compressor Assembly Refrigeration Piping Asscmhly Refrigeration Control System Schematic Roadside and Curbside Rear Wheel Asscmhlies Servicing Instructions

Compressor Oil Addition Compressor Oil f)rain Empty System Pressure Test Gas Refrigerant Addition/Charging Leak Test Liquid Kefrigerant Addition/Charging Pumpdown System Evacuation

Shutdown Instructions Emergency Shutdown Procedures Normal Shutdown f’rocedures

Solenoid Testing Solenoid Valves tSI, 52. S3.54, S5. .%I Starter Relays (K I. K2, K3l Testing Switch Testing System Description

fllower Condenser Coils Condenser Fan Control Panels EvaporationCoils Refrigerant Compressor Vehicle

System Pumpdown Testing Thermostatic Expanison Valves (Xl, X2, X3, X4) Testing Time Delay Relay (K4)Testing Troubleshooting Wiring Wiring List Wiring Schematic

001 00 Page 3/(4 Blank)

WP Number

008 00 008 00 008 00 01200 008 00 003 00 008 00 007 00 007 00 007 00 007 00 007 00 007 00 007 00 007 00 007 00 005 00 005 00 005 00 006 00 008 00 006 00 006 00 003 00 003 00 003 00 003 00 003 00 003 00 003 00 003 00 007 00 006 00 006 00 006 00 006 00 01000 01000 01000

AC-180AO-MMM-000 15 May 1991

001 01 Page 1 of 6

NUMERICAL INDEX OF PART NUMBERS

ORGANIZATIONALAND INTERMEDIATE MAINTENANCE WITH IPB

AIR CONDITIONER, AIRCRAFT GROUND COOLING

A/M32C-21

PART NUMBER 1603ASlOO-1 I

PART NUMBER

1603ASlOO 1603ASlOl 1603AS102 1603AS103 1603AS104 1603AS105

1603AS106

1603AS107 1603AS109 1603ASllO

1603ASlll

1603AS112

1603AS113 1603AS114 1603AS115 1603AS116 1603AS117 1603AS118 1603ASl20 1603ASlZl 1603AS122 1603AS123 1603AS124 1603AS125 1603ASl26 1603AS127 1603AS128

1 1603AS129 1603ASl31 1603AS132 1603AS133

WORK PACKAGE/ FIGURE NO. INDEX NO

008 00/1/l 008 00/2/161 01 I 00/2/47 008 00/4/32 008 00/8/l 008 00/5/33 011 00/2/- 008 0015169 011 OO/l/- 008 0016 008 00/2/l 008 00/l/9 008 00/4/l 009 00/4/- 008 00/4/19 008 0013/l 008 001414 010 00/l/5 008 0015/17 008 00/3129 008 00/3/l 008 001318 008 001314 008 00/3/12 008 00/3/16 008 00/7/10 01 I 00/2/43 008 001518 012 00/1/l 008 00/7/6 008 00/6/83 008 0015/22 008 00/5/13 008 0013124 008 00/6/129 008 00161120 008 00/6/l 17 008 00/7/20

PART NUMBER

1603AS134 1603AS135 1603AS136-1 1603AS136-2 1603AS137 1603AS138.1 1603AS138-2 1603AS139 1603AS140 1603AS141 1603AS142 1603AS143 1603AS144 1603AS145 1603AS146 1603AS147 1603AS148

1603AS149 1603AS150 1603AS151 1603AS152 1603AS153 1603AS154.1 1603AS154-2 1603AS155-1 1603AS155-2 lF03AS155-3 1603AS156 1603AS157 1603AS158 1603AS159 1603AS160 1603AS161 1603AS162 1603AS163 1603AS164-1 1603AS164-2


008 00/6/78 008 0016176 008 00/6/30 008 00/6/34 008 00/6/2 008 00/6/150 008 001615 008 0016154 008 0016043 008 0016045 008 00/6/155 008 00/6/164 008 0017115 01 I 00/l/26 009 00/1/l 009 00/l/l 011 00/2/61 0 1 I 00/4/22 010 00/l/64 010 0011128 010 00/3/43 010 00/3/41 010 00/3/39 008 00/5/50 008 00/5/77 010 OO/TBLl/lO 010 OOiTBLU9 010 OO/TBL1/8 010 00/3/51 010 00/3/45 009 00/4/28 009 00/4/22 009 00/4/25 010 00/l/31 010 00/l/32 009 00/4/l 01000/2/17 010 00/2/6

sl

AC-180AO-MMM-000 001 01 Page 2

PARTNUMRER

1603AS165 1603AS166 1603AS167 1603AS168 1603ASl69 1603ASlTO

1603AS171 1603AS172 1603AS173.I 1603AS173.2 1603ASl74 1603AS175 1603AS176 1603ASl77.I 1603AS177.2 1603AS179 1603ASl80 1603AS182 1603AS188 1603AS190 1603AS233 1603AS234 1603AS250 1603AS254 1603AS255 1603AS258 1603AS265 1603AS266 1603AS271 1603AS272 1603AS273 1603AS274

1603AS275 1603AS278 1603AS279 1603AS280 l603AS281 1603AS288

1603AS295 l603AS296 1603AS297 1603AS298 1603AS299

1603AS313

WORK PACKAGE/ WOKK PACKAGE/ FICUHE NO. FICUKE NO. INDEX NO PAKT NUMBER INDEX NO

0100012/19 0100012113 0l000/1/57 0100013124 01000/3/37 011 0012173 011 OO/Yl5 00800/2/116 0080016182 00800/6/68 00800/6/139 0090014110 00900/4/16 00800/8/60 01000/3/57 01000/3/58 00800/2/6 00800/1/13 0080012/1O.l 01000/1/53 00800/8/106 00800/8/2 0090015/- 00800/2/140 00800/2/129 00800/Z/76 0080012/64 0080012~141 0080012/138 OlOOO/TBLl/7 00800/5/76 0100011137 00800/l/26 010 00/l/36 01000/3/32 0100011/50 01000/1/61 0100011141 00800/4/7 00800/4/13 01000/2/1 0100011/7 010 00/l/l I 01000/1/10 0100011/2 00800/4/14 01000/2/2 01000/1/27

1603AS316 l603AS317 l603AS318 1603AS319 1603AS320-I lGOUAS320.2 lfjO3AS321.I 1603AS321.2 1603AS322.1 l603AS322.2 1603AS322.3 lf03AS322.4 lfi03AS322.5

1603AS322~7 1603AS322.8

1603AS322.9

1603AS322.10 1603AS322.II 1603AS322.I2 1603AS322.I3

I603AS322.14

1603AS322.I5 1603AS322.I6 1603AS322.I7 1603AS322.18 1603AS322.I9 1603AS323

lfXBAS32-l

lfj03AS325.1

1603AS325.2 lfiO3AS326

1603AS327 lfiO3AS333 l603AS341 lfiO:lAS342 If;fnASR.l3

01000/1/17 0l00011119 01000/2/20 01000/2/9 01000/2/16 OlOOO/2/5 0l000/2/12 OlOOO1218 00800/4/11 00800/4/12 01000/115 OlOOO/l/6 00800/4/18 0100012124 00800/4/17 OlOOO/2/23 0l000/3/55 00800/2134 01000/3/56 008 0012114 00800/2/18 fN8OO12/19 008 00/2/20 00800/Z/13 00800121136 0080012/166 0080012/137 00800/2/167 00800/2/158 008 00/2/157 008 110/2/118 00800/2/119 00800/2/33 00800/2/35 01000/1/15 01000/3/53 008 00/7/l 01200/l/. 01000/1/22 0100013115 0100013122 OlOOO/l/26 0100013117 01000/3/2 01000/3/4 0080018186 008 0018189 OlOOO/3/18

AG-180AO-MMM-000 001 01 Page 3

f’ARTNUMBER

1603AS344 1603AS346 1603AS347 1603AS348 1603AS350 1603AS356 1603AS358 1603AS360 1603AS361 1603AS371 1603AS372 1603AS392 1603AS395 1603AS396 1603AS397 1603AS398 1603AS402 1603AS403 1603AS404 1603AS407 1603AS409 1603AS410 1603AS412 1603AS416 1603AS420 1603AS421 1603AS426.1 1603AS426.2 1603AS427.100 1603125427.101 1603AS428 1603AS429 1603AS430.1 1603AS430.2 1603AS430.3 1603AS430.4 1603AS430.5 1603AS430.6 1603AS430.8 1603AS430.10 1603AS430.11 1603AS430.12 1603AS430.13 1603AS430.14 1603AS430.15 1603AS430.16 1603AS430.17 1603AS430.18


010 00/3/20 01000/3/31 010 00/3/12 0 10 00/3/S 010 00/3/7 008 0014122 008 0014125 008 00/2/15 008 00/2/l 1 008 00/2/7 01100/111 0 11 00/z/39 008 00/5/21 008 00/5/20 008 00/5/19 008 0015/18 009 00/4/13 009 00/4/19 008 00/2/154 008 00/5/75 011 00/l/30 010 00/l/22 011 00/l/5 011 00/l/16 008 00/2/29 008 00/2/61 008 00/8/68 008 00/S/85 008 0018164 008 00/8/79 01 1 00/l/2 01 I 00/l/15 01 1 0011/11 01 1 00/l/9 01 1 001114 01 1 00/l/3 01 1 00/Z/16 01 1 00/Z/24 01 1 00/2/30 01 1 00/z/29 01 1 00/2/g 01 1 0012/10 01 1 001212 1 01 1 0012123 01 1 0012/22 01 1 001312 01 1 00/313 01 1 00/3/s

PARTNUMBER

1603AS43 1 1603AS43.l 1603AS435 1603ASJ39 1603AS441 1603AS445 1603AS449

1603AS450 1603AS45 1 1603AS452 1603AS453 1603AS455 1603AS458 1603AS459 1603AS460 1603AS461 1603AS471 1603AS475 1603AS477 1603AS480 1603AS482 1603AS486 1603AS487

1603AS488 1603AS489 1603AS509 1603AS5 12 1603AS517 1603AS518 1603AS519 1603AS525 1603AS545.1

1603AS545.2

1603AS.553 1603AS554

1603AS555

1603AS556 1603AS558

1603AS559


011001118 008 00/2/120 008 00/2/l 26 008 00/5/37 008 00/2/108 008 00/2/l 12 008 00/S/69 008 0018183 008 00/S/71 008 00/8/72 008 0018173 008 0018177 008 00/2/95 008 00/8/l 5 008 0018194 008 00/S/93 011 OU11112 008 OW5148 0 I 1 001418 0110014113 008 0015132 011 001411 011 00/4/19 008 0011118 008 00/5/29 011 00/4/- 008 001511 008 00/2/133 008 00/Z/37 010 00/3/28 01 I 00/Z/25 01 1 00/2/17 011 00/2/12 011 00/2/79 009 001211 009 00/3/: 011 0011/17 009 001215 009 00/3/S 011 00/4/21 011 00/2/66 0 1 1 00/4/20 0 1 1 0012157 011 00/4/4 011 00/2/11 008 0015173 009 00/2/- 010 00/5/-

AG-180AO-MMM-000 001 01 Page 4

PART NUMBER

1603AS563

1603AS564- 1

1603AS564.2 1603AS564.3 1603AS564.5

1603AS564.6 1603AS564.7 1603AS564-9 1603AS564.IO 1603AS565 1603AS566 1603AS567.1 1603AS567.2 1603AS568.1 1603AS568.2 1603AS574 1603AS575 1603AS576 1603AS577 1603AS585 1603AS589.3 1603AS589.4 1603AS589-8 1603AS589.9 1603AS589.IO 1603AS589-11 1603AS589.12 1603AS589-13 1603AS590

1603AS591

1603AS592

1603AS593 1603AS594 1603AS595 1603AS596 1603AS597 1603AS601 1603AS602 1603AS604

WORK I’ACKACEI FIGURE NO. INDEX NO

008 00/5/74 009 00/3/- 009 00/2/z 009 0013/z 009 001313 009 001315 009 00/2/J 009 00/3/l 1 009 00131 I 2 009 0013/I 3 009 00/2/7 009 00/2/8 009 00/w 008 00/2/87 009 00/3/4 009 00/3/g 009 001316 009 00/3/10 008 00/8/l 1 008 00/S/5 008 001818 008 00/S/4 008 0018/l 4 009 0015/l 1 008 001617 009 00/5/3 011 0013/12 009 00/6/l 80 009 00/6/l 79 009 0016/l 78 009 00/6/177 008 00/6/S 009 00/5/4 009 00/5/ 15 01100/3/11 009 0015/l 0 009 00/5117 011 00/3/l 1 009 00/5/g 009 00/5/l 4 009 00/5/ 12 008 00/2/l 5 I 009 00/5/- 009 00/5/ I8 009 00/5/- 008 00/2/l 05 00800/l/14 008 00/4/29

PARTNUMBER

1603AS606.1 I603AS606.2 1603AS611 1603AS616 1603AS617 1603AS618 1603AS619 1603AS62:! 1603AS6’L3 1603AS625 1603AS626 1603AS627

I603ASCi’LS 1603AS629 1603AS630 1603AS63 1 1603AS640 1603AS644 1603AS645 1603AS646.3 1603AS646.4 1603AS646.5 1603AS646.6

1603AS646.7 1603AS646.8 1603AS646~9 1603AS647 1603AS648.7 1603AS648-8 1603AS648-10 1603AS648.11 1603AS648.12 1603AS648.13 1603AS648.15 1603AS648.I8 1603AS648-19 1603AS648-22 1603AS648.23 1603AS648.25 I603AS648.4 1 1603AS648-42 1603AS648.44 1603AS648.47 1603AS648.48 1603AS648-51 1603AS648.52

WORK l’ACKAGE/ FIGURIS NO. INDEX NO

008 00/6/l 0 008 00/G/63 008 00/6/86 008 00/7/5 009 00/4/f 005 00/8/l 2 008 00/8/l 3 008 00/4/36 008 00/2/l 63 008 00/l/10 008 00/2/85 008 00/2/94 01 I 00/l/7 008 00/Z/86 008 00/2/80 008 00/2/84 008 00/2/g 1 00800/l/15 008 00/3/33 008 00/5/60 008 00/6/28 008 00/6/l 10 008 00/6/36 008 00/6/47 008 00/6/ 124 008 00/6/52 008 00/G/7 1 008 00/6/l 34 008 0016/108 008 00/6/90 008 00/6/109 008 00/61135 008 00/G/133 008 00/6/l 40 008 00/6/137 008 00/6/l 11 008 00/6/l 28 008 00/6/75 008 00/6/126 008 00/G/125 008 00/G/123 008 00/6/32 008 0016170 008 00/6/l 52 008 00161144 008 00/6/S 008 00/6/29 008 00/6/53

001 01 Page 5

PARTNUMBER

1603AS648.57 1603AS648.68 1603AS648.75 1603AS648-76 1603AS648.77 1603AS648.78 1603AS648.79 1603AS648.80 1603AS649.1 1603AS649.2 1603AS649.3 1603AS649.4 1603AS649.5 1603AS649.6 1603AS649-7 1603AS649.8 1603AS649.9 1603AS649.10 1603AS649.11 1603AS649.12 1603AS650.1 1603AS650.2 1603AS650.3 1603AS650.4 1603AS650.5 1603AS650.6 1603AS650.7 1603AS652.1 1603AS652.2 1603AS652.3 1603AS653 1603AS654 1603AS655 1603AS657 1603AS658 1603AS659.2 1603AS661 1603AS662.1 1603AS662.2 1603AS663 1603AS665 1603AS666

1603AS667 1603AS669 1603AS670 1603AS671

WORK I’ACKAGEI FIGURE NO. INDEXNO

008 0016/147 008 00/6/l 56 008 00/6/72 008 00/G/67 008 00/G/65 008 00/6/62 008 00/G/5 1 008 00/6/48 008 00/6/23 008 0016193 008 00/6/l 12 008 0016/l 57 008 00/6/158 008 00/G/3 1 008 00/G/122 008 0016041 008 00/6/142 008 0016/49 008 00/6/64 008 1)0/6/66 008 00/6/166 008 00/6/l 008 00/6/35 008 00/G/46 008 00/6/50 008 0016173 008 00/6/132 008 00/6/4 008 00/6/33 008 0016177 008 00/G/59 008 00/5/66 008/00/5/52 011 001212 011 00/z/3 008 00/6/74 0 11 00/z/4 008 00/6/l 1 008 00/G/168 008 00/6/55 008 00/6/69 008 00/2/S 008 UO/2/98 008/00/2/123 008 00/6/19 008 0016/169 008 0018189 008 0015/12

WI

PART NUMBER

1603AS672 1603AS674 1603AS675 1603AS6’77 1603AS678 1603AS683.1 1603AS683.2

1603AS683.4

1603AS684

1603AS685 1603AS686 1603ASG87 1603AS688 1603AS688

1603AS691 1603AS692.1 1603AS692.2 1603AS692~3 1603AS692.4 1603AS692.5 1603AS692.6 1603AS692.7 1603AS692.8 1603AS699 1603AS707 1603AS708 1603AS709

1603AS710

1603AS711

1603AS712

1603AS713

DRKPACKACEI FIGURENO. INDEXNO

0 11 0012169 011 00/2/78 008 00/2/23 008 0012155 008 00/2/24 011 00/2/77 009 oo/lf4 012 00/l/14 008 00/G/3 009 00/l/8 009 00/4/g 008 00/2/43 008 00/2/54

008 0012173 008 00/5/56 008 00/2/32 008 00/2/10 008 00/2/75 008 00/2/100 008 00/2/103 008 00121125 008 00/2/159 008 0012/101 010 00/4/28 010 00/4/30 010 00/4/32 0 10 00/4/34 010 0014136 010 00/4/11 010 00/4/3 010 00/4/35 011 00/2/31 008 00/5/44 008 00/5/49 OlO/TBLl/14 010 00/4/l 010 00/l/44 Of0 OO/TBL1/15 010 00/4/5 010 OO/TBLl/f7 0 10 00/4/g 010 00/l/47 010 OO/TBL1/16 010 001403 010 00/l/19 010 OO/TBL1/19 010 00/4/17

AG-180AO-MMM-000 001 01 Page 6

I’ART NUMBER

1603AS714

l603AS715

1603AS716

1603AS717 1603AS718

1603AS719 1603AS720 1603AS72 1 1603AS722 1603AS727 1603AS733 1603AS734 1603AS735 1603AS736 1603AS737 1603AS739 1603AS740

1603AS741 1603AS742 1603AS743 1603AS744 1603AS745 1603AS746 1603AS747 1603AS748 1603AS749 1603AS750 1603AS751 1603AS752 1603AS753 1603AS755 1603AS756 1603AS757 1603AS758 1603AS759 1603AS760 1603AS761 1603AS762

W ‘ORK I’ACKAGISI FIGURE NO. INDEX NO

010 0011158 OlOOO/TBL11l8 0100014121 01000/T1~1.1/21 0 10 0014125 0100011138 01000iT1~1.1120 0 10 0014136 OlOOO/TBLl/l2 008 0012145 008 00/2/56 008 00/5/40 0 I 1 00/2/5 1 0 11 00/2/52 0 1100/2/70 0 11 00/Z/67 0 1100/2/6 0 1100/2/B 0 11 00/2/7 011 00/2/5 0 1100/2/l 008 00/2/44 008 00/2/46 008 00/2/57 008 00/2/39 008 00/Z/50 008 OO/U59 008 00/2/48 008 00/2/60 008 00/2/49 005 00/5/l 3 008 00/3/24 009 00/5/B 008 00/3/l? 008 00/3/25 008 00/6/l 16 008 00/6/l 19 008 00/6/l 18 008 00/6/l 30 008 00/6/l 38 008 00/6/105 008 00/6/l 15 008 00/6/I 00 008 00/6/99 008 00/6/l 13

I’AHTNUMBER

1603AS763 1603AS764 1603AS765 1603AS766 1603AS767 1603AS768 1603AS769 1603AS770 1603AS771 1603AS772 1603AS773 1603AS774 1603AS775 1603AS776 1603AS777 1603AS778 1603AS779 1603AS780 1603AS781 I603AS782 I603AS783 1603AS785 1603AS788 1603AS789 1603AS790 1603AS791 1603AS792 1603AS793 1603AS794 1603AS795 1603AS796

1603AS798 l603ASBOO

1603AS801 1603AS804 1603AS806 1603AS807 1603AS811 1603AS812 1603AS818- f 1603ASSlB-2 1603AS821


008 00/6/91 008 00/6/94 008 00/6/176 008 00/6192 008 0016137 008 00/6/24 008/00/6/12 008 00/G/131 008/00/6/41 008 00/6/153 00800/6/159 00800/61160 00800/F/148 008 00/6/149 00800/6/167 00800/61154 008 00/6/17 008 00161121 008 00/6/107 008 00/6/127 008 00/G/45 008 00/6/136 009 00/5/16 009 00/5/7 008 00/6/175 00800/G/170 012 00/l/15 011 00/3/7 011 00/3/13 00900/5/5 008 00/S/99 009 00/5/2 009 00/5/6 01100/2/31 011 00/3/- 011 00/3/l 011 00/3/14 011 00/3/10 011 00/3/6 011 0013121 0 11 00/3/20 00900/2/3 009 00/2/6 009 00/5/l 012 00/1/13 I

AG-180AO-MMM-000 15 May 1991

II01 02 Page 1 of 2

NUMERICAL INDEX OF REFERENCE DESIGNATORS

ORCANI%A’lTONALANLl INTERMEDIATE MAINTENANCE WITH IPB


A/M32C-21


Ref Des

Bl 82 133 B4 is5 Il6

Cl c2 CBl CTCO

Ix%1 I)S2 DS3 DS4 DS5 DSG 1x97

KPR ET1

Fl F2 F3 F4 F5 k'6 1'7 F8 F9 I:10 I:1 1 PI2 1,’ 1 3 E‘CS FSW

WP N&Fig No./ Index No.

008 00/5/13 012 OO/l/- 00800/3/24 011 00/2/f] 011 00/4/22 00 11 00/3/7

011 0012/57 011 00/4/4 010 0011128 012 00/l/10

010 00/l/22 010 0013122 010 00/3/22 010 00/3/22 010 00/u/37 010 00/3/37 010 00/l/22

008OO/fi154 010 00/3/43

010 00/2/16 010 00/2/16 010 00/2/16 010 00/2/19 010 00/2/19 010 00/2/19 010 00/2/5 010 00/2/5 010 001215 010 00/2/1‘2 010 00/2/12 010 00/2/12 010 00/2/S 0 10 00/o/34 009 0014128

l603ASl28 1603AS32-1 i603ASl29 1603ASl-18 1603ASl48 1603AS793

1603AS555 1603AS5.55 1603ASl50

1603AS325.1 1603AS325.2 1603As325.2 1603AS325~2 1603ASl69 l603ASl69 1603AS325.1

1603ASl39 1603ASl51

1603AS320.1 1603AS320.1 1603AS320- 1 1603ASl65 1603ASl6.5 1603ASl65 1603AS320.2 1603AS320-2 1603AS320.2 l603AS321-1 1603AS321.1 1603AS321-1 1603/\5321-2 1IS24523~27 I6O:jASl58

Ref Des WI’ No./Fig No./ Index No.

I I PC0 OlJ9 OO/li’Z

.J 1 ,J2 .J3 .J4

010 00/1!44 010 0011147 010 0011158 nl0 00/l/38

Kl K2 K3 K4 K5

010 00/1141 010 00/l/50 010 00/l/61 010 00/1131 0100011157

I.PCO 0090014122 IS1 01100/2/74 I.S2 01100/2/74 IS3 01100/4/15 IS4 01100/4/15

OS 009 00/4/l

I’1 P2 1'3 1'4 I’S1 PS2 I’S3 I’S4 I’S5 I’S6

u 10 00/4/l 0 10 00/4!9 00 00/4/l 9 010 0014125 009 00/1/1 009 00/l/4 009 00/l/4 009 00/4/10 009 00/4/10 009 0014116

Sl 52 s3 s4 55 S6

008OO/G12 1603ASl37 008 001612 1603ASl37 00800/6/143 1603ASl40 00800/6/155 1603ASl42 008 0016176 1603ASl35 008 olm5 1603ASl38-2

I’iN

1603ASI 60

1603,\S710 1603AS7 12 1603,\s714 lm3x716

1603AS280 1603,1S278 1603AS279 1603ASl61 1603ASl67

1603ASl59 1603ASl70 1603AS170 I 1603AS170 1603ASl70

1603ASl63

1603AS709 1603AS711 1603AS713 1603AS715 1603ASl46 1603ASl47 1603ASl47 1603ASl74 1603ASl7-l 1603ASl75

AG-180AO-M M M-000

Kef Des

SW1 SW2 SW3

SW4

TRI TKI

u1

WP No.iFie. No. Index No.

I’iN -

0l00013/18 n10 on/3/20 II IO 00/3ml

I6l)3AS3-u I6ODAS3J-l 1603ASl68

0 IO 00/3/28 1603AS512

0100013112 1603AS317 010 0011164 I603AS119

012001112

001 02 Page 2

Krf Iks WI’ No./E’ig No./ y!J Index No.

L.2 012 00/l/2

VI 008 00/6/129 1603AsI:%I I V2 008 00/6/l 17 l603ASI33 v3 008 00/6/l 42 I603ASIII v4 008 0016/lfl l603AS1-13

XI 008 00/6/l 47 I603ASl:j8. I 52 008 00/6/l 47 Ifio3AsI:15.l x :3 008 00/6/5 16clnAsl:Is.~ s-l I108 00/6/5 1603ASI:18 2

AG-1 $OAO-M M M-000 002 00 15 May 1991 Page 1 of 4

1N’I’KOI)IJCTION

OHGANI%A’i’IONAL ANI) INT~KME:I)IA’I‘I.: MAINTKNANCE

WITH ILLI.!STHAT~I) PARTS HHEAKDOWN

AIR CONDITION~H. AIHCHAFT GHOUNI) COOLING

A/.M02C-21


1. f’CRPOSIC OE’\IASLAI.. This listing is used 11) Iocat~ desired WI’ requlwd Lo perform specific maintenance tusk.

2. This milnuill provides organizational and intermediate maintenance instructions with illustrated 5. QCAI.ITY ASSLRASCb: R~:t~LIRII!vl~:STS. purts breakdown for the AiMRZC-21 Ail

1 Conditioner, part ~numhcr 1603ASlOO.1. 6. Certain prwcduws or steps in the manual are follrwcd with “QA” in parcnthcsis. Improper pcr-

3. AKRASCE~lI<S’f OF IIASUAI.,

4. This manual contains an alphabetical index a~suranw inspection of each (“QA”) step previously work package (Wf’l, an introductory \Vf’ and tech. auxmplishcd shall he made prior to proceeding to nictil content WPs. Technical WI’s arc independent, next st~.p unless it can hc determined that such self-contained procedures that ma? he used LIS inspection can he pcrformcd after completing entire handouts to support specific functional tahks. Kach procedure. WP is maintained 3s a separate entity: changes result in a reissue of the specific Wf’. WPs are 7. RF:CORI) OF’ APPI.ICAHI.E TECHNICAL identified hv unique, five digit numbers appearing l)ltwx-fvt:s. in upper rjght hand corner of each page. The numher provides a means of locating WI’s that hove 8. Technical directives applicable to this manual been storedon microfilm, permits rapid asscmhly of are listed helow by directive type/number, date of LL completc manutil, and is used for referencing issue, title, date of incorporation, and remarks. within the manu:ll. I\ numwical index of effective These technical directives also appear an title page WPs, listing all WI’s, is pru\,ided on the “A” page. of each suhscquent applicable WP.

TvpeiNumber Date Title and ECI’ No. Date Incorporated Hemarks

AG-180AO-MMM-000 002 00 Page 2

9. INTRODUCTION TO THE ILLUSTRATED PARTS BREAKDOWN.

10. GENERAL. The complete Illwr:~ted Parts Breakdown (IPB) contains information applicable to the A/VM32C-21 Air Conditioner, part number

1 1603ASlOO-1, manufactured by Engineered Air Systems, Inc. It lists and describes the parts necessary for equipment support and is used for requisitioning, and identifying parts, and for illustrating disassembly and assembly rela- tionships.

11. GROUP ASSEMBLY PARTS LIST (GAPLI. The GAPL consists of B breakdown of the complete unit into subassemblies and detail parts. Attaching parts are identified immediately following the item they attach. The GAPL is a five column format. All symbols and abbreviations used in the GAPL are in accordance with MIL-STD.12, Abbreviations For Use On Drawings and in ‘Technical Type Publications.

12. Index Sumber. In this column the index numbers are assigned in numerical sequence and are essentially in disassembly sequence. After the index numbers are assigned in this column, they are then added to the line art exploded view of the equipment/repairable.

13. Part Kumber. This column lists the prime contractor part number, government standard part number or other vendor part number.

14. Description. This column lists the item nomenclature plus those modifiers necessuy to identify the item. The assemblies, subassemblies, detail parts and attaching parts xe properly idcnti- fied (named or indented) to show their relationship to the assembly. Attaching parts are listed immediately after the part they attach and preceding any details of the assembly. The cnption /ATTACHING PARTS/ nppcars in the description column preceding the attaching parts ond the symbol ---*--. is used to indicate the end of the attaching parts for that part or assembly.

15. Vendor Codes. Part numbers other than those of E:nginecred Air Systems Inc. and stundard p;lrts arc designated by vendor code numbers in / / following the nomenclature, in accordance with the F&t-al Supply Code For !vlanufacturcrs Cataloging Ilandhook 114 and 113. If il code has not been assigned, the vendor’s complctc name and ;~ddrws will appear.

16. MMake From. For those simple items, i.e., hoses, lines, tubes, brackets, cables, etc., coded for local manufxture. the material from which the item is numufxtured will be included in / / after the item nomenclature or vendor code number.

17. Units Per Assemhlv. This column will list the total number of each part required per assembly or subassembly and ilre not necessarily the total number used in the end item of equipment. The letters “AK” iAs Required) xe used to identify bulk items. The abbreviation “REF.’ indicates Reference and indicates the part has been listed and illustrated elsewhere in the IPB and is included in the present listing for reference only.

18. Usable On Code. This column indicates the usability of parts on different models 01’ series of the equipment. If no letter ~ppenrs in this column. the part may he used on all models/series of the end item of equipment. Csable On codes :~I‘c listed following the Introduction To The Illustrated Parts Breakdown in each applicable \Vork Package.

19. Source. Maintenance ;tnd Recoverahilitv Code (SM&R). This column contains the S&\&R codes as assigned by the government. Defmitions of these codes and parts kits information are contained in NAVAIRINST 4423.3.

20. NUMERICAL INDEX. The Numerical Index (WP 001 01) is a complete alphanumeric tabulation of part numbers or noun names if a part number has not been assigned. Alphabetic “0”s nre considered numeric zeros.

21. Part Number Column. This column lists itll part numbers that appear in the Part Number column of the GAPL. This column also lists the identifying noun in lieu of part numhcr when no part number has been assigned. Part numbers are listed in alphanumeric sequence.

22. Work Paekape/Fi~[u~~/lndeu Sumher. This column lists the WPiFigilndcs So. assigned to the associated part number. The numbers are sepalatcd hy slashes. The first number is the Work Package in which the part number is located. The second number is the Figure Number within the WP and the third numhcr is the index numhcr identifying the part within thu ligure.

AG-180AO-MMM-000 002 00 Page 3/(4 Blank)

:30. I”wm the illustr;ltion, ohtain the index number ;,ssigncd to the part number. Rcfcr 11) the CAPI. for the idcntifvinr noun nnmc and NY othw specific inliwmution including the item part numhcr.

24, Rcfcrencc I)csiEnation (Refl)es) Column. This column lists the xssigncd rcferencc designation symbols. ;~rrangcd in alphanumeric sequcncc. This list contains xll refcrcncc dcsign;ition symbols contained in schematic diagrams and text pertain- ing trl thccquipment covcrcd hy the lf’li.

25. Work I’ackng!c/l:irru~e/lnder: Column. This column contains the Work Package, Figure and Index Numhcr reference for the part assigned the reference designation.

26 Part Numhcv Column. This column lists thv part number of the itum assiqncd the specific wli:r- encedesign~~tion.

112 Turn to the WP and Figure indicated itnd Iocatc the index number refercncc.

:1.l When The Rcfcrcnce I)csi?(nation Is Known. Refer to the Rcfcrencc I)wi~n;ltion Index (WI’ 001 1121~ I.ocatc the rcfewncc designation and note lhc Work I?jckagc, Figure :Llld lndcv Numher and the Part Sumhcr assitrncd to the RcfDes.

provided to help the user find items in the IPI<.

28. When The Part Numhur Is Not Known Determine the function and application of the part required. Turn to the Alphabetical Index (WI’ 001 001 und selccl the most appropriate Croup, System or Component Work Package.

Xi Turn to the WI’ and I’iqre indicated and locate the lndc Sumher rcfcrcncc in the RofDes Index.

36. If a pictorinl rcprcscntation of the part, or its Iowtion. is desired, rcfcr to the snme index numher ton the accompanying illustration.

AG-180AO-MM M-000 003 00 15 May 1991 Page 1 of 16

OKGANI%ATIONAI.ANI) INT~KM~I)IATE MAINTE:NANCE

AIK CONI)ITIONEK. AIKCKAFT CKOUNI) COOLING

AiMXX-21


Keference Material

Sane

Suhiect Alphabetical Index

,\/\132C-21 Comprmcnt I.ocator ;\/\13LC-21 Elcctric~l Schcnutic : : : : : : : : : : : : : : : :

2 I I

.\/.U32C 21 Rcfrigcratian Contwl Sntetn Schematic 13

.\/\I3!2C-21 Airflow Control System Schematic. 14 Ikscriptiun. ., I.cadinz Particulars..

: : : : : : : : 1: : : : : : : : 1: : 1: 1: : : 1: : 1: 1:: 1: : 1: : 1;

I’~inci~~le~~~fOperiltion. Conditinwd Airflow.

:t

C,,olin~\I,,dc............,.,. ,..~,::I:::::::::::::::::::::::::::::::::’:::: 17 I)ehulni[lilicati~,n .\lodc 16 I:lcclrical ;lnd Cnntwl Function.. 15 kntcring Airflow.. ..~...................... 17 Unit Operation. 15 Ventil~ti~~n~Mode........,....,:::.::::::::.:::::~:::::::::~::::::::::::::::: 15

System Description 1 IllOWC~..................... ..~.......................................... 15 CondenserCoils......................................................... CondenserFan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 15

Contr~,l~anrls............................................................... 15 F.vaporalorCoil~.........~................................................... 15 Kefrigor;lnt Compressor. I Vehicle.................................................................... 15

Tohlc I, I.cxling I’articulars 6

Kecord of Applicable Technical IXrectives

1Vwlc

I. DESCKII’TION 3. SYSTEM DESCRIPTION

2. The air conditi,,ncr (figure I) is dusigncd to pruvidc ventilntion, dchulnidificntior1, cooling:, and fiItr;rtion ofair for clcctwnic equipment. The unit is

4. The air conditioner (figure 1) is a mobile, troiler- mounted, clcctric-powered, self-contained air conditioner. The unit is powered by 440 volt, 3 phase (A, I%, Cl, 60 Hz electric motors.

intended for, hut not limited to, air conditioning airplane cabins and aircraft equipment com- partments.

5. K~FKIC~~KANT COMPRESSOR. The refrigerant system uses an accessible-hermetic, six-cylinder

I

I

I I I

AG-180AO-MMM-000 00300 Page 2

14'

16’

17

26,

Figure 1. A/M32C-21 Component Locator (Sheet 1 of 4)

AG-180AO-MMM-000 003 00 Page 3

Figure 1. AlM32G21 Component Locator (Sheet 2)

AG-180AO-MMM-000 003 00 Page 4

Flgure 1. A/M32C-21 Component Locator (Sheet 3)

AG-180AO-MMM-000 Page 5

ITEM UUMBER NOMENCLATURE

I IDuct storilgc Access Do01 2 “ondcnscr Fnn Panel Asscmhl.~ 3 Rear Condcnscr Fan Pancl 4 Cabinet Top 5 Instrument Panel Cowr Assumhly 6 I~lower Oil Fill Access I)oor 7 !)uter Fuse Bos Cover a Klectrieul Controls Panel 9 Roadside Panel

10 BlowzrlFiltcr Drier Access Door 11 &down Ring 12 Condenser Coil Grille 13 Handbrake 14 Lifting Ring 15 Front Panel 16 Front Condenser Fun Panel 17 Pressure Controls Access Door 18 Comp~cssorlReceiverl\cccss Door 19 Condcnscr Coil Grille 20 Curhsidc Panel 21 Discharge Duct Cover 22 Curhsidc Rear Panel 23 Pressure Tap Access Doors 24 Filter Access Door 25 Sightglass Access Door 26 Roadside Rear Panel 27 Head Pressure Regulator Valve (VI) 28 Unloader Solenoid 29 Compressor 30 Condenser Fan 31 Bypass Valve Asscmhly 32 Airflow Controller 33 Blower 34 Aftercooler Sightglass 35 Precooler Sightglass 36 Pressure Differential Switch (1’52, I’S31 37 Pressure Diffcrcnlial Switch (PSI) 38 Pumpdown Solenoid Valve (S5)

ITEM KJMBER

39 40 41 42 43 44 45 46 47 48 49 50

51

52

53 54 55 56 51 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

NOMENCLATURE

FillcrlDricr Assembly Blower to Molar Coupling Roadside Condcnscr Asscml~ly Blower ,MOlW Receiver Asscmhly IlOl Gus Bypass Valve (V3) llot Gas Solenoid Vulvc cS3, Atmospheric ReliefValw(V2) Receiver Outlet Valve Receiver lnlct Valve Oil Pressure Switch (OS) Pressure Diffwenlial Switch

(Close on Pressure Rise) (PS4) Pressure Diffewntial Swilch

(Close on Pwssurc Kise (PS5) Pressure Diffcrcnlial Switch

(Open on Pressure Rise (PS6) Low Pressure Switch ILPCO) Fan Cycling Switch (FSW) High I’resr;ureSwitch(lll’CO) Blower Oil Fill Plug Evapo~iltor l’rcssurc Regulator IKI’R) E:vaporator Solenoid Valve (S2) Evaporator Solenoid Valve (Sl) Condenser Fan Molar Thermostatic Expansion Valve (X3) Thermostatic bpansion Valve (Xl) Curbside Condenser Assembly Evaporator Solenoid Valve (S6) Thermostalic Expansion Valve o(4) Quench Valve (V4) Quench Valve Solenoid (S4) Thermoslalic I’:rpansion Valve (X21 Aftercooler ,Modulc lnstrumenl Panel Suhnsscmhly Precoolcr 1Module Flexible Duel

Flgure 1. A/M32C21 Component Locator (Sheet 4)

AG-180AO-MMM-000

3. CONI)bINSC:H COklI’ONE:N’t‘S

CoIIdcIIscI.: .sxv.v I’urt .so :

Curtwide Rwdsidc

‘I’ypc Finned Dimensions (inl:

Ixngth Width tlcight

Circuits t’asws:

7 Circuits 2 Circuits

sut,coolcr: Circuits PilSSL1S

1)r.v Weight (11~)

003 00 Page 6

Rointion I I.wking at Outlet1 C~~ut~t~~~l,~c~wi~;e t)vivc I)ilTct t)iamctcr(in) 42.0 Ilushin!: PI

savy Put so. l6O3AS7.50 Ibrc lin) l.62

Weight (with hushing) (11,s) 13.8 Fill1 51lltw

saw I’dIT so T&

I603ASl29 ‘1‘KFC

I IoM!po\wl 7.5 Voltuge 230/460 Ilz 60 Phase 3 (A,R.C) Speed (~-pm) I200 Weight (lbs) 123.5

4. RI.OWKR COMI’ONENTS

1603Ast23 CeIltriliI~lI

100 I)irecL

3600 I5000

If0

t603ASl28

AC-180AO-MMM-000 003 00 Page 7

TYPO ‘IXFC llorsepower 30 Voltage 460 112 60 Phase 3 (A.H,CI Speed kpm) 3600 Weight (Ihs) 214

5. KEFKIGEKAN1‘COMI’ONEN’~S

lh pansion Valves: Precooler (Xl) x2, x31:

Navy Part No. x1,x2 x3

Type Superheat Setting !‘N

Artcrcooler 1x4): Navy Part No. TYPC Superheat Setting (“Fj

Solenoid Valves: I’rccooler IS1 and S2):

Navy Part No. TYPO Voltage Hz Phase

Aftercoolcr I%): Navy Pal+. No. Type Voltage Ilz Phase

Ilot Gas Bypass (53): Navy Part No. TYPO Voltage HZ Phase

Quench (S4): Navy Part No. TYPO Vokagc Hz Phase

Pumpdown (S5): Navy Part No. TYPO Voltage Hz

I 603AS138- I I603ASl38-2 Thcr”wstulic

8

lf30i\Sl38-2 ‘I’hornwst~tic

8

Phase I w:

livuporator Pressuu! Kegulator (l<PlU: Navy Purl No. lG03ASl39 Type Open on rise i” inlet pressxe I’rcsww Adjustment (psig) 0 to 75 Pressure Sctpoint (prig) 55

lleadl’ressurc Kcgulator(V1): .Uavy Part so. lfiO3AS131 ‘l-.&W Openso” rise in inlet pressure Pressure Adjustment (psig) 65 to 225 Prussurc Setpoint (psig) 225

Receiver blief(V2): Navy Part No. 1603ASl33 KeliefSetpoint tpsig) 450

I lot Gas Bypass (V3): Navy Part No. 1603AS141 TYPO Opens on drop in

downstream pressure Pressure Adjustment ~psig) ,5.=J to 70 I’rcssurc Setpoint (psig) 55

1603ASl37 Normnlly closed

II0 60

1

Quench (V4): Navy Part No. Type

I603<\Sl43 Thermostatic Expansion

1603ASl37 Sor~nally closed

II0 GO

1

1603ASl40 Sormlly closed

110 GO

I

1603AS142 Sorn~ally closed

110 GO

I

Sightglasses: Precooler:

Savy Part No. Color wet Color Dry

Aftercooler: Navy Part No. Color wet Color Dry

Filter/Drier: Navy Part No.:

llousing COW

Rcccivcr: savy Pa!? so. Dry Weight (Ihs) Capxity Ilbs)

I:v<lpl,rators: I’rccrmlcr:

Navv I’art so. T.Vpi

1603ASl35 I’inncd Dimensions (ill): Sormally closed Ixngth

110 Width 60 lleight

1603ASI 36.2 Green

Yellow

lG03ASl36-I Crccn

Yellow

I603ASl34 163OASli2

163OAS125 96

130

Ic,O3/\Sl22 Tllk/l:i”

33 5,2 I5

AC-I 80AO-M M M-000 003 00 Page 8

Saw Part No. lGO3ASl53

Page 9/(10 Blank)

AG-180AO-MMM-000 003 00 Page 13

FILTER DRIER

COMPRESSOR SUCTION SERVICE VALVE

COMPRESSOR DISCHARGE

VlBRATlilN

CONOENSERS

VIBRATION ELIMINATOR

PRECO”‘ F--

I SIGHT GLASS

LEGEND

INLET-SERVICE VALVE INLET-SERVICE VALVE OUTLET-SERVICE VALVE OUTLET-SERVICE VALVE

Sl- EVAPORATOR SOLENOID VALVE Sl- EVAPORATOR SOLENOID VALVE SZ-EVAPORATORSOLENOIO VALVE SZ-EVAPORATORSOLENOIO VALVE %I- HOT GAS SOLENOID VALVE %I- HOT GAS SOLENOID VALVE S4- DUENCH SOLENOID VALVE S4- DUENCH SOLENOID VALVE SS-PUMPOOWN SOLENOID VALVE SS-PUMPOOWN SOLENOID VALVE SS-EVAPORATOR SOLENOID VALVE SS-EVAPORATOR SOLENOID VALVE

V,.HEAO PRESSURE REGULATOR VALVE VZ-ATMOSPHERIC RELIEF VALVE VS-HOT GAS BYPASS VALVE V4-OUENCH VALVE Xl -TtlERMilSTATlC EXPANSION VALVE X2-THERMOSTATIC EXPANSION VALVE X3-THERMOSTATIC EXPANSION VALVE X4-THERMOSTATIC EXPANSION VALVE

EPR-EVAPORATOR PRESSURE REGULATOR

Figure 3. A/M32C-21 Refrigeration Control System Schematic (Sheet 1 of 2)

AG-180AO-MMM-000

EL- DAMPER

PAECOOLEA AFTCR COOLER

003 00 Page 14

BLOWER

e fi

BYPASS OAMPER

LEGEND

PSI OELIVEREOAIRFLOW CONTROL SWITCH

PSZ- BYPASS AIRFLOW CONTROL SWITCH

PS3- BYPASSAIRFLOW CONTROLSWITCH

Figure 3. A/M32C-21 Airflow Control System Schematic (Sheet 2)

AC-1 80AO-M M M-000 003 00 Page 15

Lre~~d Lircs. Two swivel shock absorbing wheels arc provided on the center front of the unit. The wan wheels incorporate parking brakes that arc applied or released hy LI single manual control lever 113, ligure I) located at the front of the unit. The Lrailc~ is of welded steel construction. Access panels and doors are provided for full accessibility. Eight Licdown rings (I I) are provided on the lower frame. I.‘ouI. lifting rings (14) are mounted on the upper coI’llcrs.

12. I.E:AI)ING I’AH’I‘ICUI.AKS

1-I. I’KINCII’I.E:S 0FOI’~:KA’I‘ION

IS. KI.IC’l’I~ICAI, AND COSTIWI. l~‘CSC’l’I0.U (SW li~uw 21. I’owcr for operation of the unit and the clcctrical and control function is supplied from a 4.N wit, :I phase (A, 13, C), fi0 I II. so~~rcc connected to the unit hy Lhc power cable. The cahlc is connected at thu t‘wr of the unit. From the receptacle Lhc power is carried through Lhc main circuit breaker. The full 140 volt prnvcr is sent to the motor starters. I\ 0.3 KVA transformer is used in the circuit Lo IOWCI. Lhc voltage from 440 volts AC to I IO volts AC for control and instrument opcrution for the electrical and control function.

16. Placing the C[I<CUI’I‘ HI<I~:AKI:K in the OS position connects power to the circuits and lights the I’OWEl~ ON lights, IIS1 and US7 and cncrgizcs phase loss relay K5. closing contacts K5XL. Kr)Luting the PASI~ZI. l.IGIITS switch S\VI LO the right will light the panel lights, 1155 and DS6. Continued rotation of the switch Lo the tight will incrc’asc the brightness: rotation to Lhc left will decwue the brightness.

17. USI’I‘ OI’~~I~A’l‘IOS (figure 3). The iti! conditioning unit is started by placing the .1lOl)l~: switch, SW3, in the VEST position.

18. \‘I~S’I‘II,ATIOS 1lOl)E The vcntilotion mode is c.nc’~.~ixcI when S\VR is set Lo the VI,:S’I positiun and the S’I‘Al<‘I‘ switch, SWI, is pushed In addition 111 S\V3, power is supplied. through SFVI, Lo Lho 11I.OWI:ll .Uo’1‘Ol~SI’AI~I‘E:I1, Kl, con~prcswr start time delay wlil., K4 and I:l.Al’SI:l) TIMi< ~ItYI‘I~:I~. li’l‘l. The yellow VIIS’I’ light. IXL. will light. The following will occur:

AG-180AO-MMM-000 003 00 Page 16

19. ‘l’hc Kl contacts will close, the blower will start up, and ventilation air will bc delivered.

I 20. Auxiliary contacts KlX4 will close a holding circuit, enabling the system to remain on aRer SW1 is released.

21. After ten seconds, the K3Xl contacts will close cnablin~ the comp~cssor to start up when SW3 is moved tocilhcr I~ISIIUMll~o~COOI..

22. I’owcr will hc supplied to the dclivcwd ilir Ilow control switch, E’CS, through the delivcrcd air flow rclicfswilch, I’SI. enabling the dclivcwd ilir flow lo

m bc regulated.

23. Power will bc supplied to lhc bypass oil- flow control switches, I’S2 and I’S:%, cnxhliu~ the I~~P;ISS air flow to bc reyulatcd.

2-l. I~~:l1U.~II~I~ICA’~~O~ 4lOl)li. ‘I’hc dchumi- dification mode is cncr~izcd when SW3 is set to the I)KIIUMlI) position. This mode is used to I~IIID\‘C moisture from the conditioned ilir and dclivcr warm, dry air. The conditioned air is supplied at tcmpcriltwcs ~reoter thun 90dcgwes F. When SW3 is moved to the I)~~lILMII) position, the followinq will occur:

25. Powor will hc supplied lo the compressor motor starter, K2, and condcnscr fan motor starter, K3:

26. The K2 and K3 conliwts will close, lhq comprcssol-and condcnscr Fan will sturt;

27. The pumpdown solenoid valve, S5, pre-

I

cooler solenoid valves, Sl and S2, will be energized and the compressor will be unloaded by energizing the unloader solenoid valves, Ul and U2, will open;

28. IX52 will go out, und the yellow I)liIICMII) light, 11%. will illuminate.

29. Dehumidified air will bc dclivcrcd. ‘l’hc operation is as rollows:

ilir thwu~h the condcnsin:: wits. and this ilir removes heist from the hot refrigerant gas. ‘The refrigerant condenses and le~~ves the coils ;,s liquid.

31. ‘I’hc refrijiewnt liquid is then routed lo the IV- ceivcr, whcrc the csccss is stored until called upon by denund, from the receiver to the subcooler (o sm~dler section of the condenser coil used lo remove additional heat lo ensure that liquid does not flash to LI g;w due to piping pwssurc drop) ctnd t!lcn to the filtetYdricr.

35. ‘l’hc u,nditil,ncd ilir Iravinr: thl, pwcooler cri\lI- orxtl)l’ coil is con~wllr:d Lo il dewp~~int of 40 dcgrccs 1,‘ nuximum, the I~N~~LIIY condensed from the ilir is collcctcd on the mist climinutor :lnd druincd from the unit by a drain pump as controlled by float switch S7. The air is then reheated by the I heat of compression as it passes through the centrifugal blower and is delivered at temp- eratures of 90 degrees F and above.

36. PS4 and PS5 are staged to control Sl, S2, Ul, and U2 so that, as the conditioned air I heat load decreases, the precooler evaporator heat exchange surface area and compressor capacity can be reduced to match the system operating point to the heat load.

AG-18OAO-MMM-000 003 00 Page 17/(18 Blank)

AG-180AO-MMM-000 15 May 1991

004 00 Page 1 of 4


PREPARATION FOR iJSE. STORAGE, AND SHIPMENT


AIM32C-21


Reference Material

I’reoperatiorul MGntenancc Requirement Cards. AC-180AO.MRC-000

Alphabetical Index Subiect r&&

I’rcpaution for Shipment.. 2 Prepar:ltion for Storage 2 Preparation For Use I’reparationForUse,StorageandShipment .: :::::

1 3

Record of ApplicableTechnical Directives

1. PKHPARATION FOR USE

Support Equipment Required

NO"C!

Materials Required NO"t?

a. Remove all wrapping, packaging and adhc- sive tape from unit. MMake sure that ducts, doors and grillesare free ofobstruction.

b. Kemove blocks or wheel chocks from under unit.

c. Inspect unit for damage.

d. open C~MPRESSORIKIXEIVER r\ccms door by turning grip latches counterclockwise.

e. Remove valve caps (3 and 4, figure I) from receiver inlet and outlet shutoff valves (1 and 2) and open valves (I and 2) by turning valve stems counterclockwise.

f. Remove condenser fan panel assembly (WP 008 00).

g. Kemove valve caps (5 and 7) from compressor suction and discharge valves (6 and 8) and open valves (6 and 8) by turning valve stems counterclockwise.

h. Install valve caps (5 and 7) on compressor suction and discharge valves (6 and 8).

i. Install valve caps (3 and 4) on receiver inlet and outlet shutoff wives (1 and 2).

O08J60,. Install condenser fan panel assembly (WP

k. Close COMPRESSOIURECEIVER ACCESS door and secure with grip latches.

I. Perform preoperational maintenance func tions (AC-180AO-MRC-000).

AG-180AO-MMM-000 004 00 Page 2

2. PREPARATION FOR STORAGE

Support Equipment Required None

Materials Required

Specification or Part No.

MIL-D-3464 MIL-P-131C,Class 1 PPP-T-GO, Type Ill, Class I

Nomenclature Dessicant Bags Barrier Material Tape, pressure sensitive

a. Remove condenser fan panel assembly (WP 008 00).

b. Remove valve cap (3, figure 1) on receiver outlet shutoff \,alve (21 and close valve (2) by turning valve stem clockwise.

c. Install valve cap (3).

d. Start and operate compressor by switching to COOL or DEHUXIID mode. Operate unit and allow compressor to run until it shuts off.

e. Remove valve cap (4) on receiver inlet shutoff valve (1) and close valve by turning valve stem clockwise.

f. Install valve cap (4)

g. Close compressor suction and discharge valves (6 and 8) by removing valve caps (5 and 7) and turning stems clockwise until snug.

h. Install valve caps (5 and 7).

j. Set CIRCUIT BREAKER CBl (9) in OFF position.

k. Place MIL-D-3464, Type 1 dessicant bags in the electrical controls box, pressure controls box, instrument panel, air outlet, and inside 25 foot flexible duct.

1. Replace flexible duct in duct stowage compartment.

m. Secure all doors.

k. Seal the air filter, air outlet, access panels, and condenser coils with MIL-P-13lC, Class 1 barrier material and PPP-T-60, Type III, Class 1 pressure sensitive tape.

3. PREPARATION FOR SHIPMENT


None

Materials Required

Specification or

or Parl No. N0me*&ture

MIL-P-131C, Class 1 Barrier Material PPP-T-60, Type III, Tape, pressure sensitive Class 1

a. Perform Preparation for Storage (this WP, paragraph 2).

b. Wrap cabinet in MIL-P-131C, Class 1 barrier material. Secure with PPP-T-60, Type III, Class 1 pressure sensitive tape.

i. Install condenser fan panel assembly (WP 008 00). c. Block wheels

AG-180AO-MMM-000

SPRING

004 00 Page 3

Figure 1. Preparation for Use, Storage and Shipment (Sheet 1 of 2)

AG-180AO-MMM-000 004 00 Page 4

000 I ELECTRICALCONTROLS

k3 4

0 BLOWER ILI

n

POWER

Figure 1. Preparation for Use, Storage and Shipment (Sheet 2)

AC-l$OAO-MMM-000 15 May 1991

005 00 Page 1 of 8


OPERATING INSTRUCTIONS

AIRCONDITIONER.AIRCRAFl-GROUNDCOOLING

AIM32C-21


Reference Material

Preopcrational Maintenance RequirementCards. _. _. .AG-180AO-MRC-000

Subject Alphabetical Index

Controlsand Indicators. Table 1. Instrument Panel, Electrical Controls Panel, and Delivery Duct. Operating Instructions. Shutdown Instructions

Emergency Shutdown Procedures. Normal Shutdown Procedures.

Record of ApplicableTechnical Directives NOIW

Table 1. Controls and Indicators

FIGURE/ INDEX IVO.

l-l

CONTROWlNDlCATOR

DISCHARGE PRESSURE gage

FUNCTION

Indicatescompressor discharge pressure. During normal operation should indicate 140 to 365 psig.

2. Panel Lights

3. SUCTION PRESSURE gage

Provide instrument panel illumination.

Indicatescompressor suction pressure. During normal operation should indicate 20 to 70 psig.

4. ELAPSEDTIME meter Records unit running time.

AG-180AO-MMM-000

FIGURE/ INDEX NO

5. IR TEMPERATURE gage

6. IR PRESSURE gage

7.

8.

9.

10.

11.

12.

13.

14.

15.

Table 1. Controls and Indicators (Cont’d)

CONTROL/INDICATOR FUNCTION

IRFLOW CONTROL switch

ANEL LIGHTSswitch

OOL light

:ODE switch

EHUMID light

ENT light

TOP switch

TART switch

OWER light

005 00 Page 2

ndicates temperature ofconditioned air at elivered air outlet. During normal peration, gage should read as follows:

VENT mode: 50°F greater than ambient.

DEHUMID mode: 90°F (minimum)

COOL !vlode: 45”F( k5”).

ndicatcs pressure ofconditioned air at clivered air outlet. During normal peration, gage should read 0 to 3.0 psig

ncrenses or decreases conditioned airflow by lositioning inlet damper.

Lheostat controlling brightness of panel ights.

‘rovides visual indication ofCOOL mode.

‘hree-position rotary switch providing election of VENT. DEHUMID or COOL

‘rovides visual indication of DEHUMID node.

‘rovides visual indication of VENT mode

jhuts down operating unit,

legins unit operation

‘rovides visual indicationofelectrical power mat unit.

AC-180AO-MMM-000 005 00 Page 3

Table 1. Controls and Indicators (Cont’d)

CONTROWINDICATOR FUNCTION

Main Service Circuit Breaker (CBI) Provides overcurrent protection and rapid shutdown capability.

POWER light Indicates prcsenee of440 VAC, 3 phase 60 hz electrical power in ELECTRICAL CONTROLS panel.

CONDENSER FAN motor starter Resets condenser fan motor starter relay reset button circuit after starter open condition.

COMPRESSOR motor starter reset Resets compressor motor starter relay after button starter circuit open condition.

BLOWER motor starter reset button Resets blower motor starter relay after starter circuit open.

I. OPERATING INSTRUCTIONS

a. Perform preoperational checks (AC-180AO. MRC-000)

1. Condenser Fan (2 doors)

2. Instrument Panel

3. Air Outlet

b. Set main service circuit breaker, CBl, (16, Figure 1) to OFF.

c. Remove power cable (22) from storage rack. To prevent damage to the hose or ^

440 VAC electrical hazard exists at power source. To prevent injury or death, make sure power source circuit breaker is set to OFF before connecting power cable connector (23) to power source.

d. Set power source circuit breaker to OFF.

e. Connect power cable connector (23) to power source.

f. Open four doors marked OPEX DOOR BEFORE OPERATING AIR CONDITIONER I21 1.

equipment, remove hose carelully.

g. Remove flexible duct (24) from duct stowage compartment.

h. Connect flexible duct (24) to delivered air outlet.

Do not operate without flexible duct connected.

i. Set power source circuit breaker to ON.

j. Set main service circuit breaker (16) to ON

AC-180AO-MMM-000 005 00 Page 4

k. Set .MOt)E switch (10) to VENT d. PressSTOPswitch (13).

I. Press START button (14). e. Set main service circuit hreakcr (16) to OFF.

m. Set .MODE switch (10) to desired air output.

n. Adjust delivered air flow by moving AIR FLOW CONTROL (7) as required until desired air flow is shown on AIR PRESSURE (6) gage.

2. SHUTDOWN INSTRUCTIONS

3. NORMAL SHUTDOWN PROCEDURES

When connected to electronic equipment and operating in the cooling mode, the following steps must he performed in order. Failure to bring electronic equipment to ambient temperature hefore shutdown may result in excessive condensation on and damage to electronic cq”ipment.

il. Set MOIRE switch (IO, figure 1) to DEIIUMID.

h. Operate for 15 minutes.

c. Set MODE switch 110) to VENT.

NOTE

f. Remove flcxihle duct (24) and store in duct stowage compartment.

To prevent injury to personnel power source must hc OFF heforc disconnecting power cable connector (23).

g. Disconnect power cable connector (23).

h. Rewind power cable (22) onto storage rack

i. Close doors (21)

4. EMERGENCY SHUTDOWN PROCEDURES

To prevent injury to personnel or damage to equipment, this procedure should be used under emer. gency conditions only.

Compressor will operate for approximately 30 seconds as refrigerant is pumped into receiver and will shutoff.

a. Set main service circuit breaker, (16, figure 1) to OFF.

AG-180AO-MM M-000 005 00 Page 5

Flgure 1. Instrument Panel, Electrical Controls Panel and Delivery Duct (Sheet 1 of 3)

AG-180AO-MMM-000 005 00 Page 6

*o\

19 -

18 -

ELECTRICAL CONTROLS

CONDENSER FAN

Figure 1. Instrument Panel, Electrical Controls Panel and Delivery Duct(Sheet2)

AG-180AO-M M M-000 005 00 Page 748 Blank)

Flgure 1. Instrument Panel, Electrical Controls Panel and Delivery Duct (Sheet 3)

AG-I 80AQ-M M M-000 006 00 15 May 1991 Page 1 of 64

ORGANIZATIONAL AND INTERMEI~IATI? MAINTENANCE:

TESTING ANDTROUBLESHOOTING

AIR CONIlITIONER, AIRCRAFT GROUND COOLING

AlM32C.21


Reference Material

Operating Instructions . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . Removal and Installation. . . . . . . . . . . PressureSwitchesandCapillary Informatives . . . . . . Electrical Controls Panel, Fuse Box, Instrument Panel and Wiring Airflow Controller Module, Aftercooler Module and Precooler Module Kefrigeration Compressor Assembly . . . . . . . . Aircraft Electric and Electronic Wiring Installation Practices. . . . . . . . . . . Preoperational .Maintenance Requirements Cards . . .

Subiect Alphabetical Index

Control Voltage Transformer (TRl) Testing . Electrical Phase Loss Relay (K5) Testing. . Fuse Testing . . . . . . . Introduction . . . . . . . . . Main Service Circuit Breaker (CBI) Testing . PressureControls’~esting . . . . . Pressure Switches (PSI, PS2 and PS3) Testing Solenoid ValvesTesting . . . . . . Starter Relays (Kl, K2, K3) Testing . . . Switch Testing . . . . . . . . Testing.Table 2 . . . . . . . Time Delay Relay(KJlTcsting . . . . ‘rroubleshooting,‘rahle 1 . . . . . .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. . WPOO5 00

. , WPOO7 00

. . WPOO8 00

. . WP 009 00

. . wP01000

. . WPOII 00

. . wl’01200

. . .

I&cord of Applicable Technical IXrectives NonI?

NAVAIKOI-IA-505 AC-ISOAO-MKC-000

19 24 55

I 11 40 57 67. 21 27 16 33

2

1. INTRODUCTION trouble analysis in four-column format leading from This work package provides tesling and symptom to remedy. Table 2 provides detailed troubleshooting information. Table 1 provides information on testing individual components.

AC-1180AO-MMM-000 00600 Page 2

Table 1. Trol

1. Power On Lights Fail 1. No Source Power ToLight -

2. Main Service Circuit Breaker Open (Not Reset)

3. Failed Open Main Service Circuit Breaker

4. Phase Reversal

5. Phase Loss

6. Low Source Voltage

7. Faulty Phase Loss Relay (K5)

8. Failed Control Voltage Transformer

9. Failed Open Fuses (FIO, Fll, F12)

IO. Power On Lamps Burned Out

11. Faulty Light ReceptacIes

12. Faulty Wiring

bleshooting

FAULT ISOLATION

1. Verify Source Power

2. Improper Connection at Source Power

1. Observe Main Service Circuit Breaker Position

1. Test Main Service Circuit Breaker in Reset Position for Continuity (Table 2, Paragraph 1, This WP)

1. Check Source Phase

1. Check Source

1. Check Source Voltage

1. Check Phase Loss Relay (Table 2, Paragraph 4, This WP)

1. Check Primary and Secondary Coil Continuity (Table 2, Paragraph 2. This WP)

1. Check Fuse Continuity (Table 2, Paragraph 17, This WP)

1. Observe Lamp Filaments

1. Check Contiriuity with Good Lamp

1. Isolate

REMEDY

1. Correct Source Power

1. Re-Insert Connector

1. Reset

1. Replace (WPOlO 00)

1. Correct Phase

1. correct

1. Correct



1. Replace (WPOIO 00)


1. Replace Light Receptacles (WPOlO 00)

1. Repair/Replace (NAVAIR 01.lA-505)

AG-180AO-M M M-000

SYMPTOM

2. Blower Does Not Operate When Start Button Is Depressed

Table I. Troublesh

PHOBARLE CAUSE

Power On I.ights Not ”

IIlower Motor starter day, K I, Open

Phase Loss Relay lontacts, K5X1, Open

Faulty Start Switch, WI

1. 0

2. R

:

i

5 S

6 (I

7

E

9

Faulty Stop Switch, ,w2

Failed Open Fuses i-1, F2, F3, Fl3l

Blower -Motor Open

1. Faulty Wiring

Faulty Coupling

lting(Continued)

FAULT ISOLATION

I. Refer to Symptom 1

I. Overload Heater Trip

I. Cheek bleaters for Continuity (Table 2, :‘aragwph 3, This WP)

3. Check Starter Relay %I for Continuity :Tablc 2, Paragraph 3, fhis WP)

1. Check Relay “ontacts(KlXl.KlX2. K 1X3) for Conti&ty :‘rahle 2, Paragraph 3, I’his WI’)

1. Check for Continuity :Table 2, Paragraph 4, This WP)

1. Check Switch for Continuity When Depressed (Table 2. Paragraph 5, This WP)

I. Check Switch for Continuity (Table 2, Paragraph 5, this WP)

I. Check Continuity (Table 2, Paragraph 17, This WP)

I. Check for Continuity between:

Tl and T2 Tl and T3 T2 and T3

2. Check for open (infinite resistance) between:

Tl and motor casing (unpainted surface) ‘r2 and motor casing (unpainted surface) T3 and motor casing (unpainted surface)

I. lsolate

1. Inspect Coupling

Reset Replace Starter

clay (WP 010 00)

Replace Starter NP01000)

Replace starter clay (WPOlO 00)

Replace starter :clay(WPOl000)

Replace Phase ~08s Relay WPOlO 00)

Replace Switch &PO10 00)

Replace Switch WPOlO 00)

Replace (WPOIO 00)

k

I I c

:?

1 (’

1

1

1

1 (I

1 J

Replace (WPOIO 001

Replace (WPOIO 001

Replace/Repair YAVAIRO~.IA-505)

Adjust/Replace NPOO8 00)

006 00 Page 3

REMEDY

SYMmQM

i. Compressor Does Not )perate (DEHUMID, :OQL Made) After 10 iecond Time Delay

Table 1. Troublesb oting(Continued)

PROBABLE FAULT CAUSE ISOLATION

Time Delay Relay, 14. Faulty

1. Check Continuity of Coil (Table 2, Paragraph 9. This WP)

I_ Compressor Cylinder lead Temperature Cut- ht (CTCO) Open

:_ Low Pressure Cut- ht (LPCO) Open

I. High Pressure Cut- )ut (HPCO) Open

i. Oil Safety Switch OS) Open

i. Compressor Motor itarter Relay, K2, Open

2. Check Continuity of K4X1 Contact

1. Check CTCO For Continuity (Table 2, Paragraph 10, This WP)

1. Verify System Refrigerant Pressure Greater than 17 PSIG

2. Check LPCO for Continuity (Table 2, Paragraph 11, This WP)

1. Verify System Refrigerant Pressure Less Than 425 PSIG

2. Check HPCO for Continuity (Table 2, Paragraph 12, This WP)

1. CheckContinuity OS-T (Contacts L and M) (Table 2. Paragraph 13. This WP)

1. Overload Heater Trip (Table 2, Paragraph 3, This WP)

2. Check Heaters Car Continuity (Table 2, Paragraph 3, This WP)

3. Check Starter Relay Coil for Continuity (Table 2, Paragraph 3, This WP)

4. Check Relay Contacts (K2X1, K2X2, K2X3) for Continuity (Table 2, Paragraph 3, This WP)

REMEDY

1. Replace Relay (WPOIO 00)

1. Replace Relay (WPOlO 00)

1. Replace Tempera- ture Cut-Out (WPO12 00)

1. Add Refrigerant (WP 007 00)

1. Adjust (WPOO7 00) 2. Replace (WPOO9 00)

I. Bleed Refrigerant

1. Reset (WPOO7 00) 2. Adjust (WPOO7 00) 3. Replace (WPOO9 00)

1. Reset 2. Replace OS (WPOO9 00)

1. Reset 2. Replace Starter Relay (WPOlO 00)

1. Replace Starter Relay (WPOlO 00)



00600 Page 4

AC-I 80AO-M M M-000 006 00 Page 5

Table 1. ‘Troubleshooting(Continued)

I’RORAHLE FAULT SYMPTOM CAUSE ISOLATION

4. Condcnscr Fan Does Not Operute ~l)E- IIUMID, COOL Mode) When Compressor Discharge Pressure Greater Than 245 PSIC

2. Condenser Fan Motor

I. Check Continuity IleLwxn FSW Terminals I and 3 (Table 2, Paragraph 3, This WI’)

I. Overload Heater Trip Stxter. Kc&, K3,Opcn (‘l’rtble 2, l’:wagraph

3 This WPI

2. Check Ileater(s) for Continuity (Table 2, Paragraph 3, This WI’)

3. Cheek Starter Kela) Coil for Continuity (Table 2, I’uagraph 3, This WI’)

4. Check Kclay Contacts(K3X1, K3.X2, K3X3) ForContinuity (Table 2, l’xqqaph 3, This WP)

3. Failed Open Fuses (F7, F8, F9)

1. Check Fuse Continuity (Table 2, Paragraph 3, This WI’)

I 4 Condenser Fan Motor 1. Check for Continuitv 1. Replace (WPOO8 00) Open

L

between: Tl andT2 Tl and T3 T2 and T3

2. Check for open (infinite resistance) between:

Tl and motor casing (upaintcd surface) T2 and motor casing (upainted surface) 1’3 and motor casing lupxinted surface)

2. Keplacc (WPOO9 00)

2. Kcplacc Starter K&y(Wl’0I000)

I. Keplacc stxt.er Relay (WPOIO 00)

I. Kcplace starter Kf2llly

I. Keplace startc1 Kclay tWPOl0 00)

I. Keplacc (ligure 9)

I. Keplace (WPOOS 00)

AG-180AO-MMM-000 00600 Page 6

SYMPTOM

Not Operate (DE- HUMID,COOL Mode) When Compressor Discharge Pressure Greater Than 245 PSIG

Table 1. Troublesh

6. Compressor Not Operating

5. No Air Flow Control 1. Capillary Tubin To Pressure Switch. P 8 1 and/or Flaw Control Switch (FCS) Pinched, Disonnected or Defective

2. Pressure Switch, PSI Defective

3. Flow Control Switch, FCS, Defective

4. l.imit Switch, LSI, Defective

5. Limit Switch, LSZ, Defective

6. Faulty Capacitor, Cl

7. Main Air Damper Motor Open

8. Main Air Damper Linkage Loose/Broken

oting(Continued)

FAULT ISOLATION

I. isolate

1. Refer to Symptom 3

1. Inspect

1. Check for Continuity Between Terminals C and NC or C and ND

1. Check for Continuity Between Zand 3 (INCR) When Pushed and Between 3 and 1 (DECR) When Pushed

1. Check for Continuity with Switch in Closed Position


1. Check Continuity

1. Check Continuity

1. Inspect

1 REMEDY

1. Repair/Replace (NAVAIROl-IA-5051

1. Repair/Replace (WPOO9 00)

1. Replace (WPOO9 00)


1. Replace (WPOll 00) I

1. Replace(WF’O11 00) I

1. Replace (WPOll 00) 1

1. Replace (WI’011 00) 1

, 1. Repair (WF’Oll 00) 1

AC-180AO-MMM-000 00600 Page 7

SYMPTOM

I. .Vo Air Flow Control Contd)

/ 6. No Temperature 1 Control (COOL Mode)

Table 1. Troubles1

PROBABLE CAUSE

9. Pressure Switch, PS3, Defective

10. Pressure Switch PSZ, Defective

11. Limit Switch, LS3, Defective

12. Limit Switch, LS4. Defective

13. Faulty Capacitor, c2

14. Bypass Damper Motor Open

15. Bypass Damper Linkage Loose/Broke”

16. Faulty Wiring

17. Defective Delivered Air Pressure Gage

18. Ruptured Duct(s)

19. Blocked Conditioned Air Passage

20. Main Damper Damaged

21. Bypass Valve Damaged

1. Low refrigerant Charge

oting(Contiiwed)

FAULT ISOLATION

1. Check Continuity Between Terminals C and NC or C and NO

1. Check Continuity Between Terminals C and NC or C and NO


I. Check for Continuity with Switch in Closkd Position

1. Check Continuity

1. Check Continuity

1. Inspect

1. Isolate

1. Test Gage with known Pressure Source

1. Inspect

1. Inspect

1. Inspect

1. Inspect

1. Observe Sight Glass(es)

REMEDY

1. Replace(WP009 00)

1. Replace (WPOO9 001

I. Replace (WPOl 100)

1. Replace(WPO1100)

1. Replace (WPOll 00)

Replace (WPOll 00)

Repair

Repair/Replace (NAVAIROI-IA-505)

I. Replace (WPOO9 00)

I. Replace

1. Remove Blockage

1. Repair 2. Replace (WF’Oll 00:

I. Repair 2. Replace (WPOll 00)

1. Add Refrigerant :wp 007 00).

I

AG-180AO-MMM-000

SYMPTOM

i. No Temperature :ontrol (COOL Mode) Cont.43

Table 1. Troubleshl

Pressure Switch, :&4, F’aulLy

Pressure Switch, 55. Faulty

Pressure Switch, PS6 ‘a&y

i. Defective Solenoid l&e, Sl

i. Defective Solenoid Jalve, til

,ting(Continued)

FAULT ISOLATION

I. At suction pressure !ess than 30 psig, check :ontinuity between .crminals I. and M2 Open) and between I, md M 1 (Closed); at iuction pressure greater than 55 psig. check continuity between terminals I, and M2 :closed) and between I. and M 1 (Open)

I. At suction pressure less than 25 psig, cheek continuity between I. and M2 (Open) and between 1. and .M I IClosed); at suction pressure greater than 50 psig. check continuity between terminals L and 342 (Closed) and between I, and Ml (Open)

I. At suction pressure less than 20 psig, check continuity between terminals Land Ml (Close); at suction pressure greater than 4: psig, check continuity between terminals I. and Ml (Open)

1. Open Coil; check Continuity

2. Inoperable Valve

1. Open Coil;check Continuity

2. Inoperable Valve

006 00 Page 8

REMEDY

Rcplacc (Wf’OO9 00)

Replace (WPOO9 00)


1. Replace Coil WPO12 00)

I. Replace Solenoid Valve Sl (WPOO8 00)

I. Replace Coil :wpo12 00)

I. Replace Comprcssol YWP 008 00)

G-l 80AO- Page 9

Table 1. Troubles1

SYMPTOM

i. No Temperature :ontrol (COOL Mode) Contd)

P%%%LE

7. Defective Solenoid Valve, s2

8. Defective Solenoid Valve, u2

9. Defective Solenoid Valve, S6

10. Defective Solenoid Valve, s3

11. Defective Solenoid Valve, 54

12. Faulty Head Pressure Regulator (Vl)

13. Faulty Fan Cycling Switch, FSW

14. Evaporator Pressure Regulator Valve Failed Closed

15. Refrigerant Piping Leak

16. Faulty Expansion Valve(s)

17. Damaged Faaporatorw

18. Damaged Condenser(s)

19. Faulty Wiring

,ting(Continued)

FAULT ISOLATION

I. Open Coil; check Continuity (Table 2, Paragraph 20, This WP)

2. Inoperable Valve


I. Inoperable Valve

I. Open Coil; check :ontinuity (Table 2, ?aragraph 20, This WP)

1. Inoperable Valve


1. Inoperable Valve

I. Open Coil; check :ontinuity (Table 2, ?aragraph 20, This WP)

!. Inoperable Valve

I. Compressor Dis- :harge Pressure not Maintained at 225 PSIG w Greater.

1. Replace(WP00800)

1. Adjust (WPOO7 00)


t. FSW does not open at Compressor Discharge Pressure less 175 psig, Check Continuity he- ween terminals 1 and 3

1. Adjust (WPOO’7 00) 2. Replace (WPOIO 001

I. Observe Suction 1. Test Valve, Pressure for Lower fhan Normal Level

Repair/Replace (WPOO8 00)

t. Leak Check ,WP 007 00)

1. Repair, add Refrigerant (WPOO7 00)

I. Isolate

REMEDY

1. Replace Coil (WP 008 00)

1. Replace Solenoid Valve S2 (WPOO8 00)

1. Replace Coil (WPO12 00)

1. Replace Compressor (WPO12 00)

1. Replace Coil (WPOO8 00)


1. Replace Coil (WPOO8 00)


I. Replace Coil (WPOO8 00)




I. Repair/Replace (NAVAIROI-IA-505)

AaG-l$OA0-MMM-000

SYMPTOM

Unit Shuts Down Vhile Running POWER On Lights Ofll

Unit Shuts Down Yhile Running (Power n Light DS7 On, DSI m

‘. Unit Shuts Down Vhile Running (Power )n Lights On)

Table I. Troublesh

PROBAHI.,E CAUSE

No %1rce Power

Circuit Hreakcr Open

I. Failed Open Circuit greaker

1. Failed Control Joltage Transformer

i. Failed Open I’uscs FllandF12)

i. Faulty Wiring

Failed Open Fuse, r13

!. Faulty Wiring

I Blower Motor Starter <day. K 1, Open

vting(Continued)

FAULT ISOLATION

I. Verify Source Power

I. Observe Circuit :<reakcr Position

I. Test Circuit Ilrcakcr ,n Keset Position for Continuity (‘Pahlc 2, I’aragraph I, This WI’)

I. Check Primary and 3econdary Coil Continuity (Tahlc 2, I’aragraph 2, This WI’)

I. Check Fuse Continuity (Table 2, Paragraph 17, This WP)

I. Isolate

I. Check Fuse for Continuity (Table 2, Paragraph 17,This WP)

1. Isolate

1. Overload Heater IYip

2. Nuisance Trip

3. Check Starter Relay Coil for Continuity (Table 2, Paragraph 3, This WP)

4. Check Relay Contacts(KIXI, KlX2, KlX3) for Continuity

5. Check Relay Contact K 1 X4 with Start Switch, SWI, Depressed

REMEDY

I. Corrccl Source Power

I. Reset

I. Replace (WI’010 00)

I. Replace ~Wl’OlO 00)

I. Replace (WPOlO 00)

1. Repair/Replace INAVAIROI-lA-5051

1. Replacc(WPO10 00)

1. Repair/Replace (NAVAIROl-IA-5051

1. Reset 2. Replace Starter Relay lWPOl0 001

1. Adjust (WP 007 00)

1. Replace Starter Relay (WPOIO 00)

1. Replace Starter Relay (Wf’OlO 00)

1. Replace Starter Relay (WPOIO 00)

AG-‘I 80AO-M M M-O00 1006 QO Page 11

r SYMPTOM

9. Unit Shuts Down While Running (Power On Lights On) (Contd)

IO. Condenser Fan Shuts Down during Operation

(SOTE: Could Represent ~ormnl Operation During Low Imhient Temperature,

1.0~ Air Conditioning Loads)

t I c

!-

.l. Compressor Shuts Iown during Operation

12. Blower Shuts Down luring Operation.

Table 1. Troublesh

PROBABLE CAUSE

!. Phase Loss Relay Zontacts, K5X1, Open

3. Faulty Stop Switch, SW2

4. Faulty Wiring

1. Faulty Fan Cycling switch, FSW

1. Failed F&Motor 3ushing

l. Refer to Symptom 4

I. Low Compressor Oil Level

2. Refer to Symptom 3

3. Failed Compressor

I. Refer to Symptom 2

2. Failed Blowcr/.Motor Zoupling

3. Failed Blower

100

1 ( T

1 C P

1

1 R 1 lI g

2 E ‘I I: F ”

1

1 S c

I

I

ting(Continued)

FAULT ISOLATION

Check for Continuity Cable 2, Paragraph 4, ‘his WP)

Check Switch for Continuity (Table 2, ‘aragraph 5, This WP)

Isolate

Check Continuity letwcen FSW ‘erminals 1 and 3 with jischarge Pressure water than 245 psig.

Check Continuity Letween FSW ‘erminals 1 and 3 with jeweasing Discharge ‘ressure; Switch should .ot open until 175 psig

Observe

Check Oil Safety lwitch Reset and :ompressor Oil Level

Ohserve

Ohservc

REMEDY

1. Replace Phase Loss Relay (WPOlO 00)

1. Replace Stop Switch (WPOlO 00)

1. Repair/Replace (NAVAIROI-IA-505)

1. Adjust (WPOO7 00)

2. Replace i.WPOO9 00

I. Adjust (WPOO7 00)

2. Replace (WI’009 00

1. Replace (WPOOS 00

1. Reset/Service Compressor Oil (WP 007 00)

I. Repair/Replace (WPOO8 00)

I. Keplace (Wf’OO800)

1. Replace (WI’008 00)

AG-180AO-MMM-000 00600 Page 12

1 c

I \

1 n,,rt: 1. , I “ul,rcJrl”“r,~,~,u”,,rllr”r;“,

I’KOBAHLE FAULT SYMPTOM CAUSE ISOLATION KIXMEDY

3. Unit Will Not Turn 1. Faulty StopSwitch. I. Check Switch for I. Replace~WP0l0 00, MT SW2 Open when Depressed

(Table 2, Paragraph 5. This WI’)

2. Faulty Start Switch, 1. Check Switch for I. ~~~1~~~~wr~o~o001 SW1 Continuity when not

Dcprcsscd (Tahlc 2, Paragraph 5,This WP)

3. Faulty LOW Pressure 1. Check Low Side 1. Adjust (WPOO7 00) Cutout Switch system Pressure

for 0 PSI 2. Replace (WPOO9 00

4. Panel Light(s) Fails I. Defective Lamp 1. Ohserve Lamp I. Replace iw1’010 001 o Light Filaments

2. Dcfcctive Panel 1. Check Continuity 1. Rcplacc iWl’O10 00) Light Receptacle with Good Lamp

3. Defective Panel Light 1. Check Continuity 1. Replace (WI’010 001 Switch, SW4 (Table 2, Paragraph 5,

This WP)

4. Faulty Wiring I. Isolate I. Repair/Replace (NAVAIROl-IA-505t

5. Mode Light(s) Fail 1. Defective Lamp 1. Observe Lamp I. Replace (WI’010 00) o Light Filaments

2. Defective Mode Light I. Check Continuity 1. Replace (WI’010 001 Receptacle with Good Lamp

3. Defective Mode 1. Check Continuity 1. Keplxe (WPOlO 00) Switch, SW3 (Table 2, Paragraph 6,

This WP)

4. Faulty Wiring I. Isolate 1. Repair/Replace (NAVAIR 01.IA-5051

16. Discharge Pressure 1. Low Refrigerant I. Ohscrve Sight I. Add Refrigerant :age Indicates Less Charge Glass(es1 for Ruhhlcs (WP 007 00) rhan 140 Psig

2. Test System for Leaks, Repair. Recharge (WPOO7 00)

AC-18OAO-MMM-000 006 00 Page 13

[ 1 ( 1 (

c I ( r

1 ( 1

L

- . . . - . . . . . ,- . . . L ame 1. L rouo~esnoot~ng(tionrInuea,

I’KOBABLE FAULT SYMPTOM CAUSE ISOLATION KEMEDY

16. Discharge Pressure 2. Defective Cage 1. Test Gage with 1. Replace (WPOlO O( 7 sage Indicates Less Known Pressure Source Phan 140 Psig ,Contd) 3. Defective Compressor 1. Observe Compressor 1. Repair/Replace

Operation (WI’ 008 00)

17. Discharge Pressure 1. Condenser Coil(s) 1. Observe Condenser 1. Clean Coil(s) kge Indicates Higher Clogged or Obstructed Coils l’han 365 psig

2. Overcharge of Refrigerant

1. Observe Suction Pressure for Iligher Than Normal Level

1. Bleed Refrigerant from System.

3. Defective Cage 1. Test Gage with I. Replace Gage Known Pressure Source

4. Receiver Shutoff 1. Ohserve Valve Stem 1. Open Valve(s) Valve(s) Closed Position

5. Filter/Drier Clogged 1. Observe Suction I. Replace Filter/Drie, Pressure for Lower Core (WP 008 00). Than Normal Level

6. Pumpdown Solenoid 1. Observe Suction 1. Test Valve, Valve Failed Closed Pressure for Lower Solenoid, S5, and

Than Normal Level Wiring

7. Collapspd 1. Observe Suction 1. Rep&c I.ine Refrigerant Lint Pressure for Lower

Than Normal Level

8. Panels Not in Place 1. Observe Unit. 1. Replace Panels

9. system 1. Check Filter/Drier 1. Evacuate and Contaminated 2. Observe Sightglass Recharge Unit

(WPOO7 00)

18. Suction Pressure &ge Indicates Less fhan 10 psig

1. Refer to 17.3 through 17.7 above

I

AG-180AO-MMM-000 006 00 Page 14

‘rahle I. ‘rl-ouhleshooting(Continued) I I

I I’HOHAHI;K VA U I:r SYM I’TOM I CAUSE I ISOLATION I HEMEIIY I

i (NOTE: Could j lb2prcsent Normal

0pcr;llion: c-g., I.ow And~icnl, I.ow I)clivcrcd

2. Air liiltcr Dirty

6. Itot Gas llypass 6. Itot Gas llypass and/or Quench Valvc(sl and/or Quench Valvc(sl Faulty Faulty

7. Hlowcr Not 7. Hlowcr Not Operating Properly Operating Properly

9. Air Circuit Blocked

10. Faulty &pansion Valve(s)

20. Suction Pressure I. Discharge Pwssure i IndicatesGreutcl-‘l’han Too High

j 7o p”ig 2. Compressor Not Loading

I, lnspuct Air Filtc~ I. Clean Ail l“illcr(Wl’OO7 00)

I I. Ohserve Sight I. Add rcfrijicrant Clasdcs) for llubhlcs ( w I’007 00)

2. Test systclll fOl Ixnks. Repair, Add K~fl+YXflt

I. K&x to Tnblc 2. (WI’006 00)

I. IJaulty SI and/or S2: Check Continuity (Table 2, Paraguph 20, This WI’)

I. Verify Power to Solenoid (51, S3 and S4 (‘l‘&lc 2, l’ara~rilph 20, This WI’)

I. KcpairiKeplace Conlprcssor lwP01200)

I. Keplxe , WI’008 00)

I. Adjust. Kepairi Kepluce (WI’008 00)

1. Repair/Replace (WPOO8 00)

I. Ohscrw Opfr*tion I. Repair/Replace (WPOOS 00)

I. lnspcct 1. Clear Rlockage

I. Keplace (WPOO8 001

I. Perform Test Procedures in Accordance with (WI’006 00)

2. Compressor Cylinder Head Cold

1. Replace (WPOO7 00) 1

I. Replace Compressor (WPOOS 00)

AG-180AO-MMM-000 006 00 Page 15

Table I. Trouhleshooting(Continued)

PRORARLE FAULT SYMPTOM CAUSE ISOLATION

20. Suction Pressure 3. Precooler Not 1. Check for Power ON Indicates Greater Than &aging Solenoid Coil Sl and/or 70 psig(Contd) 52

I 4. Ilot Gas Bypass I.ine 1. Verify Power to Open Solenoid Valve(s) 53

and 54 I

5. Defective Compressor 1. Ohserve Compressor

21. System Will Sol Pump Down

1. Defective Pumpdown Solenoid Valve

2. Defective Mode Switch, SW3

3. Defective Kl, K2

I. Check Continuity of Coil, 55 (‘l’ahlc 2, I’arayraph 20,‘I’his WPI

1. Check Contacts

REMEDY

I. Replace Coil (WPOO8 00)

I. Adjust, Repair/ Replqe (WPOOS 00)

I. Replace Comprcssot tWP008 00)

I. Replace (Wf’OO8 00)

1. Replace Valve/Replnce Coil (WPOOS 00)

I. Rcplnce(WPOlO001

1. Replace (WPOlO O(

AG-180AO-MMM-000

Till

PROCEDURE

1. MAIN SERVICE CIRCUIT BREAKER 1 (CBI)

Support Equipment Required ; Part x0. Xomenclature

Multimeter / I Materials Required

None

To prevent injury to personnel or damage toequipment, electrical power

; must be disconnected when working inside electrical controls panel.

i a. AMake sure electrical power is OFF and connector is disconnected.

b. Open electrical controls panel by i turning grip latches counterclockwise 1 uigure 1).

c. With circuit breaker set to OFF, check continuity between Tl and Ll, T2 and L2,

I and T3 and L3.

! d. With circuit breaker set to ON, rheck continuity between T1 and LI, T2 and I.2

! and T3 and L3.

2. CONTROL VOLTAGE TRANSFORMER (TRI)

! Support Equipment Required I Part No. Somenclature I .Multimeter

Materials Required N0ne

: 2. Testin

NORMAL INDICATION

Zontinuity exists

REMEDY FOR ABNORMAL INDICATION

teplace main service circuit ,reaker (WPOlO 00).

Eeplacc main servicecircuit 1reaker (WPOlO 00).

006 00 Page 16

AC-I 80AO-M M M-000 00600 Page 17

GRIP LATCHES

ELECTRICAL CONTROLS PANEL

440 VAC 30 60 HZ

Figure 1. Main Service Clrcult Breaker (CBI) Testing

AC-1 80AO-MMM-000

Table 2.

PROCEDURE

/( a. Make sure external electrical power is

Band connector is disconnected.

b. Open electrical controls panel (figure 2 : by turning grip latches counterclockwise.

To prevenl injury to personnel or damage to equipment, electrical power must be disconnected when working inside electrical controls panel.

’ c. Removebolt(

d. Remove cover (3).

e. Disconnect unit wiring from trans- wormer wiring.

f. Checkcontinuity between X1 and X2 and between HI and H2.

g. Connect wiring.

h. Install cover (3).

i. Install bolt (1).

j. Close and latch electrical controls pane

3. MOTOR STARTER RELAY (KI. K2, K3)

Support Equipment Required Part No. Nomenclature

Multimeter 110 VAC Power source

Materials Required None

;ting(Continuedl

NORMAL INDICATION

!ontinuity exists

00600 Page 10


:eplace transformer WPOlO 00).

AC-180AO-MMM-000 00600 Page 19

-44 -4,

. -42 -43 1

ELECTRICAL -CONTROLS

PANEL

Figure 2. Control Voltage Transformer

AG-180AO-MM M-000 006 00 Page 20

Table 2.

PROCEDURE

a. Reset starter by pushing starter reset button on electrical controls panel (figure 3).

piiiiicWAINING\

To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside electrical controls panel.

b. Make sure electrical power is off, connector disconnected, and circuit breaker,

I CBI, off.

I c. Open grip latches securing electrical

controls panel. I / d. Disconnect wires from coil terminals. Check continuity between coil connections.

e. Check heaters for continuity.

To prevent injury or death, do not touch electrical connections.

f. Apply external 110 VAC power to coil terminals.

g. Disconnect wires from Ll, 1.2,1.3. Checkcontinuity between Ll andT1, L2 and T2, L3 and T3.

I. :’ h Kl. K2 Disconnect wire from X4 COM and check continuity between X4 COM and X4 NO.

i. Kl, K2: Disconnect wire from ~5 COM andcheck continuity between X5 CO&l and X5 (NC, Kl; NO, K2).

Tl?!

s

;ting(Continued)

NORMAL INDICATION

tarter resets

:ontinuity exists

iontinuity exists

:ontacts close

fontinuity exists

bontinuity erists

Ipen exists (Kl)

lontinuity exists (K2)


<eplace Overload Relay WPOlO 00)

ieplace Coil (WPOIO 001

%eplace Starter Relay WPOlO 00)

ieplace Starter Relay WPOlO 001

ieplace Starter Relay WPOlO 00)

Ieplace Starter Relay WPOLO 00)

ieplace Starter Relay WPO 10 00)

AC-18OAC.bMMM-000 006 00 Page 21

ELECTRICAL CONTROLS

RESET <\-I ~~ SUTTON

Y

STARTER RESET

COMPRESSOR STARTER RESET

SUTTON BUTTON

..” L-t.3

4

5 6

COMMON COIL /CONNECTIONS

SUTTON

Figure 3. Starter Relays (Kl, K2, K3) Testing (Sheet 1 of 2)

AG-180AO-MMM-000

u- I T STARTER

RESET T3

BUTTON \

I

2

00600 Page 22

-64 .156

-5.0

- 16 -26 -21

Figure 3. Starter Relays (Kl, K2, K3) Testing (Sheet 2)

AG-180AO-MMM-000

Table 2.

I PROCEDURE

! j. Removeexternal I10 VAC power from coil terminals..

! k. Reconnect all w~ires.

Ir 1. PHASE LOSS RELAY

I’

I. Close electrical controls panel and iecure with grip latches.

lc

t

Support Equipment Required ‘art No. Nomenclature

iVIultimeter 3 phase, 60 Hz, 440 VAC Power Supply


To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside electrical controls panel.

a. Make sure electrical power is OFF and onnector is disconnected.

b. Open electrical controls panel by urning grip latchescouterclockwise.

c. Unplug phase loss relay (Figure 4)‘,

d. Check continuity between pins 8 and 1.

,ting (Continued)

NORMAL INDICATION

ontinuity exists (K2)

lpen circuit

006 00 Page 23


:eplace starter IWay wl’olooo)

:eplace starter Relay WPOIO 001

teplace phase loss relay WPOlO 00)

L

AG-180AO-MMM-000 00600 Page 24

GRIP LATCHES~ i : - L 1

ADlUiTMENT SCREW

Figure 4. Electrical Phase Loss Relay (K5) Testing

00600 Page 25

Table 2. Testing (Continued) I I

NORMAL INDICATION

REMEDY FOR PROCEDURE ARNORMAL

INDICATION

I I I e. Reinstall phase loss relay (Figure 4).

440 VAC, 3 Phase, 60 Hz electrical power is dangerous. To prevent injury or death USC extreme cnrc when testing phase loss relay.

f. Apply external 44OV, 3 phase, 60 Hz power to pins 3 (phase A), 4 (B), and 5 (0.

g. Check for 118 VAC between pins 8 and 1.

h. Close electrical controls panel.

i. Secure electrical controls pancl hy turning grip latches clockwise.

5. START(SWl)ANDSTOP(SWZ) SWITCH


Multimeter

Materials Required NOW

To prevent injury to pe, sonnel or damage to equipment, electrical powel must he disconnected when working inside instrument panel.

Indicator light on

3.0 voltage

Replace phase loss relay (WPOIO 00)

AG-180AO-M M M-000 00600 Page 26

Table 2. Testing (Continued)

PROCEDURE NORMAL

INDICATION

a. Make sure electrical power is OFF and connector is disconnected.

I b. Open instrument panel door.

/ c. Open instrument panel by turning grip ’ latchescounterclockwise.

d. Disconnect wire 75or 77 from the ~START(SWl)switch(I,figure5).

e. Check for continuity between switch terminals (C and .X0).

Open circuit

f. Depress switch button. Check for continuity between switch terminals.

Continuityexists

g. Reconnect wires 75 or 77 to switch terminals.

h. Disconnect wire 76,86, or 77,78 from the STOP (SW2) switch (2. Figure 5).

i. Check for continuity between switch terminals (C and NC).

Continuity exists

j. Depress switch button. Check continuity between switch terminals.

I. Reconnect wires 76,86, or 77,78 to switxh terminals.

Open circuit

m. Close and secure instrument panel by turning grip latches clockwise.

n. Close instrument panel door.

REMEDY FOR REMEDY FOR ABNORMAL ABNORMAL INDICATION INDICATION

Replace switch. Replace switch. (WPOIO 00) (WPOIO 00)


Replace switch Replace switch. (WPOIO 00) (WPOIO 00)

Replace switch Replace switch. (WPOIO 00) (WPOIO 00)

6. MODE SWITCH (SW3)


Multimeter

Materials Required None / (

AG-180AO-MMM-000 006 00 Page 27

INSTRUMENT

BLOCK TBI

4

Flgure 5. Switch Testlng (Sheet 1 of 2)

AG-18OAO-MMM-000 00600 Page 28

SW3 2

103-

Flgure 5. Switch Testlng (Sheet 2)

AG-180AO-MMM-000 00600 Page 29

Table 2.

F

Testing (Continued)

NORMAL INDICATION

/

I To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside instrument panel.


b. Open instrument panel door,

c. Open instrument panel by turning grip latchescounterclockwise.

d. Disconnect wires 87,90,91,99, and 100 from terminals 1,5,9,3, and 7, respectively of the MODE (SW3) switch (3, Figure 5).

e. With the mdde switch in the VENT position, check for continuity between terminals 1 and 2,5 and 6, and 9 and 10.

f. With the MODE switch in the DEHUMID position, check for continuity across terminals 1 and 3.5 and 7. and 9 and 11.

g. With the MODE switch in the COOL position, check for continuity across terminals 1 and 4,5 and 8, and 9 and 12.

h. Reconnect wires disconnected in d. above to their respective terminals.

i. Close instrument panel by turning grip latchesclockwise.

Continuity exists

Continuity exists

Continuity exists


Replace switch. (WPOIO 00)

Replace switch. (wP01000)

Replace switch (wPo1ooo)

j. Close instrument panel door.

AG-180AO-M MM-000 00600 Page 30

Table 2.

1 PROCEDURE

7. PANEL LIGHTS SWITCH (SW4)


Multimeter

Materials Required Non.2

(4

To prevent injury lo personnel or damage to equipment. electrical power must be disconnected when working inside instrument panel.


b. Open instrument panel door.

c. Open instrument panel by turning grip latehescountercloekwise.

d. Disconnect wire 71 from terminal block location TBl-2.

e. With the PANEL LIGHTS (SW4) switch (5. Figure 5) in the OFF position, check for continuity between the terminals where wires 71 and 153 are soldered.

f. With the switch in the ON position, check for continuity between the terminals where wires 71 and 73 are soldered.

g. While monitoring the multimeter, rotate the switch through its full range.

Testing Khntinued)

NORMAL INDICATION

Open circuit

Continuity exists

Continuity exists, while the resistance level changes.




Replace switch Replace switch. (wP01000) (wP01000)

AG-180AO-MMM-000 006 00 Page 31

l’ahle 2. Testing(Continued1

PKOCEDUKE NORMAL

INDICATION

( h. Reknect wire71 toTB1~2.

i. Close instrument panel by turning grip latches clockwise.

j. Close instrument panel door.

i 8. AIK FLOW CONTKOL SWII’CH~(FCSI

Support Equipment Kequired Part so. Nomenclature

Multimeter

Materials Kequired None

To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside instrument panel.


b. Open instrument panel door.

c. Open instrument panel by turning grip i latchescounterclockwise.

d. Disconnect wire 101 from terminal 2 of 1 the air flow control fFCS) switch (4, Figure 15).

e. With the switch held in the INCREASE position, check for continuity between

I terminals 2 and 3.

1 f. With the switch held in the DE- ; CREASE position, check for continuity 1 between terminnls 2 and 1. I

Continuity exists

Continuity exists

KEMEDY FOR KEMEDY FOR AHNOKMAL AHNOKMAL INDICATION INDICATION


Replace switch Replace switch. (WPOlO 00) (WPOlO 00)

AG-180AO-MMM-000

- . . ^ - . ,^ . .

00600 Page 32

NORMAL REMEDY FOR

PROCEDURE INDlCATlON ABNORMAL INDICATlON

g. Reconnect wire 101 to terminal 2.

h. Close instrument panel by turning grip atches clockwise.

i. Close instrument panel door.

I. TIME DELAY RELAY (K4) Support Equipment Required

Part No. Nomenclature

Multimeter 110 VAC Power

source

Materials Required

NOIW

To prevent injury to personnel or damage to equipment, electrical power must he disconnected when working inside electrical controls panel.

a. Make sure electrical power is offand :onnector is disconnected.

b. Open electrical controls panel by ,urning grip latches counterclockwise.

c. Remove time delay relay (K4) (1, figure 2 from socket.

d. Check for continuity between pins 2 Continuity exists Replace time delay relay md 7. (WPOIO 00)

e. Check continuity between pins 1 and 3. Open Replace time delay relay. (wP01000)

f. Apply 110 VAC to pins 2 and 7. Check Open for approximately Replace time delay relay. :ontinuity between pins 1 and 3. 10 seconds after 110 (wP01000)

VAC application; conti- nuityaftcr 10 seconds.

Page 33

1 I ELECTRICAL CONTROLS PANEL

Figure 6. Time Delay (K4) Testing

AGd$OA0-MMM-000 006 00 Page 34


NORMAL REMEDY FOR

PROCEDURE INDICATION ABNORMAL INDICATION

g. Install relay in socket.

h. Close and latch electrical controls and.

0. COMPRESSORCYLINDER READ ‘EMPERATURE CUTOUT (CTCO)


Multimeter Salt bath or oven


a. Remove condenser fan panel assembly WP 008 00).

-b. Operate refrigerant system and pump efrigerant into receiver. (WP 007 00).

NOTE

Compressor cylinder head temperature switch is open above 325°F and closed below 250°F.

c. Remove CTCO (WP 012 00).

d. Disconnect either wire 112 or .13 from its respective wire nut splice. WP 012 00).

e. With CTCO stabilized at room emperature (70”F), check continuity between wires 112 and 113.

Continuity exists Replace Conipressor (WPOOS 00).

f. Place CTCO into a salt bath or oven md raise temperature, monitoring the emperature continuously.

AG-I $OAO-MMM-000 006 00 Page 35

PROCEbURE NORMAL REMEDY FOR

INDICATION ABNORMAL INDICATION

g. Check continuity between wires 112 and 113 as temperature exceeds 325°F (nominal).

h. Decrease temperature: check continuity between wires 112 and 113 as temperature drops below 250°F (nominal)

i. Install CTCO (WP 012 00)

II. LOW PRESSURE CUTOUT (LPCOI


Multimeter Regulated Nitrogen

Pressure Source


NOTE

Low pressure cutout opens when refrigerant pressure drops below 0 psig (nominal) and closes when refrigerant pressure rises ahove 17 psig (nominal).

a. Pump down unit (WP 007 00)

b. Open COMPRESSOR/RECEIVER ACCESS door.

c. Remove stem caps from receiver inlet and outlet service valves and close valves by turning valve stemsclockwise.

d. Remove condenser fan panel assembly (WP 008 00).

Open Replace Compressor (WP 008 00).

Continuity exists Replace Compressor (WP 008 00).


PROCEDURE NORMAL INDICATION

e. Remove stem caps from compressor suction; and discharge service valves and close valves by turning valve stems clockwise.

damage to equipment, electrical power must be disconnected when working in pressure controls box.

f. Make sure electrical power is off and connector is disconnected.

Refrigerant is toxic. To avoid injury to personnel, avoid breathing refrigerant or exposing skin or eyes to refrigerant. Do not expose refrigerant to open flame.

h. Bleed pressure from lines by loosening the capillary line fitting to the LPCO (5, figure 7).

i. Disconnect capillary line from LPCO (5, figure 8)

j. Disconnect wire 113 or wires 114 and 115 from LPCO.

k. Check continuity between terminals 2 and 3.

I. Apply a pressure source to the LPCO at the capillary connection.

00600 Page 36


Replace LPCO (WP 010 00).

AG-180AO-MMM-000 00600 Page 37

‘l‘ahle 2. ‘lestlng (Gont~nued)

NORMAL REMEDY FOR PROCEI)URE


m. Increase the prcssurc. Monitor for bntinuity os the pressure rises ahove 17 jig.

Continuity exists

__---- -

Replace I.PCO (WP 010 00).

n. Decrease the pressure. Monitor for open Replace LPCO (WP 010 00). jntinuity as the pressure falls below 0 psig.

a. Disconnect pressure source and connect lpillary line. Disconnect multimeter from mninals 2 and 3.

p. Connect wire 1 I3 or wires 114and 115.

q. Close PRESSURE CONTKOLS panel.

r. Evacuate system (WI’007 00).

s. Open compressor inlet and outlet ervice valves hy turning valve stems ounterclockwise. Install stemcaps.

t. Open receiver inlet and outlet service alves by turning valves stems ounterclockwise. Install stemcaps.

u. Close COMPRESSOR/RECEIVER \CCESS door.

v. Install condenser fan assembly (WI’ 108 00).

2. HIGH PRESSURE CUTOUT (HPCO) Support Equipment Required

Part No. Nomenclature Multimeter Kegulated Nitrogen Pressure Source

Materials Required

NOIW

AG-180AO-MMM-000 006 00 Page 38

PRESSURE CONTROLS

RESET lIUTTON~\- i 3 (SHEET 21

OS I llG&$- 117

L-Jd

2 -129 -118

120

Figure 7. Pressure Controls Testing (Sheet 1 of 3)

AG-180AO-MMM-000 006 00 Page 39

Figure 7. Pressure Controls Testing (Sheet 2)

AG-180AO-MMM-000 00600 Page 40

PS6

-135 B 1x- L Ml 131-

Figure 7. Pressure Controls Testing (Sheet 3)

AC-1 $OAO- -000

Table 2. ’

PROCEDURE

NOTE

High pressure cutout opens when refrigerant pressure is greater than 425 psig (nominal). The cutout must be manuolly reset.

a. Pumpdown unit.

b. Open COMPRESSOR/RECEIVER u2CESS door.

e. Remove stem caps from receiver inlet .nd outlet service valves and close valves by urning valve stems clockwise.

d. Remove condenser fan panel assembly WP 008 00)

e. Remove caps from compressor suction md discharge service valves and close valves ,y turning valve stems clockwise.

To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working in pressure controls box.

f. Make sure electrical power is off and :onnector is disconnected.

g. Open PRESSURE CONTROLS panel.

Refrigerant is toxic. To avoid injury to personnel, avoid breathing refrigerant or exposing skin, or eyes to refrigerant. Do not expose refrigerant to open flame.

iting (Continued)

NORMAL INDICATION


Cm Page 41

AC-1 $OAO-M M M-000 006 00 Page 42

Table 2.

PROCEDURE

- h. Bleed pressure from lines by loosening

le capillary line litting to the HPCO (6. gure 7).

i. Disconnect capillary line from HPCO.

j. Disconnect wire 114or 116 from HPCO.

k. Depress manual reset button.

I. Check continuity between terminals 1 nd 2.

m. Apply a pressure source to the HPCO t the capillary connection.

n. Increase the pressure. Monitor ontinuity as the pressure rises above 425 sig.

o. Decrease the pressure below 355 psig.

p. Depress manual reset button and monitor continuity.

q. Disconnect pressure source and econnect capillary line. Disconnect nultimeter from terminals I z,.nd 2.

r. Connect wire 114 or 116.

s. Close PRESSURE CONTROLS panel.

t. Evacuate system (WP 007 00).

u. Open compressor inlet and outlet ervice valves by turning valve stems ounterclockwise. Install stem caps.

v. Open receiver inlet and outlet service alves by turning valve stems ounterclockwise. Install stem caps.

sting (Continued)

NORMAL INDICATION

:ontinuity exists

)pen

Ipen

:ontinuity exists


&place HPCO (WP 010 00).

<eplace HPCO (WP 010 00).

<eplace HPCO (WP 010 00).

Xcplaee HPCO(WP01000).

AC-18OAO-MMM-000

PROCEDURE


NORMAL INDICATION

3. OIL SAFETY SWITCH (OS) Support Equipment Required

Part No. Nomenclature Multimeter Regulated Nitrogen

Pressure Source 110 VAC Power Source Clamp-Around Ammeter


a. Pump down unit. (WP 007 00).

b. Open COMPRESSOR/RECEIVER \CCESS door.

c. Remove stemcaps from receiver inlet .nd outlet service valves and close valves by urning valve stems clockwi~se.

d. Remove condenser fan panel assembly WP 008 00).

e. Remove stem caps from compressor uction and discharge service valves and lose valves by turning valve stems lockwise.

To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working in pressure controls box.

f. Make sure electrical power is off and onnector is disconnected.

00600 Page 43


00600 Page 44

Table 2. ’

PROCEDURE


Refrigerant is toxic. To avoid injury to personnel, avoid breathing refrigerant or exposing skin, or eyes to refrigerant, Do not expose refrigerant to open flame.

h. Bleed pressure from lines by loosening the capillary line fittings to the OS (1, figure 7).

i. Mark/tag capillaries as HIGH and LOW. Disconnect capillary lines from OS.

j. Using an external pressure source, apply pressure to the HIGH side port of the X and maintain a pressure of 50 psig.

k. Depress manual reset button.

1. Disconnect wire 116 from terminal M md wires 118and 120 from terminal 120.

m. Check continuity between terminals Z and 120.

n. Decrease the pressure to the HIGH ;ide port until the pressure drops below 5 xig.

a. Check continuity between terminals 2 and 120.

p. Increase the pressure to the HIGH side port until the pressure rises above 12 psig.

sting (Continued)

NORMAL INDICATION

Zontinuity exists

REMEIlY FOR ABNORMAL INI~ICA’L’ION

<eplace OS (WP 010 00).

ieplace OS (WP 010 00)

AG-180AO-MMM-000

Table 2.

PROCEDURE

q. Check continuity between terminals /I and L.

r. Depress manual reset button

s. Check continuity between terminals 2 .nd 120.

To prevent injury to personnel or damage to equipment, use extreme caution when working around 110 VAC electrical power.

t. Apply 110 VAC across terminals M .nd 120.

u. Decrease the pressure to the HIGH ide port until the pressure drops below 5 lsig.

v. Monitor current through terminals M md L with a clamp-around ammeter or other urrent measuring device.

w. Increase the pressure to the HIGH ide port until the pressure rises above 12 kg.

x. Allow OS internal heater to cool for a ew minutes.

y, Depress manual reset button,

z. Monitor current through terminals M md L.

an. Remove 110 VAC supply and remove wsssure source from HIGH side port.

sting (Continued)

NORMAL INDICATION

)pen

)pen

:urrent flow for appro- imately 45seconds, hen open circuit.

hrrent flow

teplace OS(WP 010 00)

ieplace OS (WP 010 00).

REMEDY FOR ARNORMAL INDICATION

<eplace OS (WP 010 00).

kplace OS (WP 010 00).

00600 Page 45

AG-180AO-MMM-000 006 00 Page 46

Table 2. ’

I’ROCEDURE

ab. Connect wire I16 to terminal ;\rl and wires 118;lnd 120 to terminal 120.

ac. Connect capillaries to OS HIGII and LOW side ports.

! I I ad. Evacuate system IWP 007 00).

ae. Close PRESSURE CONTROLS pnnel.

of. Open compressor suction and : discharge service valves by turning stems

counterclockwise. Install stem caps.

ug. Open receiver inlet and outlet

/I I

,ervice valves by turning valve stems ,ounterclockwise. Install stem caps.

ah. Close COMPRESSOWKECEIVER \CCESS door.

ai. Install condenser fan panel assembly WP 008 00).

14. FAN CYCLING SWITCH (FSW)


Part so. Nomenclature Multimeter Keg&ted Nitrogen Pressure

Source Materials Required

NOnI?


b. Open COMPKESSOWRECEIVEK I\CCESS door.

e. Remove stem caps from receiver inlet lnd outlet service valves and close valves by ;urning valve stems clockwise.

iting(Continued1

NORMAL INDICATION


AG-180AO-MMM-000

Table 2. ’

PROCEDURE

d. Remove condenser fan panel assembly WP 008 00).

e. Remove stem cops from compressor uction and discharge valves and close Aves by turning valve stems clockwise.

/-jiziq

To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside pressure controls box

f. Make sure electrical power is off and :onnector is disconnected.

g. Open PRESSURE CO.NTROLS panel.

Refrigerant is toxic. To avoid injury to personnel, avoid breathing refrigerant ^ or exposing skin or eyes to retrlgerant, Do not expose refrigerant to open flame.

h. Bleed pressure from lines by loosening the capillary line fitting to the FSW (7, figure 7).

i. Disconnect capillary line from FSW

j. Disconnect wire I15 or 1 I9 from FSW.

k. Check continuity between terminals 1 and 3.

To prevent injury, avoid breathing nitrogen. Use only in a well ventilated area.

sting (Continued)

NORMAL INDICATION

006 00 Page 47


Ieplace FSW (WP 010 00).

AG-180AO-MMM-000 00600 Page 48


PROCEDURE NORMAL

INDICATION

L

I. Apply pressure source to the FSW at the capillary connection.

m. increase the pressure. Monitor continuity as the pressure rises above 245 psig.

Continuity exists

n. Decrease the pressure. Monitor continuity as the pressure drops below 175 psig.

Open

o. Disconnect pressure source and connect capillary line.

p. Disconnect multimeter.

q. Reconnect wire 115 or 119.

r. Close PRESSURE CONTROLS panel.

s. Evacuate System (WP 00’7 00).

t. Open compressor suction and , discharge valves by turning valve stems counterclockwise. Install stem caps.

u. Open receiver inlet and outlet service valves. by turning valve stems counterclockwise. Install stem caps.

v. CloseCOMPRESSOWRECEIVER ACCESS door.

w. Install condenser fan panel assembly (WP 008 00).

Replace FSW (WP 010 00). Replace FSW (WP 010 00).

Replace FSW (WP 010 00). Replace FSW (WP 010 00).


AG-180AO-MMM-000 00600 Page 49

Table 2. TestingtContinued)

PROCEDURE I NORMAL INDICATION

15. PRESSURE SWITCHES lPS4. I’S5)


Part No. Komenclature Multimetal Regulated Nitrogen

Pressure Source



b. OpenCOMPRESSOR/RECEIVER ACCESS door.

c. Remove stem caps from receiver inlet and outlet service valves and close valves by turning valve stems clockwise.


e. Remove stemcaps from compressor suction and discharge service valves and close valves by turning valve stems clockwise.

To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside pressure controls box.

f. Make sure electrical power is off and connector is disconnected.



AG-l$OAO-MMM-000 00600 Page 50

Table 2. Testing KZontinued)

I

I NORMAL INDICATION PROCEDURE

Refrigerant is toxic. .fo avoid injury to personnel, avoid breathing refrigerant or exposing skin or eyes to refrigerant. Do not expose refrigerant to open flame.

h. Bleed pressure from lines by loosening the capillary line Fittings to PS4 and PS5 (2,3. figure 7).

i. Disconnect capillary lines from PS4 and PS5. I

j. Disconnect wire 128 from PS4 and 129 from PS5

k. Check continuity between terminals

I Open

Land M2 of PS4 and PS5. respectively.

I. Check continuity between terminals L and Ml of PS4 and PS5, respectively.

Continuity exists

To prevent injury avoid breathing nitrogen. Use only in a well ventilated area.

m. Apply a pressure source to the capillary connections of PS4 and PS5.

n. Increase the pressure. Check continuity between terminals L and M2 of PS4 and PS.5, respectively.

PS5: Continuity exists Adjust PS4 and/or PS5 above 50 psig (WPOO7 00). Ps4: Continuity exists Replace PS4 and/or PS5 above 55 psig (WP 009 00).

o. Decrease the pressure. Check continuity between terminals Land M2 of PS4 and PS5, respectively.

PS4: Open below 30 Psig PS5: Open below 25 osia

Adjust PS4 and/or PS5 (WPOO7 00). Replace PS4 and/or PS5 (WPOO9 00).


Replace PS4 and/or PS5 (WPOlO 00).

Replace PS4 and/or PS5 (WP 009 00).

OAO-MMM-000

Table 2. T tsting (Continued)


1 p. Increase the pressure. Check continuity between terminals Land :%I1 of I’S4 and PS5, respectively.

q. Decrease the pressure. Check continuity between terminals Land Ml of

! PS4 and PS5, respectively.

r. Disconnect pressure source and connect capillary lines. Disconnect multimeters.

s. Connect wires 128 and 129.

t. Close PRESSURE CONTROLS panel.

I u. Evacuate system (WP 007 00). I / v. Open compressor suction and ~ discharge valves by turning valve stems counterclockwise. Install stem caps.

I w. Open receiver inlet and outlet service i valves by turning valve stems

counterclockwise. Install stem caps.

x. Close COMPRESSOR/RECEIVER ; ACCESS door.

I y Install condenser fan panel assembly i (WP 008 00).

/ 16. PRESSURE SWITCH (PSI3 I

Support Equipment Required Part x0. Nomenclature

Multimeter Regulated Nitrogen Pressure

Source


‘S5: Open above 50 lsig 34: Open above 55 sig

‘S4: Continuity exists )elow 30 psig

35: Continuity exists )elow 25 psig


idjust PS4 and/or PS5 WP 007 00). Leplace PS4 and/or PS5 WP 009 00).

idjust PS4 and/or PS5 WP 007 00).

leplace PS4 and/or PS5 WP 009 001.

00600 Page 51

AG-180AO-MMM-000

Table 2.

PROCEDURE


b. OpenCOMPRESSOR/RECEIVER KCESSdoor.

e. Remove stem caps from receiver inlet Ind outlet service valves and close valves by urning valve stems clockwise.

d. Remove condenser fan panel assembl) WP 008 00).

e. Remove stem caps from compressor ,uction and discharge service valves and :lose valves by turning valve stems zlockwise.

To prevent injury to personnel or damage to equipment, electrical power must be off when testing pressure switches.

f. Make sure electrical power is off md connector is disconnected.

g. Open PRESSURE CONTROLS janeI.

Refrigerant is toxic. To avoid injury to personnel, avoid breathing refrigerant or exposing skin or eyes to refrigerant. Do not expose refrigerant to open flame.

h. Bleed pressure from lines by oosening the capillary line litting to PS6 (4, igure 8).

i. Disconnect capillary line from PS6

sting(Continued)

NORMAL INDICATION


00600 Page 52

AG-18OAO-MMM-000

I

c c F

b

C’ ”

d s

Table 2.

PROCEDURE

j. Disconnect wire 135 from PS6.

k. Check continuity between terminals 1 and M 1 of PS6.

To prevent injury, avoid breathing nitrogen. Use only in well ventilated area.

I. Apply a pressure source to the apillary connection of PS6.

m. Increase the pressure. Monitor ontinuity between terminals I. and M 1 of 56.

n. Decrease the pressure. Monitor etween terminals Land Ml of PS6.

o. Disconnect pressure source and onnect capillary line. Disconnect nultimeter.

p. Connect wire 135.

q. Close PRESSURE CONTROLS panel.

r. Evacuate system (WP 007 00).

s. Open compressor suction and ischarge service valves by turning valve terns counterclockwise. Install stem caps.

t. Open receiver inlet and outlet service alves by turning valve stems ounterclockwise. Install stem caps.

u. Close CO.MPRESSOR’RHXIVER LCCESS door.

v. Install condenser fan panel assembly WP 008 00).

!sting (Continued)

NORMAL INDICATION

Zontinuity exists.

Ipen abovc 45 psig

:ontinuity exists Elow 20 psig


ieplace PS6 (WP 009 00).

Idjust PS6 (WP 007 001. <eplace PS6. (WP 009 00)

Idjust PS6 (WP 007 00). <eplace PS6 (WP 009 00).

00600 Page 53

AG-180AO-MMM-000 006 00 Page 54

Table 2. ding Continued)

PROCEDURE

17. FUSES


Part Number Nomenclature Multimeter

Materials Required

Specification or Part Number Nomenclature

Antis&e Compound

To prevent injury to personnel or damage to equipment, electrical power must be off when working inside fuse box.

a. Make sure electrical power is off and connector is disconnected.

b. Remove FUSES panel (3, figure 8) by removing screws(l), washers (2) and panel (3).

c. Open fuse box (4) by removing screws (5), washers (6) and fuse box cover (7).

d. Check continuity of fuse(s) after removal from fuse holder(s).

e. Position cover (7) on fuse box.

f. Install screws (5) and washers (6)

g. Position FUSES panel (3) on top.

h. Apply antiseize compound to screws (1)

I .. I Install screws (1) and washers (2)

NORMAL INDICATION

Continuity exists

REMEDY FOR REMEDY FOR ABNORMAL ABNORMAL

I I

INDICATION INDICATION

Replace fuse (WP 010 00)

AG-18OAO-MMM-000 00600 Page 55

AG-180AO-MM M-000 00600 Page 56

r c

1

f

(

‘-

Table 2.

PROCEDURE

18. PRESSURE SWITCH (PSI)


‘art No. Nomenclature Regulated Hand Pump

Pressure Source (AIR)

Manometer, Range O-2 in. Hz0

Multimeter, Tee, 0.25 Tube size, 45” Flare c.438.20 UNF-2AThread)


a. Make sure electrical power is off and xxmector is disconnected.

b. Open BLOWER/FILTER DRIER \CCESSdoor.

e. Remove nut (6, figure 9) and washers 5) from switch bracket (4).

d. Remove switch PSl (7) from :ompartment.

((

To prevent injury to personnel or damage toequipment, electrical power must be off when testing pressure switches.

e. Remove PSI cover (3) by loosening :over screw (2).

f. Disconnect wires 88,89 from terminal 3 of PSI. Disconnect wire 101 from terminal UC and wire 102 from terminal NO.

g. Tag and disconnect the air pressure ines from the HIGH and LOW side ports of 31.

sting (Continued)

NORMAL INDICATION

REMI.:DY E’OR ABNORMAL INDICATION

I

AG-180AO-M M M-000 006 00 Page 57

BLOWER~F~LTE~~ DRIER ACCESS OOOA

SPRING LATCHES

9--

PS3

t- 69

PSZ

NC

NC 107 -+

NO

Figure 9. Pressure Switches (PSl, PS2 and PS3) Testing

AC-180AO-MMM-000 006 00 Page 58

Table 2. Testing K!onti”ued)

NOHMAL HEMEDY FOR PROCEDURE INDICATION ABNORMAL

INDICATION

h. Check continuity between terminals C and NC: continuity Replace PSI (WP 009 00). C and NC and C and NO, respectively. exists

C and X0: Open

i. Using an external pressure source Open from 0 to 1.45 in. Adjust PSI (WP 007 00). with manometer teed into the pressure line, H2D; continuity e.xists apply pressure to the HIGH side port of PSI at greater than 1.45 Replace PSI (WP 009 00). Increase the pressure from zero to greater in. H20 than 1.45 inches of water (do not exceed 2.0 inches of water) while monitoring the continuity between terminals C and NO.

j. Check continuity between C and NC. Open Keplacc I’S1 IWP 009 00).

k. Decrease the pressure to zero while Open to approx 1.3 in. Replace PSI (WI’009 00). monitoring the continuity between HzO; continuity exists at terminals C and NC. less than 1.3 in. Hz0

I. Check continuity between terminals C Opt” Replace PSI (WP 009 00). and NO.

m. Disconnect test equipment.

n. Attach the air pressure lines to switch F'S1 (7). Ensure that the HIGH and LOW side lines are attached to their respective ports.

o. Connect wires 88,89 to terminal C, wire 101 to terminal NC, wire 102 to terminal NO.

p. Replace cover (3) and tighten cover screw (2).

q. InstaIl switch PSl (7) in compartment with nut (6) and washers (5).

r. Close BLOWER/FILTER DRIER ACCESS door.

AG-180AQ- MM-000

Table 2. sting (Continued)


t 19. PRESSURE SWITCH (PS2, PS3)


Part No. Nomenclature Multimeter Kegulated Hand Pump Pressure Source (Air) .Manomcter, Range O-3 in. H20 Tee 0.25 Tube Size, 45” Flare t.438.20 L!NF-2A Thread)

Materials Required Sane


a.. .Make sure electrical power is off and onnector is disconnected.

b. Open BLOWER/FILTER DRIER ,CCESS door by turning spring latches ounterclockwise.

iP C’

e. Remove nut (6, figure S), washers i (5) from switch bracket (4).

! d. Remove switch PS2lPS3 (S/S).

I e. Remove cover (3) by loosening I two cover screws (2). / I f. Disconnect wires89.106, and 107 from ! terminals C (PS31, SO (PS3), and NC (PSZ), , respectively.

j g. Tag and disconnect the air pressure

lines rrom the HIGH and LOW side ports of / the switch housing.

006 00 Page 59

REMEDY FOR ABNORMAL INDtCATION

AG-180AO-MMM-000 00600 Page 60

Table 2.

F

h. Check continuity between C and NC and C and NO of PS2 and PS3, respectively.

i. Using an external pressure source with manometer teed into the pressure line, apply pressure to the HIGH side port. Increase the pressure from zero to greater than 2.5 inchesafwater while monitoring the continuity between (do not exceed 3.0 inches of water) PS3 terminals C and NO.

j. Check continuity between PS3 (9) terminals C and NC.

k. Decrease the pressure to zero while monitoring thecontinuity between PS3 terminals C and NC.

I. Checkcontinuity between PS3 terminals C and NO.

m.Repeat steps i. through 1. for PS2 (8).

Testing (Continued)

NORMAL INDICATION

PS2: C and NC- continuity exists; C and NO-open

PS3: C and NC- continuity exists; C and NO-open

Open from 0 to 2.5 in. 1120; continuity exists at greater than 2.5 in. Hz0

Open

Open to approx 2.3 in. H2O; continuity exists at less than 2.3 in. Hz0

open

Open from 0 to 2. I in. H20; continuity exists at greater than 2.1 in. H,O

Open from I.0 in. Hz0 to, approx., 1.9 in. H:O: continuity exists at less than 1.9 in. HIO


Replace (WPOO9 00).

Adjust PS3 (WPOO7 00).

Replace (WPOO9 00).

Replace (WPOO9 00).

Replace (WPoo9 00).

Replace (WPOO9 00).

Adjust PS2 (WPOO7 001.

Replace (WPOO9 00).

Repluce (WPOO9 00)

i I

I

AG-180AO-MMM-000 00600 Page 61

PROCEDURE NORMAL

REMEDY FOR


n. Connect air pressure lines as tagged.

o. Connect wiring as tagged and install lver (3) with screws (2). co

p. Position switch (‘7) on roadside fender.

q. Install nuts (6), washers (5) and witch PS2 (8) or PS3 (9) on Bkt (4). 9,

A I‘. Close BLOWER/FILTER DRIER

CCESS door.

1. SOLENOID VALVE (SI THROUGH 6, UI AND U2).


Part No. Nomenclature Multimeter

Materials Required NO”tZ

a. Make sure electrical power is off and mnector is disconnected. cc

(( dm

b. Remove condenser fan panel assembly ,pen BLOWER/FILTER DRIER ACCESS oar for S5).

piiiiz-)


c. Remove coil electrical junction box by Doseningiremoving the retaining screw/nut. II

le d. Remove wire nut from one electrical

:ad and separate wires.

AG-180AO-MMM-000 006 00 Page 62

Figure 10. Solenoid Valves Testing (Sheet 1 of 2)

AC-180AO-MMM-000 006 00 Page 63

Figure 10. Solenoid Valves’Testing (Sheet 2)

AG-180AO-MMM-000

Table 2.

PROCEDURE

e. Remove wire nut from second electrical lead.

f. Check continuity between the leads to solenoid coil as follows:

Solenoid Valve Wire To Wire

31 130 122 52 132 123 $3 136 139 $4 137 140 55 127 121 j6 134 138 !Jl 131 118,143 Li2 133 143

g. Join separated wires and replace wire 1ut.s.

h. Replace junction box and :xghten/replace the retaining screw/nut.

i. Replace condenser fan panel assembly Close BLOWER/FILTER DRIER ACCESS Ioor for S5).

stin (Continued)

NORMAL INDICATION

Zontinuity exists

00600 Page 64


?eplace coil (WP 008 00).

OKGANI%A’I7ONALAND INTERMEDIATE MAINTENANCE

SERVICING, LUBRICATION. ADJUSTMENT,

CLEANUPAFTERCOMPRESSOR MOTOK BUKNOUT

AIR CONDITIONER, AIKCRAFT GROUND COOLING

AiMR2C.21


Keference Material

Operating Instructions. WI’005 00 ILcmoval and Installation. WI’008 00 Fabrication :tnd Inspection of Hraxd I’iping Systems SAVSEA 0900.1.1’.001-7000

Alphabetical Index Suhiect Adjustment ............................... ............

Brake.............~~ ............................... llypass Airflow Controller ............ .............. Fan Cycling Switch (FSWI .. ........... ........... ... llcad I’ressurc Kcgulator Valve (VI 1 ................... .. lligh l’ressurc Cutout Switch LIII’CO). ..................... Inlet Airflow Controller ................................. 1.0~ I’rewxc Cutout Switch ILPCOI ...... ....... .... Main Service Circuit Brcakcr. ................... ..... MotorStartersiKl, K2, K3). ........... ................ Pressure Diffcrcntial Switch (Open on I’rcssure I&c) (l’S6). ..... I’rcssure I)iffcruntial Switch (Close o” Pressure Kise) (I’S4, PS5)

Air Filter Servicing.. ..................................... Air Filter Servicing ......... ............................ I%lower nnd Compressor Oil Servicing. ........................ l%lower Oil Servicing ..... ............................... Brake Adjustment .... .............. .................. Bypass Airflow Controller Adjustment. ...... ................ Cleanup After Compressor Motor Burnout .... ................ Evacuationandcharging .................................. Fan Cycling Switch (FSW), Low Pressure Cutout Switch lI.PCO) and

Iligh Pressure Cutout Switch LHI’CO) Adjustment. ........... Head Pressure Kegulator Adjustment. ........................ Inlet Airflow Controller Adjustment. ......................... Main Service Circuit Hrwker (CRI) Adjustment ................ Motor Starters (Kl, K2, K3) Ad.justmcnt ...................... P~essurc Differential Switchcs (I’S4, I’%, I’%) Adjustment. ....... f<cfrigcration Servicing Instwctions .........................

Compressor Oil Addition. ............................... Compressor Oil Drain. ................................. F:mpty System Pressure Test ........................... Gas Kcfrigerant Addition/Charging ....................... LcakTest ..........................................

007 00 Page 2

Alphabetical Index (Continuedl

Suhiect m Liquid Refrigerant Addition/Charging 7 Pumpdown................................................................. 3 SystemEvacuation........................................................... 3

S~stemP”mpdow”..........................................,................... 4

Record of Applicable Technical Directives None

1. REFRIGERATION SERVICING INSTRUCTIONS.


Part Number Nomenclature Refrigerant Leak

Detector Oil Charging Pump Vacuum Pump Charging Hose Vacuum Gage Manifold Gage Set Scale (0 150 lb) Wrench. Torque.

O-60 R-lbs. Wrench. Torque,

O-100 in-lbs.

Materials Required


Refrigerant, R-113 Refrigerant. R-22

VV-L-825. Type IV Charging Drum

Oil, Compressor Rermlated Pressure

P-D-680

MIL-C-16173D

Source (Nitrogen) Solvent Compound, Sealing Corrosion Preventive Compound, Grade I

To prevent injury to personnel, use care when servicing the refrigera-

tion system. High pressures are present which could cause serious injury. If a refrigerant leak is sus- pected, provide adequate ventilation and be careful not to inhale refrigerant vapors or allow any refrigerant to contact the skin.

2. LEAK TEST.


To prevent injury to personnel, be careful when working near rotating components.

b. Check all refrigerant Iittings, couplings, and valves for leaks.

c. Mark all spots where leaks are detected

d. If no leaks exist at receiver, pump down refrigerant system (this WP, paragraph 3); if leaks exist at receiver, open system to blow the charge.

e. Repair leaks (NAVSEA 0900-LP-001-7000)

f. Perform empty system pressure test (this WP, paragraph 5).

g. Evacuate system (this WP, paragraph 4) and add refrigerant (this WP, paragraph 6 or 7). I

h. Install condenser fan panel assembly (WP 008 00).

AG-18QAO-MMM-080 Cm 0 Page 3

3. I’UMI’I~OWN. 4. SYSTEM EVACUATION.

NO’I’E

I.PCO will stop comprcswr when suction pressure reaches 0 prig.

a. open CO~PKESSoR/R~C~lv~:R ACCESS door (figure I ).

b. Remove receiver outlet service valve cap and close valve 121 by turning valve stem clockwise.

c. Start air conditioner (WP 005 001 and operate with MODE switch set to DEllL.MID or COOI. position.

NOTE

The compwssor will operate, pump- ing refrigerant from the suction piping to the discharge piping and rcccivcr until the suction pressure reaches 0 prig. The LPCO will then shut off the compressor. In order to obtain a more complete pumpdown, if desired, jumper terminals 2 and 3 of the LPCO and allow the compressor to continue to operate below 3 suction pressure of 0 psig. Monitor the suction pressure gauge. and shut down the unit when the desired pressure is reached. f<emove the jumper wire i‘rom terminals 2 and 3 of the LPCO.

d. Shut down the unit IWP 005 00) and set the CIRCUIT BREAKER (3) to the OFF position.

e. Remove receiver inlet service valve cap and close valve (II by turning valve stem clockwise.


NOTE

If whole refrigeration system is to be evacuated, receiver inlet and outlet service valves must be open to allow receiver to be evacuated. If only part of refrigeration system is to be evacuated, unit must be pumped down (this WP, paragraph 3) and receiver inlet and outlet service valves closed to protect unnecessary loss of refrigerant.

b. If required, pump down refrigeration system (this WP, paragraph 3) and close receiver inlet and outlet service valves (1 and 2, figure 1).

c. Remove caps (5 and 8, figure 2) from pneumatic valves (4 and 9) of gas charging port and EPR valve.

d. Using manifold charging hoses connect pneumatic valves (4 and 9) to vacuum pump and gages. Using a 110 vat power supply connect hot wire to TBl-4 and neutral wire to ground terminal (WP 3, figure 2) to open solenoid valves Sl through S6.

e. Open compressor suction and discharge service valves fully by turning valve stems counterclockwise, then turn valves clockwise two full turns, for proper gage readings.

f. Start vacuum pump and evacute system to 2.5 MM of HG. This procedure may take 6 to 6 hours.

f. Install receiver inlet service vnlve cap and receiver outlet service valve cap.

g. Close COLIPKESSORIREC~IVER ACCESS door.

g. Note and record vacuum indicated on tw3.

h. Shut down the vacuum pump and allow system to stand for 30 to 60 minutes. Check gage. If no rise is indicated, the system is sealed and ready to be charged.

-0QQ 007 00 Page 4

SERVICE

SERVICEVALVE

Figure 1. System Pumpdown (Sheet 1 of 2)

AG-18OAO-MMM-000 007 00 Page 5

i ELECTRICALCONTROLS

Ej

0 COMPRESSOR

CONOENSERFAN

Figure 1. System Pumpdown (Sheet 2)

AC-180AO-MMM-000 Page 6

8

Figure 2. Evacuation and Charging

AC-180AO-MMM-000 007 00 Page 7

i. Charge system with refrigerant (this WP, paragraph 7).

j. Disconnect lines from pneumatic valves (4 and 9). Open compressor suction and discharge service valves fully by turning stems counterclockwise.

k. Install caps (5 and 8) on pneumatic valves (4 and 9).

1. If required, open receiver inlet and outlet service valves (1 and 2, figure 1).

m. Install condenser fan panel assembly (WP 008 00).

5. EMPTY SYSTEM PRESSURE TEST.

NOTE

This procedure shall be used when there is no refrigerant in the system (systemcompletely empty).

a. Remove condenser fan panel assembly (WP 00800).

h. Connect center charging line of charging manifold to drum of refrigerant (R-22). Open’valves on manifold.

c. Purge charging lines by opening valve on refrigerant drum.

I

d. Remove caps (5 and 8, figure 2) from pneumatic valves (4 and 9) of gas charging port and EPR valve.

e. Connect charging lines (suction and discharge) of the charging manifold to the pneumatic valves (9 and 4) of the gas charging port and EPR valve.

f. Open refrigerant drum valve fully and allow refrigerant gas to flow into the system. Allow refrigerant to flow until stabilized.

h. Disconnect center charging line from refrigerant drum.

i. Open discharge valve on charging manifold slightly to purge center line and connect center line to nitrogen cylinder.

j. Open suction valve on charging manifold. Open valve on nitrogen cylinder. Charge system with nitrogen until DISCHARGE PRESSURE gage indicates 300 psig.

k. Close valve on nitrogen cylinder

I. Pass refrigerant leak detector over all refrigerant littings, couplings, and valves. Mark all spots where leaks are detected.

ni. Close valves on charging manifold.

n. Disconnect nitrogen cylinder from charging manifold. Open valves on charging manifold and allow system to bleed off until flow through manifold has almost stopped.

o. lf any leaks were detected, repair leaks (VAVSEA 0900.LP-001-7000) and repeat pressure test.

p. Remove charging lines from pneumatic valves (9 and 4).

q. Install caps (5 and 8) on pneumatic valves (9 and 4).

r. Evacuate system (WP 007 00) and charge with refrigerant (WP 007 00).

s. Install condenser fan panel assembly (WP 00800).

6. LIQUID REFRIGERANT ADDITION/ CHARGING.

a. Attach center hose of manifold gage set to refrigerant supply bottle (R-22).

b. Place refrigerant supply bottle on scale.

g. Close charging manifold and refrigerant drum valves.

c. Open COMPRESSOR/RECEIVER ACCESS door.

AC-180AO-MMM-000 007 00 Page 8

d. Remove valve cap from receiver outlet service valve and pneumatic valve.

c. Place refrigerant supply hottle on scale.

d. Open COMPRESSOR/RECEIVER ACCESS c. Close the receiver outlet service valve by door.

turning valve stem clockwise.

f. Open receiver outlet service valve one full c. Rcmovc villve cap (8, figure 21 from gas

turn (counterclockwise). charging port pneumatic valve (9).

g. Open refrigerant supply bottle valve. f. Open refrigerant supply hottle valve

h. While purging discharge side of manifold g. While purging discharge side of manifold

gage set, attach discharge hose to pneumatic wlve gage set, connect discharge hose to gas charging

on receiver outlet service valve. port pneumatic valve.

i. Add liquid refrigerant until scale indicates h. Open refrigerant supply bottle valve fully

desired amount has been added. (If necessary, and add gaseous refrigerant until scale indicates

refrigernnt supply bottle may be turned upside desired amount has been added.

down to discharge liquid refrigerantI. i. Close refrigerant supply bottle v~lvc.

j. Close valve on refrigerant supply bottle valve.

k. Operate air conditioning unit in DEHU!vllD or COOL mode (WP 005 00). If unit cannot he fully charged with liquid, charge unit with gas ithis WP, paragraph 71.

I. Remove manifold gage set discharge hose from pneumatic valve on receiver outlet service ValVe.

,i. Remove discharge hose from gas charging port pneumatic valve (9).

k. Install cap (8) on gas charging port pneumatic valve (9).

I. Close COMPRESSOR/RECEIVER ACCESS door.

m. Shut down air conditioning unit IWP 005 00).

m. Open receiver outlet service valve completely by turning valve stem counterclockwise.

8. COMPRESSOR OIL DRAIN.

a. Remove condenser fan panel assembly (WP n. install valve caps on receiver outlet service 008 00).

valve and pneumatic valve. h. Remove caps (3 and 5, figure 3) from suction

a. Close and secure COMPRKSSOR/- and discharge service valves.

RECEIVER ACCESS door. c. Close compressor suction and discharge

p. Shut down air conditioning unit (WP 005 service valves I2 and 4) by turning valve stems

00). clockwise.

7. GAS REFRIGERANT ADDITION/ CHARGING.

a. Operate air conditioning unit in DEHU,MID or COOL mode (WP 005 00). To prevent injury to personnel, use

cure when changing compressor oil. b. Attach center hose of manifold gage set to

refrigerant supply bottle (R-22). High pressure is present which could cause serious injury.

AG-180AO-M

SIGHT GLASS X\

\\ 7 6

Figure 3. Blower and Compressor Oil Servicing

007 00 Page 10

Rcfrigcrlmt is toxic. To avoid injury to pcrsonncl, ovoid hrcathing rcfrigcrant or exposing skin or eyes to re- frigcrilnt. I)0 not cupose refrigerunt to open flame.

0

(I. Rclcasc rcfrigcront from compressor hy dcpresiing pneumatic valve (9, figure 2).

(5. l’lxc container under chassis beneath drain holr Iwnted in floorboard.

f. Remove oil drain plug (8) and drain oil

g. Install oil drain plug (8). Torque drain plug 25 to 30 foot-pounds CQA,.

h. Perform compressor oil addition (this WI’, puragraph 9).

9. COMPRESSOR OIL ADDITION.

Do not add oil to compres:;or unless oil level is below 118 level of sightglass when compressor is operating.

a. Hemove condenser fan panel assembly (WP 008 00).

NOTE

Compressor oil will absorb moisture from the atmosphere.

h. Remove cap (6, ligure 3) from oil servicing port (7).

c. Connect hose from oil charging pump to oil servicing port (7).

d. Connect oil charging pump to oil supply. Do not expose compressor oil to atmosphere.

To avoid damage to equipment, do not overfill eomprcssor oil reservoir. A complete oil till is 19 pints (9.Il’L quarts).

c. Pump oil into compressor (1) until l/8 3/8 sight ylnss wading isohtnined. A complete oil lill is I9 pints (g-112 quarts).

f. Disconnect hose from oil servicing port (7).

g. Install cap (6) on oil servicing port

h. Install condenser fan panel assembly (WP 008 00).

10. AIR FILTER SERVICING.


None

Materials Required

Specification or Part Number Nomenclature W-I,-820R LubricatingOil

(or Equivalent)

a. Remove cable assembly (2, figure 4) from storage rack (1).

h. Open FILTER ACCESSdoor

c. Remove filter (3).

d. Inspect lilter (3) for damage or deterioration. Replace Filter (3) if unserviceable.

e. Wash filter (3) with mild detergent and hot water. Rinse.

f. Allow lilter (3) to dry throughly and oil lightly with lubricatingoil.

g. Install lxter (3)

h. Close FILTER ACCESSdoor.

i. Place cable assembly (I) on storage rack (2).

AG-180AQ-M 007 00 Page 11

Figure 4. Air Filter Serwicing

007 00 Page 12

Il. BLOWER OIL SERVICING.


None

Mabxials Required

Specification or Part Number

Dexron II

Nomenclature

Automatic Transmission Fluid

e. Remove caps (5 and 7, figure 5) from compressor suction and discharge service valves. Close valves by turning valve stems clockwise.

Refrigerant is toxic. To avoid injury to personnel, avoid breathing or exposure to skin or eyes. Do not expose refrigerant to open flame.

il. Open BLOWER OIL FILL door.

b: Remove fill plug (9, figure 3) from top of gear case.

c. Place a suitable container below drain tube located on underside ofunit.

d. Loosen fan cycling switch capillary fitting and allow captive refrigerant to bleed off.

e. Disconnect fan cycling switch capillary Fitting.

f. Disconnect wire 115 from terminal I of the fan cycling switch (1).

d. Open oil drain petcock and drain oil from gear ease.

g. Using multimeter. check continuity between switch terminals 1 and 3. An open circuit should exist.

e. Close oil drain petcock. h. Connect pressure source with gage and

f. Fill gear case through fill plug hole with valve to fan cycling switch capillary fitting,

i. While monitoring the multimeter. slowly

n

automatic transmission fluid (ATF) until proper level is indicated on blower oil level gage and increase the pressure to the fan cycling switch. The fill cold to cold fill line (4 to 6 pints). switch should close at, nominally, 245 psig.

g. Install fill plug(9).

h. Close BLOWER OIL FILL door.

j. While monitoring the multimeter, slowly decrease the pressure to the fan cycling switch. The switch should open at, nominally, 175 psig.

12. ADJUSTMENT. NOTE


Part Number Somencluture

Regulated Nitrogen SOUrCe Cage 0 to 300 psi Valve Multimeter Vacuum pump

Materials Required

NOnI2

13. FAN CYCLING SWITCH (FSW).

Dcadband (differential between switch opening and closing) is 70 psi. Deadband cannot be adjusted.

Rotation of the range adjustment screw one full turn clockwise in- creilses both setpoints LOO psig; rotation of the range adjustment screw one full turn counterclockwise decreases both setpoints 100 psig.

k. Adjust switch (1) as required by turning range adjustment screw. Repeat steps i. and j. rls necessary. If switch (1) cannot he adjusted, replace it (WPOO9 00).

8. Open PRESSURE CONTROLSdoor. I. Remove pressure source nnd gage from fan

cycling switch capillary fitting.

b. Remove condenser fan panel assembly (WP m.Connect fsn cycli”g switch capillary litting to 008 001. tee.

AG-18OAO-MMM-000 Page 13

Figure 5. Fan Cycling Switch (FSW), Low Pressure Cutout Switch (LPCO) and High Pressure Cutout Switch (HPCO) Adjustment (Sheet 1 of 2)

AG-180AO-MMM-000 007 00 Page 14

RANGE AOJUSTMENT SCREW

LOW PRESSURE CUTOUT SWITCH

HIGH PRESSURE CUTOUT SWITCH CAPILLARY FITTING

Figure 5. Fan Cycling Switch (FSW), Low Pressure Cutout Switch (LPCO) and High Pressure Cutout Switch (HPCO) Adjustment (Sheet 2)

AC-180AO-MMM-000 007 00 Page 15

n. Connect wire 115 to terminnl 1 of the fan cycling switch (1).

o. Evacuate system (this WP, paragraph 4).

p. Open compressor suction and discharge service valves completely by turning valve stems counterclockwise. Install caps (5 and ‘71.

q. Install condenser fan panel assembly (WP 00800).

r. Close PRF:SSURE CONTROLS door.

14. HEAD PRESSURE REGULATOR VALVE (VI).


b. Remove valve cap from valve !I, figure G).

e. Start air conditioner (WP 005 00).

d. Observe DISCHARGE PRESSURE gage Minimum compressor discharge pressure should be 225 psig.

NOTE

One full clockwise turn of adjusting increases pressure setting 15 psig; one full turn counterclockwise decreases pressure setting 15 psig.

e. Adjust valve as required to maintain discharge presswe of225 psig.

f. Shut down air conditioner (WP 005 00).

g. Install valve cap on valve (1).

h. Install condenser fan panel assembly (WP 00800).

15. HIGH PRESSURE CUTOUT SWITCH (HPCO).

a. Open PRESSURE COSTROLSdoor.

b. Remove condenser fan panel assembly (WP 00800).

e, Remove caps (5 and 7. figure 5) from compressor suction and discharge service valves. Close valves by turning valve stems clockwise.

Refrigerant is toxic. To avoid injury to personnel, avoid breathing refrigerant or exposing skin or eyes to refrigerant. Do not expose refrigerant to open flame.

d. Loosen high pressure cutout switch capillary fitting and allow captive refrigerant to bleed off.

e. Disconnect high pressure cutout capillary fitting.

f. Disconnect wire 114 from terminal C of the high pressure cutout switch (3).

g. Using multimeter, check continuity between terminals C and NC. Continuity should exist.

h. Connect pressure source with gage and valve to high pressure cutout switch capillary fitting.

i. While monitoring the multimeter, slowly increase the pressure to high pressure cutout switch (3). The switch should open at. nominally, 425 psig.

j. While monitoring the multimeter, decrease the pressure cutout switch to 355 psig. The switch should remain open.

k. While monitoring the multimeter and with the pressure at 355 psig, depress the high pressure cutout switch manual reset button. Continuity should exist.

NOTE

Deadband (differential between switch opening and closing (with manual reset assist)) is 70 psi. Deadband cnnnot be adjusted.

Rotation of the range adjustment screw one full turn clockwise increases both pressure switch points 100 psi, rotation of the range adjustment screw one full turn counterclockwise decreases both pressure switch points 100 psi. The setpoint is the cutout pressure of 425 psig.

AG-180AO-MMM-000 007 00 Page 16

VALVE CAP

Figure 6. Head Pressure Regulator Adjustment

AG-180AO-MM M-000 007 00 Page 17

I. Adjust switch (3) as required by turning g. Using multimeter, check continuity between range adjustment screw. Repeat steps i. thru j. as terminals 2 and 3. An open should exist. necessary. If switch (3) cannot be adjusted, replace it (WP 00s 00). h. Connect pressure source with gage and valve

to low pressure cutout switch capillary fitting. m.Remove pressure source from high pressure

cutout switch. i. While monitoring the multimeter, slowly increase the pressure to the low pressure cutout

II. Connect wire 114 to terminal C of the high switch. The &itch should close & nominally. 17

~prcssurc cutout switch (3). psig.

o. Connect high pressure cutout switch j. While monitoring the multimeter, slowly

capillary fitting to tee. decrease the pressure to the low pressure cutout switch. The switch should open at, nominally, 0

p Kvucul\te syslcm (this WP, purngraph 4).

q. Open compressor suction and dischwgc service valves completely by turning valve stems counterclockwise. Install caps (5 and 71.

psig.

NOTE

r. Install condenser fan panel assembly (WP 008 00).

Deadband (differential between switch opening and closing) is 17 psi. Deadband cannot be adjusted.

s. Close PRESSURE CO.UTROLSdoor.

16. LOW PRESSURE CUTOUT SWITCH (LPCO).

a. Open PRlZ%RE CONTROlSdoor.

b. Remove condenser fan pwel assembly (WP 008 00).

Rotation of the range adjustment SETCW one full turn clockwise increases the pressure switch points 100 psig; Rotation of the range adjustment screw counterclockwise one full turn decreases the pressure switch points 100 psig. The setpoint is the cutout pressure of0 psig.

e. Remove caps (5 and 7, figure 5) from compressor suction und discharge service valves. Close vnlvcs by turning vnlve stems clockwise.

Refrigerant is toxic. To nvoid injury to personnel, avoid breathing refrigerant or exposing skin or eyes to refrigerant. Do not expose refrigerant to open flame.

d. Loosen low pressure cutout switch (2, figure 5) capillary fitting and allow captive refrigerant to bleed off.

c. Disconnect low pressure cutout switch cilpil- lary fitting.

f. Disconnect wire 113 from terminal 2 of the low pressure cutout switch (2, figure 5).

k. Adjust switch (2) as required by turning range adjustment screw. Repeat steps h. and i. os necessary. If switch cannot be adjusted, replace it (WP 009 00).

I. Remove pressure source from low pressure cutout switch.

m.Connect wires 113 to terminal 2 of the switch.

n. Connect low pressure cutout switch capillary litting to tee.

o. Evacuate system (this WI”, paragraph 4).

p. Open compressor suction and discharge service valve completely by turning valve stems counterclockwise. Install caps (5 and 7).

q. Install condenser fan panel assembly (WP 008 00).

r. Close PRESSURE CONTROLSdoor.

AG-180AO-MMM-000 007 00 Page 10

PRESSIJRECONTAOLS

I 5

4

LOW HIGH

a

Figure 7. Pressure Differential Switches (PS4, PS5, PS6) Adjustment

AG-18OAO-MMM-000 007 00 Page 19

17. PRESSURE DIFFERENTIAL SWITCH (CLOSE ON PRESSURE RISE ) (PS4, PS5).

a. Open PRESSURE CONTROLSdoor.

b. Set switches to close (cut in) by rotating adjusting screw (4, ligure 7) as follows:

PS4 - 55 psig PS5 50 psig

c. Set switches to open (cut out) BS follows by rotating adjusting screw (5):

PS4 30 psig PS5 25 psig


e. Remove caps (5 and 7) from compressor suction and discharge service valves. Close valves by turning valve stems clockwise.

f. Loosen PS4 and/or PS5 capillary fitting and allow captive refrigerant to bleed off.

g. Disconnect PS4 and/or PS5 capillary fitting.

h. Remove screw (3, figure 7) and cover (2)

i. Disconnect wire 128 from terminal Lof PS4

j. Using two multimeters, check continuity between terminals L and &lZ and L and MI of PS4 and/or PS5. Continuitv should exist between Land Ml. An open should eiist between L and MZ.

k. Connect pressure source with gage and valve to capillary fitting of PS4 and/or PS5.

I. While monitoring the multimeters, slowly increase the pressure to the switchces). For PS4, L and M2 should close and I, and Ml should open at, nominally, 55 psig. For PS5, Land M2 should close and Land Ml should open at, nominally, 50 psig.

m.While monitoring the multimeters, slowly decrease the pressure to the switch(es). For PS4, L and M2 should open and L and Ml should close at, nominally, 30 psig. For PS5, Land M2 should open and Land Ml should close at, nominally, 25 psig.

switchces) cannot be adjusted, replace it (WP 009 00).

o. Rleed remaining pressure from line(s) Lund 1‘~1tnov~ pressure source from PS4 and/or I’%

p. Connect wire 128 to terminal L of PS4

q. Install cover (2) and screw (3).

r. Connect PS4 and/or PS5 capillary fittings to tees.

s. Evacuate system (this WP, paragraph 4),

t. Open compressor suction and discharge service valves completely by turning valve stems counterclockwise. Install caps (5 and 7, ligure 5).

u. Install condenser fan panel assembly (WP 008 00).

Y. Close and secure PRESSURE CONTROLS door.

IS. PRESSURE DIFFERENTIAL SWITCH (OPEN ON PRESSURE RISE) (PS6).

il. Open PRESSURE CONTROLS door.

b. Set switch to close (cut in) at 20 psig by rotatingadjustingscrew (4, ligure 7)).

c. Set switch to open (cut out) at 45 psig by ro- tatingadjusting screw (7).


e. Remove caps (5 and 7, figure 5) from compressor suction and discharge service valves. Close valves by turning valve stems clockwise.

f. Loosen capillary fitting and allow captive refrigerant to bleed off.

g. Disconnect PS6 capillary fitting.

h. Remove screw (3, figure 7) and cover (2).

i. Disconnect wire 135 from terminal Lof PS6

j. Using B multimeter, check continuity between terminals L and Ml. Continuity should exist.

n. Adjust switch(es) as required per steps b. through g. Repeat steps n and o. as necessary. If

k. Connect pressure source with gage and valve to capillary fitting of PS6.

AC-180AO-MMM-000 007 00 Page 20

I. While monitoring the multimeter, slowly b. Adjust limit switches (8 and 10, figure 10) as increase the pressure to the switch. The switch follows: should closeat, nominally, 45 psig. (1) Remove screws (1) washers (2) and nuts

(3). m.While monitoring the multimeter, slowly

decrease the pressure to the switch. The switch (2) Loosen clamp (7) and slide clamp (7) and should close at. nominally, 20 psig. flexible duct off upper mount weldment (4).

(3) Remove upper mount weldment (4) n. Adjust switch as required per steps b.

through g. Repeat steps n. and o. as necessary. If switch cannot be adjusted, replace it (WP 008 00).

o. Remove pressure source from PS6.

p. Connect wire 135 to terminal L of PS6. To prevent injury or damage to

q. Install cover (2) and screw (3).

r. Connect PS6 capillary fitting to tee.

s. Evacuate system (this WP, paragraph 4).

equipment, exercise care when workir.g with electrical power applied to air conditioning unit.

t. Open compressor suction nnd discharge service valves completely by turning valve stems counterclockwise. Install CBDS (5 and 7, fiwre 5).

(4) Apply il 1 lOV, 60 Hz, single phase power supply across terminal C of the open limit switch, I

u. Install condenser fan panel assembly (WP I.$ and ground (terminal block’locations TBI-6

008 00). throughTBl-II).

Y. Close and secure PRESSURE CONTROLS door.

19. MAIN SERVICE CIRCUIT BREAKER.

8. Open ELECTRICAL COSTROLS panel.

b. Set circuit breaker trip adjustment to 2: (2, figure 8).

c. Close ELECTRICAL CONTROLS panel

20. MOTOR STARTERS (Kl, K2, K3).

a. Open ELECTRICAL CONTROLS panel

NOTE

If nuisance tripping of motor starters occurs, adjustment may be varied 90 to 110% of setpoint.

b. With small blade screwdriver rotate trip adjustment screw (1, figure 9) as required.

c. Close ELECTRICAL CONTROLS panel.

21. BYPASS AIRFLOW CONTROLLER.

il. Remove condenser fan panel assembly IWP 008 00).

(5) Monitor the bypass vz~lve ils it moves to the full open position. Observe position of the bypass valve as the actuator arm depresses IS3 (IO), shuttingofftheairflowcontroller motor.

(6) If the bypass wlve is not full open when LS3 (IO) shuts off the controller, loosen coupling (6).

(7) Position actuator ilrm against open limit switch (IO).

(8) Position bypass valve (5) in full open position.

(91 Apply sealing compound to coupling (61 screw.

(10) Torque coupling (6) screw 87 in-lbs. CQA)

(11) Apply the IlOVAC, 60 Hz. single phase power supply across terminal C of the closed limit switch, LS4 (a), and ground (terminal block IocationsTBl-6 through TBl-II).

(12) .Monitor the bypass valve ils it moves to the full closed position. Observe position of the bypass valve as the actuntor arm depresses LS4 (8), shutting of the airflow controller motor.

AG-180AO-MMM-000 007 00 Page 21

Figure 8. Main Service Circuit Breaker (C81) Adjustment

AC-18OAO-MMM-000 Page 22

ELECTRICAL CONTROLS

s PANEL

BLOWER

STARTER STARTER RESET RESET BUTTON BUllON

STARTER RESET BUTTON

Figure 9. Motor Starters (Kl, K2, K3) Adjustment


FLEXIBLE OUCT I kLo.\

LS-4 CLOSED LIMIT SWITCH

\ ACTUATOR

COUPLING mAPPLY SfALING COMPOUNO TO THREADS

ARM PRIOR TO ASSEMBLY. NOT SHOWN 2 TOROUE FASTENERS TO 87 INCH-POUNOS FOR CtARlTY 8 3 TREAT EXPOSED PORTION OF SHAFTS PER MIL-P-IIS”. TYPE p.,,

USING Mlt~C~l61730 CORROSION PREVENTIVE COMPOUNO. COB].

Figure 10. Bypass Airflow Controller Adjustment

AG-180AO-MMM-000 007 00 Page 24

(13) If the bypass valve is not fully closed when LS4 (8) shuts off the controller, loosen the fasteners (9) holding the limit switch (8) to the controller frame. Adjust the switch to allow additional valve travel before shutoff. Tighten fasteners (9).

(14) Repeat steps (1) through (6) as necessary to allow complete travel from full open to full closed.

(15) Disconnect power supply from unit

c. Install condenser fan panel assembly (WP 008 00).

controller frame. Adjust the switch to allow additional sliding plate travel before shutoff. Tighten screws (2).

(4) Set the AIRFLOW CONTROL switch in the decrease position, and monitor the inlet airflow controller ils the sliding plate moves to the full closed position. Observe position of sliding plate as the close limit switch, LS2, (3) is depressed, shutting off the airflow controller motor.

22. INLET AIRFLOW CONTROLLER

a. Remove cable assembly (1, figure 4) from storage rack (‘2.).

b. Open FILTER ACCESS door

c. Remove insulation (8, figure 11)

d. Remove access cover (5) by removing screws (7) and washers (8).

e. Adjust limit switches (1 and 3) as follows:

To prevent injury or damage to equipment, exercise care when working with electrical power applied to air conditioning unit.

(1) Apply a llOVAC, 60 Hz, single phase power supply to the motor by plugging the cable assembly into a 44OV, 60 Hz, three phase power source and turning air conditioner circuit breaker (CBl) on or by applying a llOV, 60 Hz, single phase power source across terminal block to location TBl- 2 and ground (TBl-6 through TBI-11).

(2) Set the AIRFLOW CONTROL switch in the increase position, and monitor the inlet airflow controller as the sliding plate moves to the full open position. Observe position of sliding plate as the open limit switch, LSI (11, is depressed, shutting off the airflow controller motor.

(5) If the fixed plate openings we not fully covered when LS2 (3) shuts off the controller, loosen screws (4) holding the limit switch to the controller frame. Adjust the switch to allow additional sliding plate travel before shutoff. Tighten screws (4).

(6) Repeat steps (2) through (5) as necessary to allow complete travel from full open to full closed.

(7) Disconnect power supply to the unit.

e. Apply continuous bead of gasket forming compound around access cover (3) mating surface and holes.

f. Install xcess cover (5) by installing washers (61 and screws (7).

g. Apply insulation adhesive to insulation (8) and mating surface. When adhesive is dry to touch, install insulation (8).

h. Close FILTER ACCESS door

i. Replace cable assembly (1, figure 4) on storage rack (2)

23. BRAKE.


None

Materials Required

None

8. Position brake lever (1, figure 12) in vertical position.

b. Rotate adjustment screw (2) clockwise to tighten.

(3) If the fixed plate openings arc not fully uncovered when LSl (1) shuts off the cuntroller, loosen screws (2) holding the limit switch to the

c. Apply brakes by positioning brake lever (1) in horizontal position.

AC-1 80AO-M M M-000 007 00 Page 25

OPEN

4 3 tiiELCH %C” ! ?

DAPPLY INSULATION AOHESIVE (P/N 520 ADHESIVE. FSCM 039381 TO INSULATION AN0 MATING SURFACE. WHEN ADHESIVE IS OAY TO TOUCH. INSTALL INSUIATION.

aAPPLY CONTINUOUS EEA0 OF GASKET FORMING COMPOUNO (P/N 69 FSCM 62377) AROUNO MATING SURFACE AN0 HOLES. ASSEMBLE PARTS AN0 TIGHlEN HARDWARE.

Figure 11. Inlet Airflow Controller Adjustment

AG-180AO-M M M-000 007 00 Page 27

d. Tow air conditioning unit. If tires skid, brakes are adjusted correctly. If tires roll, repent adjustment procedure.

24. CLEANUP AFTER COMPRESSOR MOTOR BURNOUT.


None

a. Determine cause of burnout and make any necessary corrections. Check for blown fuses, welded starter contacts, welded overload contacts, burned out heater elements. Check comwessor terminal plate for burned or damaged terminals and insulation, shorted or grounded terminals. Check unit wiring and power supply for possible grounds or shorts. Check unit wiring for loose power connections. Check for high or low voltage.

Materials Required h. Close compressor suction and discharge serv-

ice valves and bleed refrigerant from compressor. Specilicationor Pm-t Number No”e”clat”re

Refrigerant (R-113)

e. Remove suction and d&ha.-ge shut-off valve bolts and all other connections to damaged corn- pressor. Remove damaged compressor (WP 008 00).

d. Release contaminated refrigerant from system by opening compressor suction and discharge service valves. Care should be taken to release the refrigerant slowly at first as the pressure within the system will be high.

Refrigerant is toxic. To avoid injury to personnel avoid breathing or exposure to skin or eyes. Do not expose refrigerant to open flame.

e. Replace filter drier core (WP 008 00).

f. Set main service circuit breaker. CBI, OFF.

Compressor burnout produces hydrochloric and hydroflouric acid residues throughout a refrigerant system. To avoid injury to personnel, avoid contact with acidilied refrigerant or acidified compressor oil. Wear rubber gloves and facial protection when working around acidified systems.

g. Open solenoid valves as follows:

(1) Open PRESSURE CONTROLSdoor.

(2) Remove covers from PS4. PS5, and PS6.

(3) Using three jumper wires, connect terminals I, and M2 of PSd and PS5 and terminals L and Ml of PS6.

(4) Set MODE switch to COOL

To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside electrical controls, pressure controls. or instrument panel.

(5) Open INSTRUMENT panel by turning grip latches countereloekwise.

(6) Apply a IIOVAC, 60 Hz, single phase power supply across terminal block location TBI-1 and ground (TBl-6 through TBl-11). Solenoid valves Sl through S6 will open.

NOTE

This procedure is difficult, time- consuming and expensive. This procedure should be performed in the Field only if depot level facilities are unavailable or inaccessible.

h. Close compressor suction service valve

i. Connect R-113 refrigerant supply to compressor discharge service valve. Open refrigerant supply valve and flood refrigerant system.

j. Place catchpan or bucket under hole in lloor- board.

AG-180AO-M M M-000 007 00 Page 28

k. Open compressor suction service valve slowly and circulate R-113 refrigerant through system until refrigerant exiting suction service valve is Cll3XL

I. Close compressor suction and discharge service valves.

m. Replace filter/drier core (WP 008 OO),

n. Close R-l 13 refrigerant supply valve and disconnect supply from compressor discharge service valve.

o. Discard R-113 refrigerant collected in catchpan or bucket.

p. Evacuate system (this WI’, paragraph 5)

q, Connect R~l13 refrigerant supply to compressor discharge service valve and open supply valve.

r. Open compressor discharge service valve and flood refrigerant system.

Y. Close solenoid valves as follows:

(1) Remove the IIOVAC, 60 Hz, single phase power supply from terminal block location TB-1 and ground(TBI~6throughTBI~11).

12) Close INSTRUMENT panel

(3) Remove three ,jumper wires from tcrmin- als L and .M2 of PS4 and PS5 and terminals L and Ml of PS6.

(4) Replace covers on PS4, PS5, and PS6

(5) Close PRESSCRE CONTROLSdoor

w. Charge the system (this WI’. paragraph 8)

x. Operate air conditioner in COOL mode (WP 005 00). After 2-4 hours of operation, check compressor oil for discoloration and/or acidity. If oil shows signs of contamination, replace oil charge, and filter drier core.

s. Repeat stepsj. througho.

t. Install new compressor (WP 008 00). Check compressor oil level.

u. Evacuate system (this WP, paragraph 5).

y. Check oil daily for discoloration and acidity. If oil stays clean and acid-free. the system is clean. If oil shows signs of contamination. change oil and filter drier core. If filter drier core is dirty or discolored, repeat this step until system is cleaned.

AG-180AO-MMM-000 008 00 15 May 1991 Page 1 of 76


REMOVAL AND INSTALLATION INSTRUCTIONS


AlM32C-21


Reference Material Operating Instructions. ............. ............................ WP 005 00 Servicing. Lubrication. Adjustment, and Cleanup

After Compressor Motor Burnout ........................... ...... WP 007 00 Fabric&m and Inspection of Brazed Piping Systems. .................. NAVSEA 0900.LP-001.7000

Alphabetical Index Subiect m

AftercoolerModule.. ..................................................................... ..3 9 Installation. .. .. ................. ................................................ 39 Mat&&Required .................................................................. 39 Removal ............................................................................ 39 SupportEquipmentRequired ......................................................... 39

Air Conditioner. Aircraft Ground Cooling, A/M32C-21 ....................................... 4 Atmospheric Relief Valve (V2) ............................................................. 61

Installation. ...... ....... ..... .................................................... 62 Mat&&Required .................................................................. 61 Removal ............................................................................ 61 SupportEquipmentRequired ......................................................... 61

BlowerAssembly ........................................................................ 28 Installation.......: .................................................................. 28 MaterialsRequired .................................................................. 28 Removal ............................................................................ 28 SupportEquipmentRequired ......................................................... 28

Blower, Blower Motor, Precooler and Aftercooler Modules. ..................................... 29 BrakeAssembly ......................................................................... 75

Installation. ... .. ............. ..................................................... 75 Mat&&Required .................................................................. 75 Removal ............................................................................ 75 SupportEquipmentRequired ......................................................... 76

Chassis and Wheel Assemblies. ............................................................. 64 Compressor Assembly ................................................................... 62

Installation .......................................................................... 63 MaterialsRequired .................................................................. 62 Removal ............................................................................ 62 SupportEquipmentRequired ......................................................... 62

Compressor, Receiver and Condenser Coil Assemblies. ........................................ 59 CondenserFan .......................................................................... 18

Installation .......................................................................... 18 MaterialsRequired .................................................................. 18 Removal ............................................................................ 18 Support Equipment Required ......................................................... 18

AG-180AO-MMM-000 008 00 Page 2

Alphabetical Index (Continued) Subiect m

C,,ndc,,ser Fan md Motor ........ .. .... ........................................ 19 Cl,,,dcnscr~“anMol,,r ...................................................................... 16

installation .......................................................................... 18 .Matcriuls Kcquircd ....... ........... .. ....................................... 16 I~c,no”nl .... .. ... ........................................................... 18 Support Equipment Kequircd .... .. ............................. .. ..... 18

Coupling, Illowcr to Mlotur ......................................................... ........ 37 lnstall;ltion .......................................................................... 37 MaterialsKcquired .................................................................. 37 Kcmoval ............................................................................ 37 Support Equipment Kequired ............................ ............................ 37

I)uctSto~agcHack ......................................................................... 22 Instnllation .......................................................................... 22 Materials Required ............ .. .. .. ............................... ........ 22 Rcmo”al ....... .... ............................................................... 22 Support Equipment Kequired ..................................................... ... 22

I~Ilcctrical Controls Panel ................................................................... 26 Instullati(,il .......................................................................... 26 Materials Kequircd ......................... ..................................... .. 26 Ke~noval ............................... ............................................ 26 Support Equipment Kequired ... ................................................ 26

Ihpmtor Pressure Kegulato ,. Valve ....................................................... 53 Installation .......................................................................... 54 Materials Kcquircd ........... ......................................... ....... 53 Removal ....... .... ................ ............................. ... 53 Support Equipment Koquiwd ...................................................... .. 53

I~‘iltcr I)rier ................................................................... ....... 40 Installation .......................................................................... 40 ?vlaterialsKequired .......................................................... ... 40 K~moval ... ... ..... .. .................................. .... ...... 40 SupportEquipmcntKequired .............................................. 40

I’ront Wheel Assembly ............................................................ ..... 63 Installation .......................................................................... 70 Materialsl~cquired .................................... .._ ........................... 70 Kemoval ................................................................... 70 Support Equipment Required .. .............................. ......... 63

Ileud l’rcssure Kugulator Valve ............. ............................................ 54 Installatil)n ...................................................... ., ., ., ., ., ... .. 54 IMMaterials Kcquired ............................................................. .. 54 Kernoval ......................................................................... . 54 Support Equipment Required .. .. .. ........................................ 54

Ilol Gas Rypass Valve ........ ..... .. ......................................... ...... 55 Installation .......................................................................... 55 Materials Kequircd ..................... ................................... .. 55 Ikmxll ................................................................. ... ... 55 Supporl Equipment Kcquired ............ ..................................... ..... 55

Inst~umentPancl......................................................, .................. 26 Installation .......................................................................... 27 MaterialsKequired ............................................ ..................... 26 Removal ......................................................... .._ ... ............ 27 Support Equipment Required ... .. .. ..................... ......... ............ 26

AG-180AO-MMM-000 008 00 Page 3

Alphabetical Index(Continued) Subiect m

~lotor30HPBlower ....................................................................... 35 Installation .......................................................................... 36 MaterialsRequired .................................................................. 35 Removal ............................................................................ 35 SupportEquipmentRequired ......................................................... 35

Panel Assemblies and Duct Storage Rack ..................................... . ........... 23 Panel and Door Assemblies ......... .. ....... ......... ..... ..... .. .... 7 I’recoolerModule...........................................................................3 8

Installation .......................................................................... 38 MaterialsRequired .................................................................. 38 Removal ............................................................................ 38 Support Equipment Required .. ........ ....... .............................. 38

PressureControlsPanel. ................................................................... 22 Installation .......................................................................... 22 MaterialsRequired ........................................... ...................... 22 Removal ............................................................................ 22 Support Equipment Required ...... ........................ ............ ............ 22

QuenchValve .......................................................................... 56 lnstallation............................................................~ ............. 56 MaterialsRequired .................................................................. 56 Removal ............................................................................ 56 Support Equipment Required ................. ....................................... 56

I~earWheelAssemblies............................: ........................................ 71 ReceiverAssembly ....................................................................... 58

Installation .......................................................................... 61 MaterialsRequired .................................................................. 58 Removal ................................................................ ..I ......... 58 SupportEquipmentRequired .......................................... .............. 58

Refrigeration Piping Assembly .... ................ ........... ............. ...... ... 41 Roadside and Curbside Rear Wheel Assemblies ... ............ ........ ......... ... ...... 70

Installation .......................................................................... 70 MaterialsRequired ............ ..I ................................................... 70 Removal ............................................................................ 70 Support Equipment Required ... ............................................... .. 70

Solenoid Valves (Sl, 52, S3, S4, S5,, S6). ........................................ ...... ... 40 lnslallalion .......................................................................... 53 MaterialsRequired .................................................................. 40 Removal .................................................................. ......... 40 Support Equipment Kequired .. ......................................... ........... 40

Thermostatic Expansion Valves(X1, X2, X3, X4). .................................. ........ 57 Installation .......................................................................... 57 MaterialsRequired ............................................................ .... 57 Removal ................................................................... ...... 57 Support Equipment Rcquircd ........................................................ 57

Record of Applicable Technical Directives NWlC

AG-180AO-M M M-000 008 00 Page 4

Figure 1. Air Conditioner, Aircraft Ground Cooling, A/M32C-21 (Sheet 1 of 3)

AG-180AO-MMM-000 00800 Page 5

INDEX PART UNITS USABLE SM&R NO NUMBER DESCRIPTION PERASSY ON-CODE CODE

1 1603ASlOO AIRCONDITIONER,AIRCRAFT GROUNDCOOLING, A/M32C-21. . . . . . . . . .

2 NONUMBER .

3 NONUMBER .

4 NONUMBER _

5 NONUMBER .

6 NONUMBER .

NONUMBER .

NONUMBER .

1603AS110 .

10

11

12

13

1603AS625 .

MS16051.I .

MS3584216 .

1603AS180 .

PANELANDDOORASSEMBLIESI SEEFIGUREZFOR BREAKDOWN. . , . . . . CONDENSERFANANDMOTORI SEEFIGURE3FOR BREAKDOWN. . . . . . . ELECTRICALCONTROLSPANEL, FUSEBOX,ANDlNSTRUMENT PANEL/SEEFICURE4FOR REMOVAL/SEEWPOlOOO FORBREAKDOWN. REARWHEEL ASSEMI;l.Y/SEE FlGURE9FOR RREAKDOWN _ . . . . . COMPRESSORANDRECEIVER ASSEMBLYISEEFlGURE7FOR REMOVAL/SEEWP01200FOR COMPRESSORBREAKDOWN. BRAKELEVERSEEFIGURE7 FORBREAKDOWN . . . . . CHASSISANDWHEELASSEMBLIESI SEEFIGURE a FOR BREAKDOWN. . . . . . . PANEL,PRESSURECONTROLS /SEEFlCURE4FORREMOVAL/ SEEWP00900FOR BRtiAKDOWN . . . . . _ . DUCTASSE.MRLY,FLEXIBLE _c AIRHOSE. . . . . . . . . . COUPI,ING,Gf~OUNDCOOLING,

N/A

S/A

1

1

N/A

S/A

S/A

N/A

S/A

COMBATTYPEAIRCKAFT , . CLAMP,HOSE: LOWPKESSURE

TYPE F . . . . . . . . . DUCT, FLEXIBLE AIR

ADGGG

AGGGG

PACZZ

PAGZZ

IIoSE/16632/AM~:2097/. . . I XBG%%

1 PEOGD

Figure 1. Air Conditioner, Aircraft Ground Cooling, A/M32C-21 (Sheet 21

AC-180AO-MMM-000 008 00 Page 6

INDEX PART X0 NUMBER DESCRIPTION

UNITS USABLE SM &R PERASSY ONCODE CODE

14

15

16

17

1603AS602 .

1603AS640 -.

MS35842.15

NO NUMBER

18 1603AS487

19 5SE01030.4

20

21 22

MS90556C 44152P MS3368.4.4D 5SEO1030.5

23 CAB-A-1

24

25 26

M23053/ 2.109-c MS20659.113 1603AS274

PACKING, PREFORMI 16632iDEA-003391 . . . . CONNECTOR ASSEMBLY/ 905981 . . . . . . . . . CLAMP, HOSE: LOW PRESSURE-TYPEF . . _ .

PRECOOLER AND AFTER- COOLER MODULES/SEE FIGURE 5 FOR REMOVAL/SEE WPOll OOFOR BREAKDOWN . . . . . . . CONTROLLER, AIR FLOW/ SEE FIGURE 5 FOR BREAKDOWN . . . . . . CABLE ASSEMBLY, 1NPUT POWER, 440 VOLT, 60 IIZ, CLASS I, CONSECTOR, SIZE 2,60 FT. LONG/ 2863% . . . . . _ . . . . . CONNECTORPLUG. . . .

STRAI’,CABLE. . . . . . . CABLE, AWG2/MlL-C-34321

TYPE DESIGNATION CO-041 TO F-4/21400/ . .

. MARKER, WIRE/85480/ (COVER WITH ENDITEM24) . . . . . .

. TUBING,SHRINK . . _ .

LUG,TERMINAL . CABLE SEALING,GRIP . ’ . 1.50 INCH/49367/ DBZM-58241 . . . . . . . .

1 PAGZZ

1 AGGGG

2 PAGZZ

1 N/A

1 AGGGG

1 AGCGG 1 PAGZZ

1 PAGZZ

1 PAGZZ

1 PAGZZ 4 XBGZZ

1 PACZZ

1 PAGZZ

Figure 1. Air Conditioner, Aircraft Ground Cooling, A/M32C-21 (Sheet 3)

AG-180AO-MMM-000 008 00 Page 9

INDEX PART NO NUMBER DESCRIPTION

UNITS USABLE SM &R PERASSY ON CODE CODE

1

NO NUhlBER

1603AS109

2 3 4 5

6

7

8

9

10

MS27183.10 MS90725.5 MS27183-15 MS35206.295

1603AS179

1603AS371

1603AS666

M24243l l-F604 1603AS688

11 1603AS361

12 MS35190.288

13 1603AS322.12

14 1603AS322.9

15 1603AS360

16 MS35333.40 17 MS35206280

. PANELAND DOOR ASSEMBLIES /SEE FIGURE 1 FOR NHA/ . .

PANEL ASSEMBLY ’ . CONDENSERFAN . . . .

/ATTACHING PAKTSI . . WASIIER, FLAT . _ . . . . . SCREW,CAP. . . . . . . . f WASIIER,FLAT . . . . . . . SCREW,MACIIINE . . _ .

*.

. . BUMPER, PLUG/704851 11422-360331 . . . . . . .

. . .

. . .

. . .

. _ .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

PANEL, TOP, WELDMENT. . . .

DOOR, INSPtiCTION /ATTACHING PARTS/

RIVET . . . . . . . SCREW, MACHINE/ INTERCHANGEABLE WITH MS35357, NOMINALSIZE ,251 . .

..*.. PANEL, REAR- CONDEN- SER FAN.. . . . . . . /ATTACHING PARTS/ SCREW,MACHINE . . .

*..

GASKET, PANEL, 14.77 L X .50 W/86730/41 1 I ?IDB/ GASKET, PANEL, 52.14 I. X .50 WIDE/867301 4111SDB/ . . . . . . .

*.. PANEL, FRONT. CON. DENSER FAN. . . . . IATTACIIING PARTS/ WASIIER, LOCK . . . . SCREW,MACIIINE . . .

1 XBGGGH

34 PAGZZ 34 PAGZZ

8 PAGZZ 8 PAGZZ

I FAG%%

1

1

10

1 XHGGG

1 XBGGG

1

IO 10

XBGCG

XBGGG XBGGG

XHGZZ

XBGGG

PAGZZ

XBCGG

I’AGZZ PAGZZ

Figure 2. Panel and Door Assemblies (Sheet 2)

AC-180AO-MMM-000 008 00 Page 10


UNITS USABLE SM &R PER ASSY ON CODE CODE

18 1603AS322.9

19 1603AS322.10

20 1603AS322.I 1

21 NAS1464.044. 04c

22

23

IMIL-R-242431 lF402 1603AS675

24 1603AS678 25 .MS35206-280 26 MS51922.1 27 MS35191.272 28 MS21044S3

29 1603AS420

30 MS35338.43 31 MS35207.263 32 1603AS687

33

34

1603AS322-19

1603AS322.8

. . . GASKET, PANEL, 14.77 L X .50 WIDE1867301 4lllNDBI . . . . . . .

. . . GASKET, PANEL, 15.14 I. X .50 WIDE/86730/ 4IIINDBI . . . . . .

. . . GASKET, PANEL, 18.26 LX .50 WlDE/86730/ 411lNDB/ . . . . . .

. , CLIP, SPRING TENSION . . . , . . /ATTACHING PARTS/

. . . RIVET, BLIND . . . . . *

. . KEEPER,PASEL. . . . /ATTACHING PARTS/

. . PLATE, REINFORCING .

. . . SCREW,IMACHINE . . . . NUT, SELF-LOCKING .

. . . SCREW,MACHINE . . . . NUT, SELF-LOCKING . .

* . . COVER TOP PANEL

INSTRUMEN’T- ASSE,MBLY . . . . . . . /ATTACHING PARTS

. . WASHER,LOCK . . . . .

. . SCREW,MACHINE . . . .

. . . COVER, TOP, PANEL, INSTRU%IENT, WELDMENT. . . . .

. . . GASKET, PANEI.. 25.12 I. X .50 WIDE/86730/ 4111NDB/ . . . . . .

. . GASKET, PANEL, 18.64 I, X .50 WIDE/86730/ 4111NDBI . . . . . . .

4 XBGZZ

2 XBGZZ

2 XBGZZ

2 PAGZZ

2 PAGZZ

2 XBGZZ

2 .MGGZZ 12 PAGZZ

2 PAGZZ 8 PAGZZ 8 PAGZZ

1 MGGGZ

2 XBGZZ

XBGGG

PAGZZ PACZZ

XBCZZ


AC-180AO-MMM-000 008 00 Page 11

INDEX NO

PART SUMBER DESCRIPTION

UNITS USABLE SM &K PERASSY ONCODE CODE

35 1603AS323

36

37

M24243/6 A403H

1603AS509

38

39

MM2424316 A403H

1603AS741

40 m35190-253 41 .MS27183-7 42 MS21044SO8

43 1603AS684

44 1603AS739

45 1603AS718

46 1603AS740

47 .MS51922-5

48 1603AS744 49 1603AS746

50 1603AS742

51 .MS35190-253 52 MS27183.7 53 MS21044NOS

. .

. .

. .

. .

. .

. .

. . .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. LATCH /94222/43-1-16-O/ . . . . /ATTACHING PARTS/

. RIVET,POP . . . . . . -.*..

. PLATE, OPERATING INSTRUCTIONS . . . . /ATTACHING PARTS/

. RIVET,POP . . . . . .

..*.. SUPPORT-TOP DOOR,L.H. . . . . . . . /ATTACHING PARTS/ SCREW,MACHlNE . . . . WASHER,FLAT . . . . NUT, SELF-LOCKING . . .

*.. BRACKET, SUPPORT /82851/107045/ . . . . . BAR, REMOVABLE, I,.H/82851/107029/ . /ATTACHING PARTS/ BOLT, CARRIAGE /82851/156950/ . . . , . WASHER, FIBER, FRICTION /828511157040/ . . . . . NUT, SELF-LOCKING . .

*.. STOP, SUPPORT, L.H. . . BAR ASSEMBLY, STATIONAKY, L.H /82851/107003/ . . . . .

SUPPORT-TOP DOOR, R.H. . . . . . . SCREW,MACHINE . . . . WASHER,FLAT . . . . . NUT, SELF-LOCKING . . .

6

12

1

6

1

PAGZZ

PAGZZ

MGGZZ

PAGZZ

XBGZZ

PAGZZ PAGZZ PAGZZ

MGGZZ

XAGZZ

PAGZZ

PAGZZ PAZZZ

XAGZZ

XBGZZ

XBGZZ PAGZZ PAGZZ I’AGZZ


AC-180AO-MMM-000 008 00 Page 12

INDEX I I PART NO NUMBER

I DESCRIPTION 1 Pii-i%Y 1 ::i%i 1 sdMo:i 1

54 1603AS684 . .

55 1603AS677 . .

56

57

1603AS718 . .

1603AS740 . .

58 MS51922.5 . .

59 1603AS743 . . 60 1603AS745 . .

61 1603AS421 . .

62 MS35338.43 . . 63 MS35207.263 . .

64 1603AS258 . .

65 MS27183.12 . . 66 MS35206.295 . . 67 iMS90725-29 . . 68 lMS9072532 . . 69 MS24693.5273 . . 70 LMS90725.5 . . 71 MS27183.IO . . 72 IMS51922-1 . .

73

74

1603AS685 . .

MS35338.44 . .

. BRACKET, SUPPORT 182851/107045/ . . .

. BAR, REMOVABLE, R.H./82851/107037/ . /ATTACHING PARTS/

. BOLT, CARRIAGE /82851/156950/ . . .

. WASHER, FIBER, FRICTION 1828851/157040/. . .

. NUT, SELF-LOCKING *..

STOP, SUPPORT, R.H. : BAR ASSEMBLY,

STATIONARY, R.H. /82851/107011/ . . .

COVER, TOP, OUTER- FUSEBOX. . . . . . /ATTACHING PARTS/ WASHER,LOCK . . . SCREW,MACHISE . .

..*- TOP,CABISET. . . . IATTACHISG PARTS/ WASHER,FLAT . . . SCREW,MACHISE . . SCREW,CAP. . . . . SCREW,CAP. . . . . SCREW,MACHISE . . SCREW,CAP. _ . . . WASHER,FLAT . . . NUT, SELF-LOCKING .

*..

. .

. .

. . 1 PAGZZ

. . .

. .

. .

. .

. .

. .

. .

. . . .

.

. . . . . .

BRACKET, HOLD-DOWS, PANEL . . . . . . . . . /ATTACHING PARTS/ WASHER.LOCK . . . . .

1

I

10 10

1

34 11 11 12 10 10 20 10

2

2

MGGZZ

XAGZZ

PAGZZ PAZZZ

XACZZ

XAGZZ

MBGZZ

PAGZZ PAGZZ

MGGZZ

PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ

MGGZZ

PAGZZ


AC-180AO-MMM-000 008 00 Page 13

INDEX PART UNITS USABLE SM &R NO NUMBER DESCRIPTION PERASSY ON CODE CODE

75 1603AS688

76

77 78 79

80

1603AS255

MS90725.32 MS27183.12 MS90725.29

1603AS629

81 MS35207.264 82 MS27183.42 83 MS21044N3 84 1603AS630

85 1603AS626

86 1603AS628

87 1603AS566

88 MS35207.264 89 MS27183.8 90 MS21044N3

91 1603AS63 I

92 MS90725.5 93 MS27183.10

94 1603AS627

95 1603AS455

96 MS27183.I2

.

.

.

. .

.

.

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

SCREW, MACHINEI INTERCHANGEABLE WITH MS35357, NOMINAL SIZE ,251. . . . . . . . .

.-*- PANEGCURBSIDE . . . . IATTACHING PARTS/ SCREW.CAP. _ . . . . . WASHER.FLAT . . _ _ . SCREW.CAP. _ _ . . . .

*.. COVER ASSEMBLY, DUCTDISCHARGE _ . _ . /ATTACHING PARTS/ SCREW,CAP. . . . . _ . WASIIER, FLAT . . . . . NUT,SEI.F-LOCKING . . _

COVER, DUCT _ _ _ _ . DISCIIARGE /ATTACHING PARTS/ FASTENER, LNTURN /94222/85-l l-280-16/ . . . RETAINER, SPLIT 194222185.34.101.20/ . . . CABLE,RETAINING _ _ /ATTACHING PARTS/ SCREW.MACHINE . . . WASHER,FLAT . . . . NUT . . . . . . . . .

*.. BRACKET, DUCT COVER.STORAGE . . . . /ATTACHING PARTS/ SCREW,CAP. _ . . . . . WASHER,FLAT _ . . . .

*.. RECEPTACLE, l/4 TURN/ 94222/85-47.101.15/ _ _ . _ PANEL, REAR, CURBSIDE-WELDMENT . _ /ATTACHING PARTSI WASHER,FI.AT . _ _ . .

2

1 MGGZZ

8 PAGZZ IO PAGZZ

2 PAGZZ

1 XBGGG


XBGZZ

PAGZZ PAGZZ PAGZZ

MGGZZ

PAGZZ

PAGZZ XBGZZ

PAGZZ PAGZZ

PAGZZ

XBGGG

PAGZZ


AG-180AO-MMM-000 008 00 Page 14

INDEX PART X0 NUMBER DESCRIPTION


97

98

99 100

MS90725.32

1603AS666

M24243/1-F604 1603AS688

101 1603AS691

102 M24243/1-F604 103 1603AS688

104 1603AS182

105 1603AS601

106 MS90725.58 107 MS2-7183.I4

108 1603AS441

109 110 III

112

113 114 115

MS35190.287 iMS27183.10 IMS51922-1

1603AS445

MS90725.5 MS27183.10 MS51922-I

. .

. .

. .

. .

. .

.

. .

. .

.

. .

. .

. .

. .

. .

.

. .

. .

. .

. .

SCREW.CAP. . . . . . . ..*i.

DOOR,INSPECTION . . /ATTACHING PARTS/ RIVET. . . . . . . . . SCREW, MACHISE/ INTERCHASGEABLE WITH MS353.57,

NOMINALSIZE ,251 . . . ..I-.

DOOR, ACCESS, PRESSURETAP . . . . /ATTACHING PARTSI RIVET. . . . . . . . . SCREW, MACHINE/ INTERCHASGEABLE WITH MS35357, NOMINALSIZE .25/ . . .

*. RING, TIEDOWN, 10,000 LB 17U153148B7796l . . . . . RACK, CABLE STORAGE. . /ATTACHING PARTS/ SCREW,CAP. . . . . . , WASHER,FLAT . . . . .

* DOOR STOI’, UPPER- WELDMENT. . . . . . . /ATTACHING PARTS/ SCREW,MACHINE . . . . WASIIER, FLAT . . . . NtiT,SELFLOCKING . .

* DOOR, FILTER ACCESS- WEI.DMES’I’. . . . . . /ATTACHING PARTS/ SCREW,CAP. _ . . . . . WAStIER, FIAT _ . _ . . NUT, SELFLOCKING . . .

*

1 XBGZZ

1 XBGZZ

12 PAGZZ 4 XRGZZ

8 PAGZZ 8 PAGZZ

PAGZZ

XBGZZ

PAGZZ

XBGGG

PAGZZ

MGCLZ

PAGZZ PACT% FAG%%

XBGGG

PAGZZ FAG%% PAGZZ


AG-180AO-MMM-000 008 00 Page 15

116 1603AS171

117

118

M24243l 6.A403F

1603AS322.17

119

120

121 122

1603AS322.18

1603AS434

MS90725.32 MS27183.12

123

124 125

1603AS666 DOOR,INSPECTION . ‘/ATTACtIINGPARTSI

. .

MS24243/1-F604 . 1603AS688 .

126 1603AS435 .

127 MS27183.12 . 128 MS90725.32 . 129 1603AS254 .

. RIVET. . . . . . . . .

. SCREW, MACHINE/ INTERCHANGEABLE WITH MS35357, NOMINAL SIZE .251. . . . . . . .

DOOR, STOP, LOWER- WELDMENT. . . . . . . WASIIER, FLAT . . . . SCREW, CAP. . . . . . . PANEL,ROADSIDE . . . .

/ATTACHING PARTS/ *..

130 MS27183.12 . WAStIER, FLAT . . . . 131 MS90725.32 . SCREW,CAP. . . . . . . 132 MS90725.29 . SCREW,CAP. . . . . . .

133 1603AS489 .

134 MS27183.IO .

DOOR, ACCESS. . . . IATTACIIING PARTS/ WASIIER.t’I.A’I’ . . . .

PART UNITS USABLE SM &R NUMBER DESCRIPTION PERASSY ON CODE CODE

. .

. .

. .

. .

. .

. PLATE, WIRING DIAGKAM _ . _ . . . . IATTACIIING PARTS/

. RIVET, POP. . . . . . .

*.. GASKET, PANEL, 28.06 L X .50 WIDE 186730/4tllNDB/. . . . .

. GASKET, PANEL, 28.80 L X .50 WIDE /86730/4111NDB/. . . . .

PANEL, REAR, ROADSIDE- WELD.MENT. . . . . . . /ATTACHING PARTS/ SCREW,CAP. . . . . . . WASHER,FLAT . , .

*..

1

10

2 XBGZZ

2 XBGZZ

1 XBGGG

10 PAGZZ 10 PAGZZ

1 XBGGG

1 PAGZZ

XBGZZ

PAGZZ

XBGZZ

MGGZZ I’AGZZ PAGZZ

MGGZZ

PAGZZ PAGZZ PAGZZ

XBGGG

PAGZZ


AC-180AO-MMM-000 008 00 Page 16

INDEX PART UNlTS USABLE SM &R NO NUMBER DESCRIPTION PERASSY ONCODE CODE

135 MS90725-3 136 1603AS322-13

137 1603AS322-14

138 1603AS266

139 MS90725.5 140 MS27183.10

141 1603AS265

142 MS27183-10 143 MS90725.5 144 1603AS250

145 MS27183-12 146 MS90725-32 147 MS27183.14 148 MS90725.58 149 MS27183-10 150 MS90725-5

151

152 153

154

1603AS594

MS27183.12 MS90725.32

1603AS404

155 156

157

MS27183.10 MS90725-5

1603AS322.16

158 1603125322.16

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

.

. ,

.

. .

SCREW,CAP. . . . . . . 3 PAGZZ GASKET, PANEL, 10.00 L X .50 WIDE /86730/4111NDBI . . . . 2 XBGGG

, GASKET, PANEL, 12.00 I. X .50 WIDE /86730/4111NDBl . . . .

-*-. 2

GRILLE, CONDENSER COIL . . . . . . . . . . /ATTACHING PARTS/ SCREW, CAP. . . . . . WASHER.FLAT . . . . .

..*-.

XBGGG

PAGZZ PAGZZ

STOP,GRILLE . . . . . . /ATTACHING PARTS/ WASHER,FLAT . . . . . SCREW,CAP. . . . . . . PANEL,FRONT . . . . . IATTACHING PARTSI WASHER,FLAT . . . . SCREW,CAP. . . _ . . . WASHER,FLAT . . . . . SCREW,CAP. . . . . . . WASHER,FLAT . . . .’ . SCREW, CAP. . . . . . .

2

40 40

2

16 16

1

MGZZZ

PAGZZ PAGZZ

MBGZZ

..*-. KEEPER,TOWBAR . . . . /ATTACHING PARTS/ WASHER,FLAT . . . . . SCREW . . . . . . . . .

..*..

8 PAGZZ 8 PAGZZ

17 PAGZZ 17 PAGZZ

9 PAGZZ 9 PAGZZ

I MGZZZ

2 PAGZZ 2 PAGZZ

DOOR, PANEL, CONTROLS, PRESSURE-WELDMENT. . /ATTACHING PARTS/ WASHER.FLAT . . . . ‘. SCREW, CAP. . . . . . .

-*.. . GASKET, PANEL, 7.84 L

X .50 WIDE /86730/4111NI~Bl . . . .

. GASKET, PANEL, 24.84 I. X .50 WIDE /86730/4111NDB/ . . . .

XBGGG

PAGZZ PAGZZ

XBGZZ

XBGZZ


AG-180AO-MMM-000 008 00 Page 17


159 1603AS688

160 161

162

163

MS35338.44 1603AS101

M24243/1-8404

1603AS623

164 MS27183-10 165 MS90725-3

166 1603AS322.13

167 1603AS322-14

168 NAS1298.3-3 169 MS21044N3 170 MS27183.9

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

SCREW, MACHINE /INTERCHANGEABLE WITH MS35357, NOMINAL SIZE .25/ . . . . . . . WASHER,LOCK . . . . . PLATE, DATA . . . . . . /ATTACHING PARTSI RIVET . . . . . . . . .

.-*- DOOR, ACCESS, DUCTSTORAGE . . . . . /ATTACHING PARTS/ WASHER,FLAT . . . . . SCREW,CAP. . . . . . .

* . GASKET, PANEL, 12.00 L

X .50 WIDE /86730/4111NDBI . . . .

. GASKET, PANEL, 10.00 L X .50 WIDE /86730/4111NDBl . . . .

*

. SCREW, BRAZIER HEAD.

. NUT,SEI.F-LOCKING . .

. WAStIER,FLAT . . . .

2 2 1

4 PAGZZ

2 XBGZZ

XBGZZ PAGZZ

MGGZZ

XBGGG

PAGZZ PAGZZ

XBGZZ

PAGZZ PAGZZ PAGZZ


AG-180AO-MMM-000 008 00, Page 18

1. CONDENSER FAN.


Part Number Nomenclature Wrench, Torque

d. Loosely install washers (21, (3). and screws (4).

e. Check fan-to-grille clearance hy rotating fan (17). Adjust condenser fan grille (1) so that fan (17) rotates freely.

Soecification O-50 ft-lhs f. Tighten screws (4)

or Part Number MIL-C-16173D

Nomenclature Corrosion Preventive Compound, Solvent Cutback, Cold Application, Grade 1

Materials Required

None

2. REMOVAL.

a. Shut down unit (WI’ 005 00).

g. Treat exposed portion of condenser fan motor shaft per the preservation methods of MII..P-11611, Type P-l using MIL-C-16173Dcorrosion preventive compound.

h. Install condenser fan panel asremhly (I, figure ‘2).

4. CONDENSER FAN MOTOR.


Part Number SOIW3lCl~lU!T

- Sling(O-150 Ihs.1

To prevent injury to personnel or damage to equipment, unit shutdown and removal of power source must be completed before removing condenser fan.

1Konc

5. REMOVAL.

b. Remove condenser fan panel assembly (1, figure 2).

a. Shut down unit IWP 005 00).

IW*IININGQ

To prevent injury to personnel or c. Remove screws (4, figure 3), and washers (‘2)

and (3) fromcondenser fan grille (1).

d. Remove condenser fan grille (1)

damage to equipment, unit shutdown and removal of power source must bc completed before removing condenser fan motor.

e. Remove screws (20).

f. Place screws (20) in two push-off holes in hushing(l8).

g. Tighten screws (20) until fan blade loosens

h. Remove condenser fan (171, key (19) and bushingtIE).

h. Remove condenser fan (this WP, paragraph 1).

c. Tag and disconnect wiring.

d. Support motor (241 and remow screws (27), washers (28), nuts (29), spacers (25) and shims (26). Retain spacers (25) shims (26) for installation.

e. Remove motor (24)

3. INSTALLATION.

a. Position condenser fun (17, figure 3) in place.

b. Install bushing (181, key (19), end screws (20). Torque to 192 + 10 inch-pounds. (QA)

c. Position condenser fan grille (1) in place.

6. INSTALLATION.

a. Position motor (24, figure 3) on motor mount (30).

h. Position shims 126) and spacers 125) under fan motor (24).

AG-l$OAQ-MMM-000 008 00 Page 19

NUSED HOLES IN FEET ARE UP.

SHIM CONOENSER FAN MOTOR AS REOUIREO TO POSlTlON CENTER OF FAN HUB 34 INCHES FROM CENTERLINE OF CURBSIOE CONOENSER FAN PANEL ASSEMBLY BOLT HOLES AND 4.42 INCHES AFT OF FOURTH CONDENSER FAN PANEL ASSEMBLY BOLT HOLE. USE UP TO SIX MOTOR MOUNT SHIMS. STOW UNUSED SHIMS ON FAN FRAME WITH NYLON TIE.

APPLY ANTlSElZE CONlPOUND TO THREAOS PRIOR TO ASSEMBLY.

AFlEA ASSEMBLY. TREAl EXPOSED PORTION OF SHAFT PER Mlt-P-116H. TYPE P-l. USING Mlt-C-161730 CORROSION PREVENTIVE COMPOUNO GRI.

Figure 3. Condenser fan and Motor (Sheet I of 3)

AC-180AO-MMM-000 008 00 Page 20


I DESCRIPTION

1

10 11 12

13

14 15 16

17

1.3

19

20

NO NUMBER

1603AS115

.MS27183-10 MS35338.44 MS90725.8

1603AS117

iMS90725-8 MS27183-10 MS35338-44

1603AS116

MS90725.8 MS27183.IO MS35338.44

1603AS118

MS90725-58 MS27183-14 MS51922.9

CONDENSER FAN AND MOTOR ’ /SEE FIGURE 1 FOR NHA/ . .

. . .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

1603AS120 - . .

1603AS750 . .

KEOlAAOl . 0838250 lMS90725-60 . .

GRILLE, WELDMENT- CONDENSERFAN . . . . /ATTACHING PARTS/ WASHER,FLAT . . . . . WASHER, LOCK, SPRING. . SCREW,CAP. . . . _ . .

*.. FRAME, CURBSIDE- CONDENSERFAN . . . . /ATTACHING PARTS/ SCREW,CAP. . . . . . . WASfIER,FLAT . . . . . WASHER, LOCK, SPRING .

t.. FRAME, ROADSIDE- CONDENSERFAN . . . _ /ATTACHING PARTS/ SCREW,CAP. _ . . . WASHER,FI.AT . . . WASIIER, LOCK, SPRING .

*..

FRAME, REAR- CONDENSERFAN . . . . /ATTACHING PARTS/ SCREW, CAP. . . . . . . WASHER,FLAT . . . . . NUT, SELF-LOCKING . . .

*.. FAN, CONDENSER16398Pd 42.12.5ZLPPG-40”AS . . . /ATTACHING PARTS/ BUSHING,SPLIT, TAPERED, MALLEABLE /6A844/ PI . . . . . . . . KEY318WX3116HX 2.88L.

SCREW,CAP. . . . . . .

1 XBGZZ


I


1


1 XBGGG

XBGZZ

XBGZZ

PAGZZ PAGZZ PAGZZ

XBGZZ

XBGZZ XBGZZ

PAGZZ

Figure 3. Condenser Fan and Motor (Sheet 2)

AG-180-AO-M M M-000 008 00 Page 21



21

22 23

24 1603AS129

25 1603AS748 26 1603AS751 27 MS90725-I 18 28 MS27183.18 29 MS51922.33

30 1603AS114

31 MS90725.60 32 MS27 183-14 33 M&51922-9

34 1603AS644

35 MS90725.6 36 MS2-7183.IO

. . . BLADE/63988/ 42.12-5ZL-PAGl. . . . . /ATTACHING PARTSI

. . f BOLT,1/4X20XILC . .

. . . HUB/63988/HZ12.03/ .06ASFORPI _ . . . .

* . . MOTOR, CONDENSER FAN,

7.5 HP1507061 5K254HL3169F2J . . . . . IATTACHING PARTS/

. . SPACER, MOUNT, MOTOR .

. . SHIM, MOUNT, MOTOR . .

. . SCREW,CAP. _ . . . . .

. . WASHER,FLAT . . . . .

. . NUT,CAP . _ _ . . . . . *

. . MOUNT, MOTOR- CONDENSERFAN . . . . IATTACHING PARTSI

. . SCREW,CAP. . . . . . .

. . WASHER,FLAT . . . . .

. . NUT . . . . . . . . . . -.*..

. BRACKET, FRONTTUBING SUPPORT . . . . . . . . . /ATTACHING PARTS/

. SCREW,CAP. . . . . . .

. WASHER,FLAT . . . . . .

12 XBGZZ

12 XBGGG

1 XBGZZ

1 PBGDD 1

2 MGGZZ AR MGGZZ


1 XBGZZ

6 PAGZZ 10 PAGZZ

4 PAGZZ

MGGZZ

PAGZZ PAGZZ

Figure 3. Condenser Fan and Motor (Sheet 3)

AG-180AO-MMM-000 008 00 Page 22

c. Install washers l28), nuts (291, and screws 11. REMOVAL. (27).

d. Shim motor (24) with shims (26) as required to position center of condenser fan hub 34 inches from ecnter line of curbside condenser fan panel assembly bolt holes and 4.42 inches aft of fourth condenser fan panel assembly bolt hole. Use up to six shims (26). Stow unused shims on fan frame with nylon tie.

e. Connect wiring as tagged.

f. Install condenser fan (this WP, paragraph Il.

7. DUCT STORAGE RACK.

Support Equipment Hequired

INone

Materials Kequired

8. REMOVAL.

a. Remove condenser fan panel assembly (1, licrure 2).

b. Remove nuts (35, figure 41, washers (341, screws (331 from bracket (29),

c. Remove duct storage rack (32),


h. Shutdown unit (WI’005 00)

c. Remove cabinet top(64, figure 21

To prevent iqjury to personnel or damage to equipment, unit pumpdown, shutdown and removill of power source must be completed hefore removing pressures control Pd”d

d Kemove stem caps from compressor discharge and coxnprcssor suction service valves. Close vnlvcs by turning stems clockwise.

e. Open I’KKSSL-RE COSTKOLS panel by turning spring latchescounte~cl~)ckwise.

[WARNING ]

Refrigerant is toxic. To avoid in,jut-y to personnel, avoid breathing or CY- posure to skin or eyes. Do not rxpost: refrigerant to open flame.

9. INSTALLATION.

a. Position duct storage rack (32, figure 4) in place.

b. Install washers (34). screws l33), and nuts (35).

c. Install condenser fan panel assembly (I, ligure 2).

f. I.oosen prcssurc switch capillary lines and bleed excess refrigerant pressure to atn~osphcrc.

g. Disconnect pressure switch capillary lines ~wP00900).

h. Tag and disconnect wirings

i, Kemovc screws (2, figure 4) and washers (3).

j. Kemove pressure controls panel (I 1.

10. PRESSURE CONTROLS PANEL.


None

Materials Required

Specification S”mc”clatulY or Part Number

Antiseize Colnoound

12. INSTALLATION.

il. Position pressure controls panel (I, figure 41 on front panel.

b Apply antiseize compound to threads of scwws(2).

c. Install washers (31 and XI-EWS (2),

d. Connect wiring as tagged.

c. Install pressuw switch capillary lines (WI’ 009 00)

AG-WOAO-MMM-000

GRIPLATCHES \

INSTRUMENTPANEL SUBASSEMCUYWPOlO00

00800 Page 23

16

mAPPlY ANTISEIZE COMPOUNO TO THREAOS PRIORTO ASSEMBLY

Figure 4. Panel Assemblies and Duct Storage Rack (Sheet 1 of 3)

AG-18OAO-MMM-000 008 00 Page 24

INDEX PART UNITS USABLE SM &R NO NUMBER DESCRIPTION PERASSY ONCODE CODE

1 1603ASllO

2 MS90725-5 3 x27183.to

4 1603AS112

5 MS90725-32 6 hts27183.12 7 1603AS281

a m27183.12 9 m27183.lo

10 MS5 1849.96

11 1603AS322.1

12 1603AS322.2

13 1603AS288

14 1603AS299

15 m27ta3.42 16 MS35207.263

17

la

1603AS322.6

1603AS322.5

NO NUMBER PANEL ASSEMBLIES AND DUCT ’ STORAGE RACK/SEE FIGURE 1

FOR NHAI . .

. .

. .

. .

. .

. .

. .

. .

.

. .

. .

.

. .

. .

. .

. .

. .

. .

PRESSURE CONTROLS PANEL /SEE WP 009 00 FOR BREAKDOWN/. . . . . . /ATTACHING PARTSI SCREW, CAP. . . . . . . WASHER,FLAT . . . . .

*.. PANEL, CONTROLS, ELECTRICAL/SEE WP 010 00 FORBREAKDOWN/. . . . /ATTACHING PARTS/ SCREW. . . . . . . . . WASHER,FLAT . . . . .

PANEL, CONTROLS ELEC- TRICAL-WELDMENT . . /ATTACHtSG PARTS/ SCREW,MACHtNE . . . WASHER.FLAT . . . , NUT, SELF-LOCKISC . .

*..

GASKET, PANEL 18673014111NDBi . . . . GASKET, PANEL /86730/4111.\JDB/ . . . . BOX, FCSE-WELDMENT /SEE WP 010 00 FOR BREAKDOWN/. . . . . COVER,TOP, PANEL, CONTROLS . . . . . . IATTACHISG PARTS/ WASHER, FLAT . . . . SCREW.MACHlNE . .

GASKET, PANEL /86730/4111NDB/ . . . .

GASKET, PANEL 186730/411 INDB/. . .

1

6 6

I

a 16

a

2

2

I

I

10 10

2

2

ADGGG

PAGZZ PAGZZ

ADGGG

PAGZZ PAGZZ

MGGZZ

PAGZZ PAGZZ PAGZZ

XBGZZ

XBGZZ

MGGZZ

MGGZZ

PAGZZ PAGZZ

XBGZZ

XBGZZ.

Figure 4. Panel Assemblies and Duct Storage Rack (Sheet 2)

AG-180AO-MMM-000 008 00 Page 25

INDEX PART NO NUhtBEK, DESCRIPTION

UNITS USABLE S.M &R PER ASSY ON CODE CODE

19

I I I I I

1603ASlll _ PASEL, INSTRUMENT /SEE WP 010 00 FOR ----

20 lMs27ia3-10 21 MS90725.6

22 1603AS356

23 24

25

MS27183.10 MS90725.6

1603AS358

26 x27183.to 27 .Ms35338-44 28 MS90725-6

29 1603AS604

30 31

Ms27ta3.lo MS90725-3

32 1603AS103

33 MS90725.6 34 Ms27183.12 35 MS51922.1

36 1603AS622

37 .MS35207-263 38 Ms35338.43 39 MS2104453

BREAKDOWN/. . . . . . /ATTACHING PARTS/

. WASHER,FLAT . . . . .

. . SCREW,CAP. . . . . . . *

. . SUPPORT,TOP, PANEL, INSTRUMENT. . . . . . /ATTACHING PARTS/

. . WASHER, FLAT . . . . .

. . SCREW,CAP. . . . . . . *

. SUPPORT, BOTTOM, PANEL, ISSTRUMEST . . . . . . /ATTACIIISG PAKTSI

. WASIIEK,FLAT . . .

. WAStIEK,LOCK . .

. SCREW,CAP. . . . . . . *

. BKACKET, DUCT STORAGE . . . . . . /ATTACllISG PARTS/

. WASHER,FLAT . . . .

. . SCREW,CAP. . . . . . . *

. . RACK, DUCT STORAGE . IATTACHISG PARTS/

. . SCREW,CAP. . . . . . .

. . WAStIER, FLAT . . .

. . SUT, SELF-l.OC!KISG . . . *

. . RETAISISG ROD WIT11 CABLE . . . . . . . . . IATTACttISG PARTS/

. SCREW,MACHISE . .

. . WASHEK / LOCK . . . . .

. NCT,SELF-LOCKISG . . *

4 PAGZZ a PAGZZ 4 PAGZZ

AGMxi

PAGZZ PAGZZ

MGGZZ

PAGZZ PAGZZ

MGGZZ

PAGZZ PAGZZ PAGZZ

MGGZZ

PAGZZ PAGZZ

LIGGZZ

AGGGG

PAGZZ PAGZZ PAGZZ

Figure 4. Panel Assemblies and Duct Storage Rack (Sheet 3)

AC-180AO-MMM-000 008 00 Page 26

f. Evacuate unit (WP 007 00) and check for leaks.

g. Open compressor suction and discharge valves by turning valve stems counterclockwise. Instnll stem caps.

d. Open ELECTRICAL CONTROLS panel door.

e. Remove screws (16, figure 4) and washers (15).

f. Remove controls panel top cover (14).

h. Operate air conditioning unit (WP 005 00) and evaluate performance. Add refrigerant if necessary (WP 007 00).

i. Close PRESSURE CONTROLS panel.

j. Install stem caps.

k. Leak test connections

I. Install cabinet top (64, figure 2).

13. ELECTRICALCONTKOLS PANEL.


None

g. Disconnect power cable from CBI.

h. Tag and disconnect electrical connectors Pl-P4.

i. Remove screws (5) and washers (6).

j. Remove electrical controls panel (4),

15. INSTALLATION.

il. Position electrical controls panel (4) on roadside fender.

b. Apply antiseize compound to screws (5)

c. Install screws (5) and washers (6),

Materials Required

Specification or

d. Connect electrical connectors PI-P4.

e. Install power cable to CBI

Part Number Nomenclature f. Position controls panel top cover (14) on fuse

Antis&e box (13).

14. REMOVAL.

Compound g. Install washers (15) and screws (16).

a. Shut down unit (WP 005 00). h. Close and secure ELECTRICAL CONTROLS

panel door.

i. Install roadside rear panel assembly (120, figure 2).

To prevent injury to personnel or damage, to equipment, unit shutdown and removal of power source must be completed before removing electrical controls panel.

b. Remove cabinet top (64, figure 2).

j. Install cabinet top (64, figure 2).

16. INSTRUMENT PANEL.


None

I c. Remove roadside rear panel ussembly (120, Materials Required

ligure 2). None

Page 27

17. KEMOVAL.

a. Pump down unit (WI? 007 00).

b. Shut down unit (WP 005 00)

c. Remove cabinet top (64. figure 2)

To prevent injury to Qersonnel or damage to equipment, unit pumpdown. shutdown and removal of power so,,rce must be comQleted before removing instrument panel.

d. Remove caps from compressor discharge and compressor suction swvicu valves. Close villves by turning stems clockwise.

-igerant is toxic. To avoid injury to personnel, avoid breathing 01‘ cx- posure to skin or eyes. l)o not CXQOSC refrigerant to OQE" flame.

e. Open instrument punel suhassemhly (figure 4) by turning grip lutchcs counterclockwise.

f. Loosen compressor suction pressure gauge capillary line (WP 009 000) and bleed refrigerant pressure to atmosphere.

g. Loosen compressor discharge QESS”R gauge capillary line (WP 009 000) and bleed refrigerant pressure to atmosphere.

h. Disconnect compressor suction prcssurf gauge capillary line from compressor suction QWSS”W @I”@.

i. Disconnect compressor dischuge prcssurc gauge capillary line from compressor discharge QWSS”W gauge.

j. Disconnect delivered airflow Qrcssure gauge capillary line from delivered airflow Qrcssure gauge.

k. Remove delivered air temperature gauge (wP01000).

I. Tag and disconnect wiring in instrument Qa”‘2l (19, figWe 4).

m. Remove screws (21), and washers (20).

n. Remove instrument panel (19).

o. For disassembly or assembly instructions SC%! WP 009 00.

18. INS’I’ALLATION.

il. Position instrument puncl (19, figure 4) on SUQQWt (Z‘s?).

Install washers (20) ilnd screws (21 I

Instill1 dclivcrcd air tcmpcroturc gauge (WI’

c. Connect delivered airflow prcssure gauge capillary line to delivered airflow pressure gauge.

f. Connect compressor discharge pressure gouge capillary line to compressor discharge pressure gauge.

g. COn,W!Ct CO,llQ,“SSO~ SUCtiOn QWSS”E! !$I”@?

CaQilh’y line to compressor suction pressure gauge.

h. Close instrument panel subassembly by turning grip latches clockwise.

i. Evacuate unit (WP 007 00) and check for leaks.

j. Open compressor suction and discharge service valves by turning valve stems counterclockwise. Instoll stem caps.

k. 0Qcr;ite air conditioning unit (WP 005 00) und monitor performance. Add refrigerant if necessary (WP 007 00).

I. Install cohinet top (63, figure 2).


19. BLOWER ASSEMBLY.


Part Number Nomenclature Sling Caliper or Micrometer (O-3 in.) Torque Wrench (O-25 ft/lbs.) Straightedge Crane or Hoist (O-200 Ihs.)

Materials Required

Specification or Part Number Somenclature

f, Loosen setscrew (27) on coupling flange (26).

g. Slide flange (26) on blower shaft towards motor (13).

h. Remove nuts (II), screws (10) and washers (9).

i. Attach sling to blower (8) and carefully hoist.

21. INSTALLATION.

a. Using sling carefully lower blower assembly (8, figure 5) into position.

h. Install washers (9), screws (lo), and nuts (11).

c. Position key (24) on motor shaft,

MIL-C-16173D Type Pl

Corrosion Preventive Compound, SOlvent Cut-Back

d. Position coupling flanges (23 and 26) with an equal length of shaft extending into each flange.

T,‘Q’2 F or Dexron II

Cold Application, CR1 Automatic Transmission Fluid Sealing Compound

20. REMOVAL.

e. Position coupling flanges (23 and 26) 2.563 inches apart.

f. Apply sealing compound to motor side setscrew (27) and tighten motor side flange (23) into its final position. Torque setscrew (27) to 13 ft/ Ibs. I (GJA).

g. Slide flange (26) far enough away to install key (28).

NOTE

To prevent injury to personnel or damage to equipment, unit shutdown and removal of power source must be COmpleted hefore removing blower.

Do not move the wire retaining ring to its final position.

h. Install neoprene sleeve (25) allowing it to hang loosely in the groove adjacent to the teeth.

b. Remove cabinet top (64, figure 2). NOTE

c. Remove electrical controls panel (this WP, paragraph 13).

d. Remove clamps (78, figure 5) and flexible ducts 177) from blower adapters (12).

c. Pry retaining ring out of groove in coupling (221.

Setscrews (27) must be positioned 90 degrees apart.

i. Position setscrews 90 degrees apart. Slide the loose flange (26) on the shaft until the sleeve is completely seated in the teeth of each flange.

AC-180AO-MMM-000 00% 00 Page 29

SHEET2 a=- 1. \ 34-J

SEE

Figure 5. Blower, Blower Motor, Precooler and Aftercooler Modules (Sheet 1 of 6)

AG-180AO-MMM-000 008 00 Page 30

DAPPLY ANTISEIZE COMPOUNO TO THAEAOS PRlOA TO ASSEMBLY.

DAPPlY PIPE SEALANT (P/N 59231. FSCM 05972) TO THE THAEAOS PRIOR TO ASSEMBLY

DAPPtYSEALlNG COMPOUNO TO THREAOS PAlOA TO ASSEMBLY.

14 - =AFTEA ASSEMBLY. TREAT EXPOSE0 PORTION OF SHAFTS PER MIL-P-116H. TYPE P-l. USING Mll-C-161730 CORROSION

Figure 5. Blower, Blower Motor, Precooler and Aftercooler Modules (Sheet 2)

AG-180AO-MMM-000 008 00 Page 31

IlUDEX PART CNITS USA13LE 541 &R so NUMRER I)ESCRIPTIoIU PER ASSY ON COI)lc CODE

NONUMHER . I%I.OWKK AND MOTOR ASSE,MRLY, I’l~lx00LEK AS0 AFTKK COOLER MoDCLE:S/SEE FIGLKE 1 FOR NHA/

I 1603AS488 . . HLOWE:R ASI) MOTOR ASSE:MI%LY. . . . . . . . I /ATTACHING PARTS/

*

2 MS2’7183-14 . . WASfIEK. FLAT. . . . . . 4 3 MS90725.58 . . SCREW . . . . . . _ . . 4 4 MS51922.9 . NCT,SEI.F-LOCKING . . . 4 5 MS27183.14 . _ WAStIEK, FLAT. . . . . . 8 6 !MS90725-60 . SCREW . . . . . . 4

* 7 X435489-20 . . GIw~I>l1:‘r . . . . . . I 8 1603ASl23 . . I1I.0WI:I~/60125/1~3230

c93owl~‘!vll . . . . I /A’l’TACIIISG PARTS/

9 MS27183.21 . . WASIIb:It, FI.AT . . . 6 IO MS90725.I64 . . SCRl:\V,CAl’ . _ . . 4 II .MS51922-49 . . SUT, SK1.F.LOCKISG. . 2 I2 1603AS671 . . Al)Al”l’~:I~, HI.OW~:R . . . 2

*

I3 1603AS128 . . MOTOR, IsLoWEK. 30 IIf’ 150706 /5K256HLl339~F2/. . . I IATTACIIISG PARTS/

I4 !v’lS27183-I6 . . . WASHER, FLAT. . . . 6 I5 MS90725-90 . . . SCREW. . . . . . 4 I6 .MSl6228-7C . NUT,SEl.F-I.OCKISG. . 2

*

17 1603ASl13 . . l%ASE, I%I.OWE:R, i-:VAl’ORATOR. . . . 1

I8 1603AS39.3 . . FITTISG,I’IPE, ISL-SlIISGi30327/

AGGGD

PAGZZ PAGZZ PAGZZ PACZZ I’AGZZ

I’AGZZ

I’f-iGGD

PAGZ% PAGZZ PAGZZ PAGZZ

I’RGGI)

PAGZZ PAGZZ [‘AC%%

MGGZZ

110.13-08X02/ . . . . I 19 IfiOiASR97 . . FITTISG PIPE,

sriw~:~r i~:i.isowi

PAGZZ

30327/l 16-fs-0% . . . . I I’AGZZ


AG-180AO-MMM-000 008 00 Page 32

ISDEX PART UNITS USABLE SM &R NO NUMBER DESCRff”TfON PERASSY ON CODE CODE

20 1603AS396

21 1603AS395

22 1603AS127

23

24 ._ 25 ._

26 -.

27 ._ 28 ._ 29 1603AS487

30 31

32

33

MS3533844 MS90725-5

1603AS480

1603AS105

34 MS27183.14 35 MS90725.60

36 iMIL-F-16552 . . FILTER, AIR ENVIRONMENTAL CLASS 2 CONTROLSYSTEM, SIZE 14 AF CLEANABLE . . . . . . . 1

. . . VALVE, DRAIN COCK/30327/325EI . . . .

. . . HOSE,DRAINI 11288/5A. . . . . . . .

*..

1 PAGZZ

1 XBGZZ

. . . COUPLING, BLOWERTO MOTOW79425l 7Sl-12/7Sl-58/7N/ . . . . 1

. . . . FLANGE, FINISHED BORE, (KEYSEAT ,375 WIDE, ,188 DEEP)/79425/ 7SXl-5/a/. . . . . . .

. . . . KEY c.377 SQ X 2.88 LG).

. . . . SLEEVE, NEOPRENE (2 PIECE) WITH RETAINING RING 179425/7Nl . . . . . .

I NIA 1 N/A

1 N/A . . . . FLANGE, FINISHED BORE

(WITH KEYSEAT ,375 WIDE X ,188 DEEP)

/79425/7SXI-1121 . . . . . . . . SCREW,SET . . . . .

KEY f.377 SQ X 2.50 LC). 1 1 CONTROLLER,

AIRFLOW . . . . . . . . /ATTACHING PARTS/ WASHER, LOCK. .

: : SCREW . . . . . : : : : ..*..

. . COUPLING, FLEXIBLE/ 70901/58035/8X 9/16/ . . . .

. . MODULE, PRECOOLER. . .

N/A NIA N/A

AGGGG

PAGZZ PAGZZ

XBGZZ AGGGG

(SEE WP 01100 FOR BREAKDOWN) /ATTACHING PARTS/

. . WASHER, FLAT. . . . . . 6

. . SCREW . . . . . . _ . . 6 ..*-

PAGZZ PAGZZ

PAGZZ

Figure 5. Blower, Blower Motor, Precooler and Aftercooler Modules(Sheet4)

AG-180AO-MMM-000 008 00 Page 33



37

38 3Q

40

41 42 43

44

45 46 47

48 49

50

51

52

53 54 55

56

57 58 59

1603AS439

MS27183.IO MS90725.5

1603AS719

. .

. .

. .

. .

MS27183.14 MS90725-44 MS51922.9

1603AS707

. .

. .

. .

. .

MS35338.44 . . MS27183.10 . . MS90725-5 . .

1603AS471 1603AS708

1603AS154.1

. .

. .

. .

MS35842.14 . .

1603AS655 . .

MS90725.6 . . MS27183.10 . . MS51922.1 . .

1603AS686 . .

X390725-6 MS27183.10 MS51922.1

. .

. .

. .

ANGLE, SCPPOKT, WELDMENT . . . . . . . WASHER, FLAT. . . . . . SCREW, CAP . . . . . . .

.-*.. VALVE:, BYPASS 04613/061-703-030. 100-0501 . . . . . . . . . /ATTACHING PARTS WASHER, FLAT. . . . . . SCREW,CAP . . . . . NtJT,SELF-LOCKING. . . .

1 MGGZZ 12 PAGZZ 12 PAGZZ

1 PAGZZ


* MOUNT, LOWER, WELDMENT . . . . . . . /ATTACHING PARTS/ WASIIER, LOCK. . . . . ‘. WASHER, FLAT. . . . . . SCREW, CAP . . . . . . .

* GASKET, BYPASS VALVE.

:ilOUNT, UPPER, WELDMENT . . . . . . . DCCT, FLEXIBLE/l6632/ FLXlOOl-00241 . . . . . /ATTACHING PARTS/ CLAMP, HOSE: LOW PRESSL!RE,TYPEF . . . .

BAFFLE . . . . . . . . . /ATTACHING PARTS/ SCREW,CAP . . . . . . . WAStIER,FLAT . . . , . . NUT,SELF-LOCKING . .

* ANGLE, SUPPORT, CAPILLARYTUBES . . . IATTACttING PARTS/ SCKEW,CAI’ . . . . . WASHER, FI.AT . . . , . . NUT,SELF-LOCKING . .

*

MGGZZ

PAGZZ PAGZZ PAGZZ

PAGZZ

XBGZZ

XBGZZ 6

2 PAGZZ

MGGZZ

FAG%! PAGZZ PAGZZ

I’AGZZ FAG%! FAG%%


AG-180AO-MMM-000

60

61 62 63 64 65

66

67 68

69

70 71 72

73

74

75

76

77

78

79

INDEX PART UNITS USABLE S.M &R NO NUMBER I~ESCRII”I‘ION PICK ASSY OS CODE CODE

1603AS645 . . BAFFLE . . . . . . . /ATTACIlING PARTS/

MS90725.32 . SCREW, CAP . . . . MS27183.12 . . WAStIER. FLAT. . . . . .MS51922-9 . . SUT,SEI.F-LOCKING . . . MS90725.5 . . SCREW, CAP . . . . . . . MS27183.10 . . WAStIER, FLAT. . . . . .

*~.

1603AS65.4 . . BAFFLE . . . . . . . _ IATTACIIING PARTS

MS90725.5 . SCREW (KEY) . . . . . . . .MS27183-10 . . WASHER(REF) . . . . . .

*..

1603ASlO6 . !.IODUl.E, AFTEK- cooLEI~ (SEE WI’01 I 00

1 MGGZZ

4 I’AGZZ 8 FAG%% 4 I’ACZZ 4 FAG%% 4 PAGZZ

1 MGGZZ

2 FAG%% 2 PAGZZ

FOR BREAKDOWSI . . . I /,\TTACIIISG PARTS/

MS9072533 . SCKI~:w . . . . . . 3 .MS27183-12 . WASIIER, FLAT . . . . . . 6 MS51922.9 . SUT, SE1.FLOCKISG . . . 3

*~-

1603AS558 . . BLOWER AIR Fl.OW DELTA PRESSURE

AGGGG

FAG%% FAG%% FAG%%

CAPILLARY INFOR.MATIVE. I (SEE WI’009 00 FOR BKEAKDOWN)

1603AS563 . DELIVERED AIR FLOW DELTA AIR PRESSURE CAPILLARY INFORMATIVE. I (SEE WP 009 00 FOR BREAKDOWN)

1603AS407 . . ADAPTER, MALE PIPE TO HOSE BARB1930611

XCGGG

XCGGG

125HBL-4-61. . . . . . . . I 1603AS272 . . HOSE, DRAIN/lDS07/R-3603/

(CUTTO2l.50INLG). . _ . I 1603AS154.2 . . DUCT, FLEXIBLE

/16632/FLXOOI-0018/ . . . . 2 IATTACIIING PARTS/

MS35842.15 . . CLAMP. IIOSB: LOW PRtiSSURE,TYPEF. . . . 4

*.. Ms35489.345 . GKOMMET . . . . . . . . I

XBGZZ

XBGZZ

XBGZZ

PAGZZ

FAG%%

008 00 Page 34

1

Figure 5. Blower, Blower Motor, Precooler and Aftercooler Modules(Sheet 6)

AG-180AO-MM M-000 008 00 Page 35

I j. Apply sealing compound to setscrew (27). Torque setscrew(27) to 13 ft/lbs. (QAI.

NOTE

Parallel misalignment between coupling flanges (23 and 26) should not exceed 0.020 inches.

k. Check parallel alignment by placing a straightedge across the two coupling flanges (23 and 26) and measuring the maximum offset at various points around the coupling without rotating the coupling. If the maximum offset exceeds 0.020- inches, realign the shafts. Shim blower base ss required. (See detail A, figure 5). (QA)

.Minimum and maximum angular offset between coupling flanges must not exceed 0.081 inches.

I. Check angular alignment with a micrometer or caliper. Measure from the outside ofone flange to the outside of the other flange around the coupling at various points without rotating the coupling. If the maximum or minimum offset exceeds 0.081 inches, parallel alignment must be adjusted. Shim blower and/or motor base as required. (See detail A, figure 5). (QA)

22.30 HP BLOWER MOTOR.


Part Number Nomenclature

Wrench, Torque (O-25 ft/lbs) Straightedge Micrometer or Caliper, (0 3 inch) Sling Crane or Hoist (O-250 Ibs.)

Materials Required


MIL-C-16173H Corrosion Preventive Type Pl Compound, Cut-Back,

Cold Application, CR1 Sealing Compound

23. REMOVAL.

a. Shut down unit (WP 005 001

To prevent injury to personnel or damage to equipment, unit shutdown and removal of power source must be completed before removing motor.

m. Position retaining ring into center groove of neoprene sleeve (25). b. Remove condenser fan panel assembly (1,

figure 2).

n. Treat exposed portion of shafts with MIL-C- 16173D corrosion preventive compound.

c. Remove condenser fan (this WP, paragraph 1).

o. Install flexibleducts (77).

p. Install clamps(78).

d. Loosen setscrews (27, figure 5) on coupling flange (23).

e. Slide coupling (22) on shaft towards blowol q. If required, service blower (WI’007 00) with 2 (8). Remove key (24).

quarts of automatic transmission fluid. f. Tag and disconnect wiring from motor

r. Install electrical controls panel (this WP, asscmbly(l3).

paragraph 13).

s. Install cabinet top (64, figure 2). g. Remove screws (15), washers (14) and nuts

(16).

AG-l$OAQ-MMM-000 008 00 Page 36

NOTE

To prevent condenser coils from damage. B cover may be fabricated from plywood or cardboard and placed between motor and condensercoil.

j. Slide the loose flange (23) on the shaft until the sleeve is completely seated in the teeth of each flange.

k. Apply sealing compound to setscrews (27). Torque setscrew (27) to 13 ft/lbs. (QA).

h. Attach sling and carefully remove motor (13).

NOTE

24. INSTALLATION.

3. Using sling, carefully lower motor assembly 113, tigure 5) into position.

h. Install washers (14), screws (151, and nuts (16).

c. Install keys 124 and 281

d. Position coupling flanges (23 and 2fi)with an equal lengthofshaft cutending into each flange.

e. Position coupling flanges (23 and 261 approximately 2.563 inches apart.

1 f Applv sealmg compound to setscrew (27)and _ tighten blower side flange (26) into its final position. Torque setscrew (27) to 13 ffflbs. ($A)

g. Slide other flange (2.3) far enough away to install sleeve (25).

NOTE

Do not move the retaining ring to its final position.

h. Install neoprene sleeve (251, allowing it to hang loosely in the groove adjacent to the teeth.

NOTE

Parallel misalignment between coupling flanges (23 and 26) should not exceed 0.020 inches.

I. Check parallel alignment by placing B straightedge across the two coupling flanges (23 and 26) and measuring the maximum offset at various points around the coupling without rotating the coupling. If maximum misalignment exceeds 0.020 inches, realign the shafts. Shim motor base as required. (See detail A, figure 5). (QA)

NOTE

Minimum and maximum angular

offset between coupling flanges must not exceed 0.081 inches.

m.Check angular alignment with & micrometer or caliper. Measure from the outside of one flange to the outside of the other flange around the coupling at various points without rotating the coupling. If the maximum or minimum offset exceeds 0.081. inches, parallel alignment must be adjusted. Shim as required. (See detail A, figure 5). (QA)

n. Position retaining ring into center groove of neoprene sleeve (25).

o. Install wiring as tagged to motor assembly (13).

Setscrews (27) must he positioned 90 degrees apart.

i. Position setscrews 127) 90 degrees apart from opposite flange.

p. Install condcnserfan (this WI’, paragraph 1).

q. Install condenser fan panel assembly (1, figure 2).

AG-180AO-MMM-000 008 00 Page 37

25. BLOWER TO MOTOR COUPLING



Wrench,Torque (O-25 ft/lbs) Straightedge Micrometer or Caliper, (0 3 inch)

Materials Required


Sealing Compound

26. REMOVAL.

a. Shut down unit (WP 005 00)

b. Remove condenser fan panel assembly (I, figure 2).

I c Pry retaining ring out of sleeve (25, figure 5).

d. Loosen setscrews (27) on coupling flanges (23 and 26).

I e. Slide coupling (22) towards motor (13).

f. Remove keys (24 and 28)

g. Remove screws (15), washers (14) and nuts (16).

h. Slide motor (13) away from blower (8).

i. Remove coupling (22).

21. INSTALLATION.

a. Slide flange (23) on motor shaft.

b. Slide flange (26) on blower shaft

c. Install keys (24 and 28)

d. Position motor (13) so that shafts line up

e. Apply sealing compound toscrews (15)

f. Install screws (15) washers (14) and nuts (16).

g. Position coupling flanges (23 and 26) approximately 2.563 inches apart.

h. Apply sealing compound to setscrews (27) and tighten flange (23) to its final position. Torque setscrew (27) to 13 ft. Ibs. (QA)

i. Slide flange (26) far enough away to install sleeve (25).

NOTE

Do not move retaining ring to its final position.

j. Install neoprene sleeve (25), allowing it to hang loosely in the groove adjacent to the teeth.

NOTE

Setscrews (27) must he positioned 90 degrees apart.

k. Position setscrews (27) 90 degrees apart from opposite flange.

I. Slide loose flange (23) on shaft until sleeve (25) is completely seated on teeth of each flange.

m.Apply sealing compound to setscrews (27). Torque setscrews (27) to 13 ft/lbs. (QA)

NOTE

Parallel misalignment between coupling flanges should not exceed 0.020 inches.

n Check parallel aiignmcnt by placing a stlaightcdgc across the two coupling flanges 123 ancl 26) and measuring the maximum offset at

AC-180AO-MMM-000 00% 00 Page 38

various points around the coupling without rotating the coupling. if parallel misalignment is greater than 0.020 inches, shim blower or motor base as required. (QA)

NOTE

Minimum and maximum angular offset between coupling flanges must not exceed 0.081 inches.

o. Check angular alignment with a micrometer or caliper. Measure from the outside of one flange to the outside of the other flange around the coupling at various points without rotating the coupling. If the maximum or minimum offset exceeds 0.081-inches, parallel alignment must he adjusted. Shim as required. (See detail A, figure 5). (QA)

p. Position retaining ring into center groove of neoprene sleeve (25).

q. Install condenser fan panel assembly (1, figure 2).

28. PHECOOLEH MODULE.


Part Number ~‘omenclature Wrench,Torque (O-25 ft.lbs) Sling Crane or hoist (O-200 Ibs)

Materials Required

None 29. HEMOVAL.

a. Pump down unit (WP 00’7 00).

h. Shut down unit (WP 005 00).

Pumpdown, shutdown and removal of power source must be completed hefore removing compressor. Fail- ure to comply could result in personal injury or death.

c. Remove cabinet top(64, figure 2).

d. Remove aftercooler module (this W,P, paragraph 32).

e. Remove precooler module refrigerant lines. (Refer to NAVSEA-0900.LP-001-7000 and Figure 6, this WP).

f. Loosen clamps (78, figure 5) and remove flexible duct (77).

g. Remove instrument panel (this WP, paragraph 17).

h. Remove screws (351 and washers (34) from lower flange of support angle weldmcnt.

i. Using slings and hoist, lift precooler module (33) out of air conditioning unit.

30. INSTALLATION.

a. Position prccoolcr module (33, figwe 5) in air conditioning unit.

h. Install washers (34) and SCI‘EWS (35) in air conditioning unit.

c. Install refrigerant lines (Refer to XAVSEA- 0900.LP-001~7000 and figure 6, this WP).

d. Position support angle (37) on precooler module (33).

e. Install washers (38) and ~crcws (39).

f. Install flexible duct (77) and clamps (78).

g. Install instrument panel (this WP, paragraph 19).

h. Evacuate system (WP 007 00).

i. Leak test system (WP 007 00).

Jo lnst.all cabinet top (64. cgure 2).

AG-180AO-MMM-000 008 00

31. AFTERCOOLER MODULE.


Sling Crane or hoist (O-200 Ihs)


32. REMOVAL.

a. Pump down unit (WP 007 00).


Pumpdown, shut down and removal of power source must be completed before removing compressor. Fail- ure to comply could result in personal injury or death.

c. Remove cabinet top (64, figure 2).

d. Remove curbside panel (76).

e. Remove rear curbside panel weldment (95)

f. Remove stem caps from compressor discharge service valve and compressor suction service valve. Close valves by turning stems clockwise.

g. Remove stem caps from receiver inlet and outlet service valves. Close valves by turning stems clockwise.

(W*RNING 4

Refrigerant is toxic. To avoid injury to personnel avoid breathing refrigerant or exposure to skin eyes. Do not expose refrigerant to open flame.

g. Bleed excess refrigerant pressure to atmosphere by depressing pneumatic valves on receiver inlet and outlet service valves.

Page 39

h. Remove aftercoole; refrigerant lines. (Refer to NAVSEA-OQOO-LP-001-7000 and figure 6, this WP).

i. Remove clamps (51 and 78, figure 5) and flexible duct (50 and 77).

j. Disconnect elbows (73 and 74)

k. Remove screws (39) and washers (38).

1. Remove szrew (67) and washers (68)

m.Remove screws (71). washers (70) and nuts (72).

n. Using hoist and sling, remove aftercooler module (69).

33. INSTALLATION.

a. Using hoist and sling, position aftercooler module (69, ligure 5) on curbside fender.

b. Install washers (70). screws (71) and nuts (72)

c. Install washers (68) and screws (67).

d. Install washers (38) and screws (39). 0

e. Position flexible ducts (50 and 77) and install clamps (51 and 78 ).

f. Install elbows (73 and 74).

g. Install refrigerant lines. (Refer to NAVSEA- 0900.LP-001-7000 and this WP, figure 6).


i. Leak test system (WP 00700).

j. Install valve stem caps

k. Install rear curbside panel weldment (95, figure 2).

I. Install curbside panel (76, figure 2).

m.Install cabinet top (64, figure 2).

AC-180AO-MMM-000 008 00 Page 40

34. FILTER DRIER.


None

Materials Required

35. REMOVAL.

NOTE

The following information is supplied for complete system contamination/evacuation. For component replacement, refer to the maintenance steps and isolate BS specified. This will eliminate the necessity to evacuate the entire system for component replacement.



c. Remove cabinet top (64, figure 2).

Pump down, shut down and removal of power source must be completed before removing filter drier. Failure to comply could result in personnel injury or death.

d. Remove cap from compressor discharge service valve and close valve by turning stem clockwise.

e. Remove caps from receiver inlet and outlet service valves and close valves by turning steins clockwise.

Refrigerant is toxic. To avoid injury to personnel avoid breathing or exposure to skin or eyes. Do not cxpose refrigerant to open flame.

f. Slowly bleed refrigerant from receiver inlet service valve pneumatic valve.

g. Remove nuts (81, figure 6) and screws (80).

h. Remove cap (79) and filter element (82).

i.. Remove screws (871, washers (88) and nuts (89).

j. Remove straps (86).

k. Remove screws (84) and washers (85)

I. Remove bracket (83).

m.Remove inlet and outlet lines from filter drier (78). (Refer to NAVSEA-0900-LP-001-0700).

36. INSTALLATION.

a. Install inlet and outlet lines on filter drier (78, ligure 6). (Refer to NAVSEA-0900-LP-OOl- 0700).

b.

c.

d.

e.

f. (89).

g.

Install filter element (82) in filter drier (78).

Position bracket (83) around filter drier.

Install washers (85) and screws (84).

Install straps (86).

Install screws (87) washers (88) and nuts

Position cap (79) in place and install screws (80) and nuts (81).

h. Leak test filter drier (‘78)

i. Evacuate unit (WP 007 00).

j. Add refrigerant (WP 007 00)

k. Install cabinet top (64, figure 2)

37. SOLENOID VALVES (Sl. S2. S3, S4.55. SW.

Support Equipment Required NOW

Materials Required NO”@?

38. REMOVAL.


b. Shut down unit (WP 005 00)

Pump down, shutdown and removal of power source must be completed before removing solenoid valve. Failure to comply could result in personnel injury or death.

AG-180AO-M M M-000 008 00 Page 43


1 1603AS650.2 . .

2 1603AS137 . .

3 1603AS683-4 _ _

4 1603AS652-1 . .

5 1603AS138.2 . .

6

7

8

9

10

11

A-1211 . .

1603AS589.4 . .

1603AS590 . .

1603AS648.48 . .

1603AS606.I . .

1603AS662.1 . .

12

13

14 15 16

1603AS769 . .

MS21322.40 . .

MS35207-264 . . MS27183.42 . . MS21044N3 . .

1603ASl07 . PIPING ASSEMBLY- REFRIGERATION/ SEE FIGURE 1 FOR NHAI _ .

ELBOW, 90,“SHORT RADIUS, FITTING X COUPLING, 518 DIA/41947Mr-23261. . . . VALVE. SOLENOID, EVAPORATOR/78462 /E9S250-110 (MKC-2COIL)I. . . . . . BUSHING, UNIVERSAL 128520/2119/. . . . . . . ELBOW, 90”, SHORT RADIUS, FITTING X COUPLING, 5/8 DIA 141947/W-26261 . . . . . VALVE, EXPANSION, THERMOSTATIC1784621 XVE-5-GN . . . . . . . /ATTACHING PARTS/ STRAP, TUBE,COPPER PERFORATED1419471. . .

*.. TtiBE,COPPER, 18 LG, .250OD,0,30WALL. . . . NCT, SHORT1303271 511.cs-04/ . . . . . . . TUBE, COPPER, REFRIG- ERATION, .250 LG, .875 OD. BUSHING, FLUSH 1-118X 7/8 /41947/w17371 . . . . . COCPLINC, ROLLED STOP I-1/8OD 141947/w-1047/ . . . . . TUBE, REFRIGERANT ,625 OD X ,040 WALL . . . /ATTACHING PARTS/ CLAMP, LOOP- ALUMINUM, .62lD. . . . SCREW,MACHINE. . . . WASHER,FLAT . . _ . . NtiT. SELF-LOCKING _ .

*..

1 AGGGG

6 PAGZZ

PAGZZ

PAGZZ

PAGZZ

PAGZZ ”

1 PAGZZ

1 XBGZZ

5 XBGZZ

1 XBGZZ

4 PAGZZ

3 PAGZZ

1 XBGZZ

1 PAGZZ 1 PAGZZ 1 PAGZZ 1 PAGZZ

Figure 6. Refrigeration Piping Assembly (Sheet 2)

AC-18OAO-MMM-000 008 00 Page 44

DESCRIPTION USABLE SM &R

PERASSY ON CODE CODE

17 1603AS779

18 MS21322.45

19 1603AS667 20 MS35207.264 21 MS27183.42 22 MS21044N3 23 1603AS649.1

24 1603AS768

25 MS2 1322.40

26 MS27183.42 27 MS35207.265

28 1603AS646.3

29 1603AS648.51

30 1603ASl36.1

31 1603AS649-6

32 1603AS648.41

33 1603AS652.2

34 1603AS136.2

35 1603AS650.3

36 1603AS646.5

37 1603AS767

38 MS21322.43

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

.

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .


TUBE, REFRIGERANT, . . 1 1.125 OD X .050 WALL /ATTACHING PARTS/ CLAMP- LOOP, ALUMINUM, .62 ID . . . . . . . . . 3 ANGLE, CLAMP SUPPORT. 1

SCREW,MACHINE. . . . 1 WASHER,FLAT _ . . . . 1 NUTSELF-LOCKING. . . 1 TEE, REDUCING1419471 W-40081. . . . . . . . . 1 TUBE, REFRIGERANT, ,625 OD X .040 WALL . _ . 1 IATTACfIINC PARTS/ CLAMP- LOOP, ALUMINUM, .62 ID . . . . . . . . . 1 WASHER, FLAT . . . . . 1 SCREW,MACHINE. _ . . 1

*.. ELBOW, 90”, SHORT RADIUS, 5/8 DIN419471W.20221 . . 2 TUBE, COPPER, REFRIGERATION,l.62L. 0.625ODp040WALL _ _ _ 2 GLASS. SIGHT178462l SA-15-S/ . . . . _ . . . 1 TEE, REDUCING, 718 X 518 X 718 /419471w-40411 . . - . 1 TUB&COPPER, REFRIGERATION, 5.001.,0.875OD . . . . . 1 ELBOW, 90”, SHORT RADIUS, FITTING X FITTING, 718 DIA 141947/w-2634/ _ . _ . . 1 GLASS, SIGHT/78462 ISA-17-S . . . . . . . . 1 ELBOW, 90”, SIIORT RADIUS, FITTING X COUPLING, 718 DIN41947iW23341 . . 6 ELBOW, 90”, SHORT RADIUS, 718 DIN41947iW-20341 . . 2 TUBE, REFRIGERANT, -875 OD X ,045 WALL . . 1

/ATTACHING PARTSI CLAMP- LOOP, ALUMINUM, .881D . . . . . f . . . 1

XBGZZ

PAGZZ MGGZZ PAGZZ PAGZZ PAGZZ

PAGZZ

XBGZZ

PAGZZ PACZZ PACZZ

PAGZZ

XBGZZ

PAGZZ

PAGZZ

XBGZZ

PAGZZ

PAGZZ

PAGZZ

PAZZZ

XBGZZ

PAGZZ

AG-180AO-MMM-000

I INDEX NO

008 00 Page 45

39 40

41

42

43 44

45 46

MS35207.265 MS27183-42

1603AS771

MS21322.43

MS35207.265 MS27183.42

1603AS783 1603AS650-4

_ _ - .

. .

. _

. .

. .

. .

. .

47 1603AS646.6 . _

48 1603AS648-80 . .

49 1603AS.649.IO - .

50 1603AS650.5 . _

51 1603AS648.79 . .

52 1603AS646-7 - .

53 1603AS64f.52 . .

54 1603ASl39 _ .

55 56 57

1603AS663 . . MS90725.6 . . MS27183.10 . _

PART NUMBER

I DESkRH’TION

SCREW.MACHINE. . . . WASHER,FLAT. _ _ _ .

t.-

TUBE. REFRIGERANT, .875 OD X .045 WALL. _ _

CLAMP- LOOP, ALUMINUM, .88 ID _ . . . . . . . . SCREW.MACIHNE. . . . WASHER,FLAT _ . . . .

t..

TUBE, REFRIGERAYT . ELBOW.90”. SIIORT RADIUS.

FITTING x COUPLING /41947/w-23441 . . . .

- ELBOW, 90”. SHORT RADIUS, l-l/8 DIN41947 Ml-20471 . _ _ . . . .

. TUBE, COPPER, REFRlGERATION.6.00L, 1-1/8OD . . . . . . .

. TEE, REDUCING, 1-5/8X 1-118X l-3/8/41947/ /w-4096/ . . . . * . .

. ELBOW, 90”. SHORT RADIUS. FITPING X COUPLING, l-518 DIAi41947 I%-23851 . . . . . _ _

_ TUBE, COPPER, REFRIGERATION 5.12 L, 1.62 OD, .060 WALL. . .

. ELBOW, 90”, SHORT RADIUS, l-518 DIAf41947 lw-2058/ . . . . _ _ .

. TUBE, COPPER, REFRIGERATION 2.56 I., 1.62OD . . _ _ _ . .

. VALVE, PRESSURE REGU- LATOR.EVAPORATOR /78462/0RIT-20.0175. 1-5/8ODF-120/50-60/ _ . IA’lTACllING PARTS/

. STRAP.VALVE . . . _

. SCREW.CAP . _ _ . .

. WASHER.FLAT _ . . .

I 1

1

1 1 I

I

2

3

1

I

1

1

1

1

1

2 4 4

PACZZ PACZZ

XBGZZ

PAGZZ PAGZZ PAGZZ

XBGZZ

PAZZZ

PAGZZ

XAGZZ

PAZZZ

PAZZZ

XAGZZ

PAZZZ

XAGZZ

XAGZZ

MGGZZ PAGZZ PAGZZ


AC-180AO-MMM-000 008 00 Page 46


UNITS USABLE SM &R PER ASSY ONCODE CODE

58

59

MS51922.1

1603AS653

60 61

62

MS90725-3 MS27183.IO

1603AS648.78

63

64

1603AS606.2

1603AS649.11

65 1603AS648.77

66 1603AS649.12

67 1603AS648.76

68 1603AS1’73.1

69 1603AS665

70 1603AS648.42

71

12

73

74

1603AS646.8

1603AS648.75

1603AS650.6

1603AS659.2

. . . NUT, SELF-LOCKING . *

. . . BRACKET, REGULATOR VALVE. . /ATTACHING PARTS

. . . SCREW,CAP . . . . .

. . . WASHER, FLAT. . . . *

. . . TUBE, COPPER, REFRIGERATION 3.06 L, 1.62 OD, ,060 WALL. . .

. . . BUSHING, FLUSH 2-118 X l-5/8 141947/w-1758/ . . . .

. . . TEE, REDUCING 2-118 X 2.118 X 718141947 Iw-40106 . . . . . . .

. . . TUBE, COPPER, REFRIGERA- TION 3.75 L,2-118 DIA., ,070 WALL . . . . . .

. . . TEE, REDUCING 2-118 X 2.118 X l/2/41947 m-40148/. . . . . . .

. . . TUBE, COPPER, REFRIGERA- TION 5.50 L, 2.12 OD, ,070 WALL . . . . . .

. . . ELIMINATOR, VIBRATION /70510/211220/. . . . .

. . . ELBOW, 90”, SIIORT RADIUS, 2.118 DIA . _ . . . .

. . . TUBE, COPPER, REFRIGERATION 9.00 L, 2.12OD . . . . . . .

. . . ELBOW, 90”, SHORT RADIUS, 2.118 DIA I419471 I%-20861 . . . . . . .

. . . TUBE, COPPER REFRIGERATION 6.50 L. 2,12OD,070 WALL. . :

. . ELBOW, 90”, SHORT RADIUS, FITTING X COUPLING 2-l/8 DIA 141947 m-23861 _ . . . . . .

. . ELBOW, 45”, 1.132 OD /41947/w-3044/ . . . . .

4 PAGZZ

MGGZZ

PAGZZ PAGZZ

XAGZZ

PAZZZ

1 PAZZZ

1 XAGZZ

1 XAGZZ

XAGZZ

XAGZZ

XAGZZ

1 XAGZZ

1 PAZZZ

1 XAGZZ

PAGZZ

PACZZ


AC-1 86AQ-M M M-000 008 00 Page 47

USABLE SM &R DESCRIFTION PER ASSY ONCODE CODE

75 1603AS64519

76 1603AS135

77 1603AS652.3

78 1603AS134

79 NO NUMBER

80 NO NUMBER 81 NO NUMBER

82 1603AS172

83 1603AS126

ii

86

87 88 89

90

MS90725-3 MS27183-IO

1603AS611

MS90725-8 1MS27183-10 MS51922.1

1603AS648-7

91 1603AS763

92 1603AS766

93 1603AS649.2

94 1603AS764

. _

. .

. .

. .

. .

. .

. .

. .

. _

. .

. .

. .

. .

. .

. .

. .

. .

. .

.

.

TUBE, COPPER REFRIGERATION 3.50 L 1.125OD..050WALL. . _

VALVE, SOLENOID, PUMPDOWN E19S290-110 (MKC-2COIL)I. . . . . . ELBOW, 90”. SHORT RADIUS, RADIUS FITTING X FITTING, l-l/8 X 1.127 OD/41947 Ml-26441 . . . _ _ . . _ DRIER, FILTER/78462 %489-G/ . . . _ . . . . . CAP. . . . . . _ . .

IATl’ACHING PARTS! . BOLT 5/16X l-3/4 . . . . NUT 5116 _ . . . . .

i..

. CORE, REPLACEABLE, DRIER, FILTER/78462 IRC-48641. . . . . . .

BRACKET, WELDMENT, DRIER,FILTER _ . . . . /Al-l-ACHING PARTS/ SCREW,CAP.. _ . . . _ WASHER, FLAT. _ . . .

STRAP, DRIER, FILTER. . IATTACHING PARTS/ SCREW,CAP. _ . . . . . WASHER,FLAT . _ _ . . NUT, SELF-LOCKISG . .

..*.. TUBE. COPPER, REFRIGER- ATION 6.50 L, ,875 OD, ,045 WALL . . . . . . . TUBE, REFRIGERANT, .875 OD X ,045 WALL . . _ TUBE, REFRIGERANT, .875 OD X ,045 WALL . . . TEE, REDUCING 314 X 314 X 718 /41947/w-4046/ . . . . . TUBE, REFRIGERANT, .750OD X ,042 WALL . . . /ATTACHING PARTS/

1 XBGZZ

1 PAGZZ

2 PAGZZ

1 PAGZZ 1 N/A

8 N/A 8 N/A

PAGZZ

MGGZZ

PACZZ PAGZZ

MGGZZ

PAGZZ PAGZZ PAGZZ

XAGZZ

XBGZZ

XBGZZ

PAGZZ

xmzz


AG-180AO-MM M-000 008 00 Page 48


U-NITS USABLE SM &R PER ASSY ON CODE CODE

95

96 97 98

99

100

101

102 103 104

105

106 MS21322.43

107 108

1603AS781 1603AS647

1603AS648.8 109

110

111

112

113

114

MS21322.42

MS35207.266 MS27183.42 MS21044N3

1603AS761

1603AS760

MS21322.42

~MS35207-266 MS27183.42 MS21044N3

1603AS758

1603AS646.4

1603AS648.I5

1603AS649.3

1603AS762

MS21322.42

.

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

.

.


CLAMP, LOOP-ALUMINUM, .75ID . . . . . . . . . SCREW,MACHINE. . . . WASHER,FLAT . . . . . NUT, SELF-LOCKING . .

TUBE, REFRIGERANT, .750ODX.042 WALL . . . TUBE, REFRIGERANT, ,750 OD X ,042 WALL . . . /ATTACHING PARTS CLAMP, LOOP- ALUMINUM, .75ID. . . . SCREW,MACHINE. . . . WASHER,FLAT . . . . . NUT, SELF-LOCKING . .

* TUBE, REFRIGERANT, ,875 OD X ,045 WALL . . . /ATTACHING PARTS CLAMP, LOOP-ALUMINUM, .81 ID . . . . . . . . .

* TUBE, REFRIGERANT . . . TEE, COPPER, 7/8 DIA

/41947/W4031/ . . . . . TUBE, COPPER,

REFRIGERATION 0.875 OD X 2.00 L, ,045 WALL . . . . _ .

ELBOW, 90”, SHORT RADIUS: 314 DIAl41947IW20281 . . TUBE, COPPER, REFRIGER- ATION 6.12 LG, 1.1/8OD, ,050 WALL . . . TEE, REDUCING 718 X 718 X l-118/41947 /w.~4033/ . . . . . . . TUBE, REFRIGERANT, .750OD X ,042 WALL . . . /ATTACHING PARTS/ CLAMP, LOOP-ALUMINUM, .751D . . . . . . . . .

*

1 XBGZZ

3

4

1 XBGZZ

1 PAGZZ

PAGZZ PAGZZ PAGZZ PAGZZ

XBGZZ


PAGZZ

XBGZZ

PAZZZ

XAGZZ

PAGZZ

PAGZZ

XBGZZ

008 00 Page 49

INDEX NO

PART NUMBER

UNITS USABLE SM &R DESCRI~ION PERASSY ON CODE CODE

115 1603AS759 . .

116 1603AS752 . .

117 1603AS133 _ _

118 1603AS755 . .

119 1603AS753 . .

120 1603AS132 . .

121 1603AS780 . . 122 1603AS649-7 . .

123 1603AS648-25 . .

124 1603AS6466 . .

125 1603AS64823 . .

126 1603AS64822 _ .

127 1603AS782 126 1603AS64818 : :

129 1603AS131 . .

130 1603AS756 . .

131 1603AS770 . .

132 1603AS650-7 . .

133 1603AS64611 . .

TUBE. REFRIGERANT, .875ODX.O42WALL . _ _ TUBE. REFRIGERANT. 1.1250DX.050WALL VALVE, RELIEF-ATMOS . PllERIC/28193/5223, 450 PSI/ . _ . . _ . . . TUBE, REFRIGERANT. I.125 OD X .050 WALL . _ TUBE, REFRIGERANT, 1.1250DX.050WALL _ _ VALVE, SERVICE117812 l44208-PI _ . . _ . _ . _ TUBE. REFRIGERANT . _

TEE. REDUCING l-l/8X 314 X 3/4/41947n4-402351 . . . TUBE, COPPER, 2.56L. REFRIGERANT, 1.125 ODX.050WALL. _ . . ELBOW, 90”. SHORT RADIUS. J-118 DDV41947 /w-20471 _ _ _ _ . _ . TUBE, COPPER, REFRIG- ERATION 3.13L. 1.125 ODX.050WALL. . . . TUBE, COPPER, REFRIG- ERATION 3.69L, 1.125 ODX.050WALL. . . .

TUBEREFRIGERANT . _ TUBE, COPPER, REFRIGERATION, 3.50 L, 1.125OD. .050WALL . . . VALVE, PRESSCRE REGULATOR. HEAD /78462/X 75.ORI-JO- 65/225/. . . . _ . . . . TUBE, REFRIGERANT. 1.125 ODX .050 WALL . . TUBE, REFRIGERANT. 1.375 OD X .055 WALL _ . . ELBOW, 90”. SHORT

RADIUS. FITTING X COUPLING l41947lW2384l _ . . .

. TUBE, COPPER, REFRIGERA- TION 4.06 L.. 1.375 OD, .055 WALL _ . . . . .

I

1

1

I

1

2 I

1

1

2

1

1 1

1

1

I

1

1

1

XBGZZ

XBGZZ

PAGZZ

XBGZZ

XBGZZ

FAG%% XHGZZ

XAGZZ

XAGZZ

XBGZZ

XBGZZ

XBGZZ XBGZZ

XBGZZ

PAGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ


AC-1 80AO-MMM-000 008 00 Page 50

INDEX PART UNITS USABLE SM &R NO NUMBER DESCRIPTION PER ASSY ONCODE CODE

134 1603AS646-9

135 1603AS648-10

ELBOW, 90” , SHORT * RADIUS/419 147/w-2064/ . _ TUBE. COP1 ?ER. ,REFRIGERA-

XBGZZ

136 1603AS785

137 1603AS648-13

XBGZZ

PAGZZ

138 1603AS757

139 1603AS173.2

140 1603AS648.12

TION 6.00 L., 1.375 OD, ,055 WALL . . . . . .

VALVE, CHECK/58553 /807C-I%/ . . . . . . . TUBE, COPPER, REFRIGERATION 2.25 L, 1.375 OD, .055WALL . . . . . . . TUBE, REFRIGERANT, 1.125 OD X ,050 WALL . . ELIMINATOR, VIBRATION /705lo/211t92/. . . . . . TUBE, COPPER, REFRIGERA- TION, 3 .OO L, 1.375 OD, ,055 WALL . .

XBGZZ

XBGZZ

PAGZZ

141 1603AS649-8

142 1603AS649-9

143 1603AS140

. .

. .

. .

* .

. .

. .

. .

. .

. .

. .

. .

. .

. .

.

. .

. .

. .

. .

TEE, REDUCING; 1:3/8x’ l-.3/8 X l-118/41947/W40691, . . TEE, REDUCING, 1-3/8X 718 X 1-1/8/41947/W-4079/. . . VALVE, SOLENOID, HOT GAS/78462/E145270-110 (MKC2COIL)/. TUBE, COPPER, REFRIGERATION 1.75 L. ,875 OD, .045 WALL . . . . . . . VALVE, HOT GAS BYPASS /78462/DRPE-3.55.70AK/. . /ATTACHING PARTS/ STRAP, TUBE, COPPER, PERFORATEDl41947l. . .

1

1

1

2

1

1

1

1

1

1

2

I

1

1

1 I

2

1

XBGZZ

PAGZZ

PAGZZ

PAGZZ 144 1603AS648-47

145 1603AS141 XBGZZ

PAGZZ

146 A-121 1 PAGZZ

* 147

148

149

150

151

1603AS648.57

1603AS775

1603AS776

1603AS138.1

TUBE, COPPER, REFRIGERA- TION, 2.75 I., ,625 OD, ,040 WALL . . . . . . . TUBE, REFRIGEKANT, .625ODX.O40WALL . . . TUBE, REFRIGERANT. . . ,625 OD X ,040 WALL VALVE, EXPANSION THERMOSTATIC178462 IXVE-2.I/2-GA/ . . . . . /ATTACHING PARTS STRAP, TUBE, COPPER, PERFORATED1419471. . .

XBGZZ

XBGZZ XBGZZ

PAGZZ

A-121 I PAGZZ


008 00 Page 51


152 1803AS64844

153 1603AS-772

154 1603AS778

155 1603AS142

156 1883AS848-68

157 1603AS649-4

158 1603AS649.5

159 1603AS773

160 1603AS774

161 MS21322.40

162 MS35207-265 163 MS27183.42

164 1603AS143

165 A-1211

166 1603AS650.I

167

168

1603AS777

1603AS662.2

169 1603AS669

170 1603AS791

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

.

TUBE, COPPER, REFRIGERA- TION, 2.75 L. .875 OD. .045 WALL . . . . . . . TUBE. REFRIGERANT, .625ODX.O40WALL . . . TUBE. REFRIGERANT, .3750DX.O30WALL . . . VALVE, SOLENOID, QUENCH i78462/A3Sl-110 (MKC-I COIL)/. . . . . . TUBE. COPPER, REYKIGEKA- TION, 1.94 I., .375 OD X.030 WALL . . . . . . . . . TEE, REDUCING, 718 X 718 X 518 /41947AN-4033/ . . . . . TEE. REDUCING. 718 X 518 X 518 /41947/w40431 . . . . . TUBE, RRFRIGERANT, .0625 OD X .040 WALL . . TUBE, REFRIGERANT. .0625 OD X .040 WALL . . /ATTACHING PARTS4 CLAMP, LOOP- ALCM1NU.M .62 ID. SCREW,MACHINE. : : : WASHER.FLAT . . . . .

t VALVE, QUENCH178462 /xv-I-L2/. . . . . . . . STRAP, TUBE, COPPER, PERFORATEDl41947l. . .

* ELBOW, 90”. SHORT RA,DIUS, FFITING X COUPLING. 112 D1;2/419471W-23211 . _ TUBE, REFRIGERANT, .500OD X ,035 WALL . . . COCPLING, ROLLED STOP, l-318 DIA I 41947/w-10551. . . . . . TUBE, COPPER, 5.25 LG, l-3/8 DIA . . . . . . . IATTACHING PARTSI TUBE, CAPILLARY VALVE, HOT GAS BYPASS. /ATTACHING PARTS/

1 PAG%%

1 PAGZZ I PAGZZ

AR PAGZZ

1

1

XBGZZ

XBGZZ

XBGZZ

XBGZZ

PAG%%

I’AGXZ

XBGZZ

XBGZZ

PAGZZ

PAGZZ

PAGZZ

XBGZZ

XBGZZ

XBGZZ


AG-180AO-MMM-000 008 00 Page 52

171 MS21322.34

172 MS35207.264 173 MS21044N3 174 MS21322.45

175 1603AS790

176 1603AS765

177 1603AS589.13

178 1603AS589.12

179 1603AS589-11

180 16ORAS589.IO

. .

. .

. .

. .

. .

. .

. .

. ,

. .

. .

CLAMP, LOOP- ALUMINU.M, .25 ID. SCREW, MACIIISE. NUT,SELF-LOCKING CLAMP, LOOP- AI.UMINUM, 1.12 ID . STRAP, CI,AMP,TtiIIk:

*.. TUBE, RI<FRIGERAST, 1.12501~X.050WAI.I. TUHE, COPPb;K 24.12 L, ,250 01) . . . TUBE, COPPER 26.25 I., .2SOOl) . ‘I-URif coPPKI~ 17.25 I., ,250 01) . . TlJI1lc, coI’I~‘l’l~ 22.00 I,. .250 01) . .

3 4 4

XI%G%%

XIX%%

XI~G%%

XIIG%%


AG-180AO-MMM-000 008 00 Page 53

c. Remove condenser fan panel assembly (1, Figure 2).

d. Remove cover from solenoid valve.

e. Disconnect wiring from solenoid valve and tag wires.

f. Remove caps and close compressor suction and discharge service valves by turning stems fully clockwise.

g. Open COMPRESSOR/RECEIVER access door.

h. Remove valve stem caps on receiver outlet and inlet shutoff valves and close valves by turning valve stems fully clockwise.

Refrigerant is toxic. To avoid injury to personnel avoid breathing or exposure to skin or eyes. Do not expose refrigerant to open flame.

i. Remove cap from pneumatic valve closest to solenoid and bleed refrigerant to atmosphere.

j. Loosen solenoid body nut and bleed excess refrigerant to atmosphere.

k. Remove inlet and outlet lines from solenoid valve (Refer to NAVSEA-0900.LP-001-7000 and this WP, figure 6).

1. Remove solenoid valve.

39. INSTALLATION.

a. Position solenoid valve in piping.

b. Connect inlet and outlet lines. (Refer to NAVSEA-0900.LP-001-7000).

c. Connect wiring to solenoid valve as tagged.

d. Install cover in place.

e. Install capon pneumatic valve.

f. Leak test solenoid valve

g. Evacuate unit (WP 007 00).

h. Service unit (WPOO7 00).

i. Install condenser fan panel assembly (1, figure 2).

j. Close nnd secure COMPRESSOR/RECEIVER accessdoor by turning grip latches.

40. EVAPORATOR PRESSURE REGULATOR VALVE.


None

Materials Required

NO”‘2

41. REMOVAL.

a. Pumpdown unit (WP 007 00)

b. Shut down unit (WP 005 00).

Pump down, shut down and removal of power source must be completed before removing evaporator pressure valve. Failure lo comply could result in personnel injury or death.

c. Remove condenser fan panel assembly (1, ligure 2).

Refrigerant is toxic. To avoid injury to personnel avoid breathing or exposure lo skin or eyes. Do not expose refrigerant to open flame.

d. Remove cop from EPR service port and bleed cxccss refrigerant to atmosphere.

e. Remove lines from EPR valve (54, figure 6).

f. Remove nuts (58) washers (57) and screws (56) from strap (55). I

AG-18OAO-MMM-000 008 00 Page 54

piGGiG-(

Pump down, shut down and removal of power source must be completed before removing head pressure regulator valve. Failure to comply could result in personnel injury or death.

d. Remove caps from compressor discharge and suction service valves nnd close valves by turning valve stems clockwise.

I g. Remove strap (55).

h. Remove inlet line and outlet line from EPR valve (54). (Refer to NAVSEA 0900-LP-001-7000).

i. Remove EPR valve (54).

42. INSTALLATION.

a. Position evaporator pressure regulator valve (54, figure 6) in place.

b. Install inlet and outlet lines. (Refer to NAVSEA-0900-LP-001-7000).

I c. Position strap (55) on valve (54).

d. Install washers (571, screws (561, and nuts (58).

e. Install lines to EPR valve (54).

f. Install cap on EPR service port,

g. Perform leak test (WP 007 00).

h. Evacuate unit (WP 007 00)

i. Service unit (WP 007 00)

j. Install condenser fan panel assembly, figure 21.

43. HEAD PRESSURE REGULATOR VALVE (v1).


Sane

44. REMOVAL.

a.. Pumpdown unit (WP 007 00 1

h. Shutdown unit (WP 005 00).

c. Remove condenser fan panel assembly (1, figure 2).

e. Remove caps from receiver inlet and outlet service valves and close valves by turning stems clockwise.

to personnel avoid breathing or exposure to skin or eyes. Do not expose refrigerant to open flame.

f. Remove cap from receiver inlet service valve pneumatic valve.

g. Bleed refrigerant from receiver inlet service valve service.

To prevent injury to personnel use extreme cnre when brazing near receiver. .Application of heat to refrigerant-charged receiver creates a dangerous overpressure situation.

h. Remove lines from lIPR valve (129, figure 6). (Kefer to SAVSEA-0900.LP-001-0700).

i. Remove HPR vnlve (129).

45. INSTALLATION.

il. Position head pressure regulator valve (129, figure 6) in place.

b. Install lines. (Refer to NAVSEA-0900.LP- 001-7000).

AG-180AO-MMM-000 008 00 Page 55

e. Install cap on receiver inlet service valve pneumatic valve.

d. Leak test unit (WP 007 00).

e. Evacuate unit (WP 007 00).

f. Add refrigerant unit (WP 00’7 00).

g. If necessary, adjust valve (see WP 007 00)

h. Install condenser fan panel assembly (1, ligure 2).

46. HOTGAS RYPASS VALVE.


NO”lZ

Materials Required


107408 Heat Conductive Compound

47. REMOVAL.



I c. Remove condenser fan panel assembly (1, ligure 2).

d. Open COMPRESSOR/RECEIVER ACCESS door.

m

Pumpdown, shutdown and removal of power source must he completed before removing hot gas bypass valve. Failure to comply could result in personnel injury or death.

e. Remove caps from compressor suction and discharge service valve stems and close valves by turning valve stems fully clockwise.

f. Remove caps from receiver inlet and outlet service valves and close valves by turning stems clockwise.

Refrigerant is toxic. To avoid injury to personnel avoid breathing or eu-

posure to skin or eyes. Do not expose refrigerant to open flame.

g. Bleed refrigerant from receiver inlet service valve pneumatic valve.

Do not allow kinks or hinds in capillary line. If this should occur, valve must be replaced.

h. Disconnect capillary line (170, figure 6) from .. hot gas bypass valve (145). I-

i. Remove screw, nut and strap (146).

j. Carefully coil capillary line and sensor.

To prevent injury to personnel use extreme core when brazing near receiver. Application of heat to refrigerant-charged receiver creates a dangerous overpressure situation.

k. Remove inlet and outlet lines. (Refer to NAVSEA-0900.LP-001-7000).

I. Remove hot gas bypass valve (145).

48. INSTALLATION.

To prevent injury to personnel use extreme core when brazing neer receiver. Application of heat to refrigerant-charged receiver creates a dangerous overpressure situation.

u Position hot gas bypuss valve (145, figure 6) and install inlet and outlet lines. (Refer to SAVSEA-0900.LP-001-7000).

b. Apply heat conductive compound between sensing bulb and tube (51).

AG-180AO-MMM-000 008 00 Page 56

Do not allow kinks or binds in capillary line. If this should occur, capillary must be replaced

c. Install capillary sensing bulb with strap (146), screw and nut.

d. Install capillary lines (170)

e. Leak test unit (WP 007 00)

f. Evacuate unit (WP 007 00)

g. Add refrigerant, if required. (WP 007 00)

h. Close COMPRESSOKiRECElVER ACCESS door.

i. Install condenser fan panel assembly (I, figure 2).

49. QUENCH VALVE.


NOW

Materials Required

Specification or Part Number 107408

Nomenclature Heat Conductive Compound

50. REMOVAL.

a. Pumpdown unit (WP 007 00)

b. Shutdown unit (WP 005 001

c. Remove condenser fan panel assembly (I, figure 2).

d. Open CO~PRF,SSOfliKEC~IV~:K ACCESS door.

e. Kemove caps from receiver inlet and outlet service valves and close valves by turning vnlve stems fully clockwise.

Pumpdown, shutdown and removal of power source must be completed before removing quench valve. F’ail- ure to comply could result in personnel injury or death.

f. Remove caps from compressor suction and discharge service villve stems and close compressor suction and discharge service valves hy turning valve stems fully clockwise.

g. Kemove cap from ev;lporator pressure regulator EPR (54, figure 6) pneumatic valve,

Kefrigewnt is toxic. To avoid injury to personnel avoid breathing or exposure to skin or eyes. Do n’ot expose refrigerant to open flame.

h. Bleed refrigerant from EPR pneumatic valve.

Do not allow kinks or hinds in capillary line. If this should occur, capillary must be replaced.

i. Rcmovc screw, nut and strap (165)

j. Carefully coil capillary line and sensor.

k. Remove inlet and outlet lines. (Kcfer to NAVSEA-0900.LP-001-7000).

I. Kemove quench valve (164)

51. INSTALLATION.

u. Position quench valve (164, figure 6) in pluce and install inlet and outlet lines. (Kefcr to NAVSEA-0900.LP-001-7000).

b. Apply heat conductive compound between sensor hulh and tube (70).

AG-180AO-MMM-000 008 00 Page 57

Do not allow kinks or binds in capillary line. If this should occur. copil- lary must be replaced.

c. Secure sensor bulb with strap (16%. screw and nut.

d. Open compressor suction and discharge service valves by turning valve stems fully clockwise.

e. Install caps on compressor suction and discharge service valve stems.

f. Leak test quench valve ( 164).

g. Evacuate unit (WPOO7 00).

h. Add refrigerant (WP 007 00).

i. Close COMPRESSORIRECEIVER ACCESS door.

j. Install condenser fan panel assembly (1, ligure 2).

52. THERMOSTATIC EXPANSION VALVES (Xl. x2, x3, X4).


Materials Required

53. REMOVAL.

Pumpdown, shutdown and removal of power source must be completed before removing thermostatic expansion valves. Failure to comply could result in personnel injury or death.



c. Remove condenser fan panel nsscmhly (I, figure 2).

d. Open COMPRESSOR RECEIVER ACCESS door.

e. Remove caps from compressor suction and discharge service valve stems and close compressor suction and discharge service valves by turning valve stems fully clockwise.

f. Remove caps from receiver inlet and outlet service valves and close receiver inlet and outlet service valves by turning valve stems clockwise.


h. Loosen capillary line nut (8, figure 6) at exnansion valve and bleed excess refrigerant to atmosphere.

i. Disconnect capillary line from expansion valve (5 or 150, figure 6).

thermostatic

Do not allow kinks or hinds in capillary line. If this should occur, capillary must be replaced.

j. Remove screw, nut and strap (151).

k. Carefully coil capillary line and sensor,

I. Remove inlet and outlet lines. (Refer to NAVSEA-0900.LP-001-7000).

m. Remove thermostatic expansion valve (5 or 150).

54. INSTALLATION.

a. Position thermostatic expansion valve (5 or 150, figure 6) and install inlet and outlet lines. (Refer to NAVSEA-0900-LP-001.7000).

AG-180AO-MMM-000 008 00 Page 58

b. Install capillary line (7) on thermostatic expansion valve with nut (8).

[-I

Do not allow kinks or binds in capillary line. If this should occur, capillary must be replaced.

56. REMOVAL.



c. Remove cabinet top (64, figure 2)

d. Remove front panel (144, figure 2).

e. Apply heat conductive compound between e. Remove condenser fan (this WP, paragraph sensor bulb and tube. 11.

d. Install sensor bulb(s) with strap (1511, screw and nut.

f. Remove duct storage rack (this WP, paragraph 7).

e. Evacuate unit (WP 007 OO),

f. Add refrigerant to unit (WP 007 001,

g. cb~e and secure COMPRESSOR/RECEIVER ACCESS door.

h. Install condenser fan panel assembly (1, ligure 2).

To prevent injury to personnel or damage to equipment, unit pumpdown, shutdown and removal of power source must be completed before removing receiving assembly.

55. RECEIVER ASSEMBLY.



Sling

Hoist (O-200 Ibs)

Materials Required


Antiseize Compound

R-22 Refrigerant, R-22 (I30 Ibs)

NOTE

All rcfrigcrant in air conditioning unit must be released before removing receiver. Refrigerant release may be accomplished rapidly by opening more than one pneumatic valve.


g. Remove cap from receiver inlet service valve pneumatic valve.

h. Release refrigerant by opening pneumatic valve. Rapid refrigerant release may be accomplished by opening more than one pneumatic valve. Pneumatic valves are located on receiver inlet and outlet service valves, compressor suction and discharge valves and evaporator prc?ssurc regulator (EPR) valve.

i. Remove refrigerant lines from top of receiver assembly (6, figure 7). (NAVSEA-0900.LP-OOI- 7000).

j. Remove nuts (9), screws (7) and washers (8).

k. Attach sling and remove receiver assembly (6).

AC-180AO-MMM-000

COMPRESSOR

00800 Page 59

DISCHARGE PRESSURE

COMPRESSOR

;p$fgR h%%"E

UNLOAOER SOLENOIO

SUCT,ON pREssf%,;~ 'T] & ,COMPRESSOR

COMPRESSOR SUCTION SERVICE

CAPILLARY INFORMATIVE

1. APPLY ANTISEIZE COMPOUNO TO THREAOS PRIOR TO ASSEMBLY

Flgure 7. Compressor, Receiver and Condenser Coil Assemblies (Sheet 1 of 2)

AC-180AO-MMM-000 008 00 Page 60

INDEX NO

PART NUMBER DESCRIPTION


1 1603AS324

2 MS90725.68 3 MS90725-66 4 MS27183.15 5 1603AS616

6 1603AS125

7 MS90725.60 8 MS2’7183.14 9 MS51922.9

10 1603AS121

11 MS90725.6 12 MS27183.10 13 MS51922.1 14 MS90725.5

15 1603AS144

16 MS90725.6 17 MS27183.10 18 MS51922-1 19 MS90725.5

20 1603AS133

NO NUMBER . COMPRESSOR, RECEIVER AND CONDENSER COIL ASSEMBLIES/SEE FIGURE 1 FOR NHN

. . COMPRESSOR ASSEMBLY, REFRIGERATION/SEE WP 012 00 FOR BREAKDOWN /ATTACHING PARTS.. . .

. .SCREW,CAP . . . . . . .

. .SCREW, CAP . . . . . .

. . WASHER, FLAT . . . . . .

. .SPACER,COMPRESSOR . . *

RECEIVER LIQUID . ‘KEFRICERANT- R22

/23587/V33099-c/. . . . . . IATTACFI[NG PARTS/

. .SCREW,CAP.. . . . . . .

. . WASIIER, FLAT. . . . . .

. . NUT,SELF-LOCKING. . . . *

. .COIL, CONDENSING ROADSIDE. . . . . . . . .

/ATTACHING PARTS/ _ . SCREW, CAP. . . . . . . . . . WASHER, FLAT . . . . . . . . NUT, SELF-LOCKING. . . . . .SCREW,CAP. . . . . . .

* . . COIL, CONDENSING

CURBSIDE . . . . . . . . /ATTACHING PARTS/

. .SCREW. . . . . . . . _ .

. . WASHER, FLAT . . . _ . . NUT, SELF-LOCKING.

: :SCREW,CAF. . . . . : : : *

. .YALVE, RELIEF-ATMOSPHERIC /28193/5223.45OPSI/ . . . .

1 2 2 4 4

1

4 8 4

1

IO 15 15

5

1

IO 15 15

5

1

ADGGD PAGZZ PAGZZ PAGZZ XBGZZ

XBCZZ

PAGZZ PAG%% PAGZZ

PAGZZ

PACZZ PAGZZ PAGZZ PAGZZ

PAGZZ


PAGZZ

Figure 7. Compressor, Receiver and Condenser Coll Assemblles (Sheet 2)

Page 61

57. Ii’lSTALLATIBN.

a. Using sling position receiver assembly (6. figure 7) on chassis.

b. Apply antiseize compound to screws (7)

e. Install washers (8). screws (7) and nuts (9).

d. Install refrigerant lines to top of receiver assembly. (NAVSEA-0900.LP-001-7000).

To prevent injury, death or damage to equipment, receiver fusible plug and atmospheric valve must bc securely installed before charging unit.

e. Make sure receiver fusible plug, atmospheric relief valve and refrigerant connections we sccurc.

f. Install duct storage rack (this WP, paragraph 7).

g. Install condenser fan (this WP, paragraph 1).

h. Install front panel (144. figure 2)

i. Evacuate unit (WP 007 00).

j. Leak test unit (WP 007 00)

k. Charge unit with refrigerant (WPOO’I 00)

I. Install cabinet top (64, figure 2)

58. ATMOSPHERIC RELIEF VALVE (VZ).


NOW2

Materials Required

Specilication or Part Number Nomenclature

R-22 Refrigerant, K-22 (130 Ibs)

59. KEMQVAL.


b. Shutdown unit (WP 005 00)

c. Remove condenser fan panel assembly (this I, figure 21.

d. Open COMPKESSOR/KlXEIVER ACCESS door.

Pumpdown, shutdown and removal of power source must be completed before removing atmospheric relief valve. Failure to comply could result in personnel injury or death.

Refrigerant is toxic. To avoid injury to personnel avoid breathing or cx~ posure to skin or eyes. 110 not expose refrigerant toopen flame.

NOTE

All refrigerant must bc bled from receiver before removing atmospheric relief valve.

c. Kemovo cap from receiver outlet service valve pneumatic valve.

NOTE

All refrigerant in air conditioning unit must be released before replacing atmospheric relief valve.

f. Open receiver inlet service valve by opening pneumatic valve. Rapid refrigerant release may be accomplished by opening more than one pneumatic v&c. Pneumatic valves arc located on the rcccivel inlet and outlet service valve, compressor suction and discharge valves and evaporator pressure regulator CEPR) valve.

AC?-l$OAO-MMM-000 008 00 Page 62

g. Remove atmospheric relief valve (20, figure 7) from receiver assembly.

60. INSTALLATION.

a. Install atmospheric relief valve (20, figure 7) on receiver assembly.

b. Install cap on receiver valve service valve pneumatic valve.

c. Leak test unit (WP 007 00).

d. Evacuate unit (WP 007 00)

e. Add refrigerant (WP 007 00)

f. Close and secure COMPRESSOR/RECEIVER ACCESS door.

g. Install condenser fan panel assembly (1, figure 2).

61. COMPRESSOR ASSEMBLY.



Sling Crane or Hoist (O-600 Ibs) Wrench, Torque (0.200 ft-lbs)

Materials Required

NO”@

62. REMOVAL.

a. Identify and correct cause of compressor failure. Check for compressor motor burnout (WP 006 001, burned contactars, blown fuses, inoperative press”reco”trols, etc.

NOTE

If compressor failed and the cause of failure is not identified and corrected, the replacement compressor will fail.

Cleanup after compressor motor burnout is difficult, time consuming and expensive. Cleanup should be performed in the field only if Depot level facilities are unavailable or inaccessable.

Compressor motor burnout produces toxic compounds.

b. If possible, pump down unit (WP 007 00)

c. Shut down unit (WP 005 00).

Removal of power source must be completed before removingcompres- ser. Failure to comply could result in personnel injury or death.

d. Remove condenser fan (this WP, paragraph I).

e. Remove duct storage rack (this WP, paragraph 7).

f. Open COMPRESSOR/RECEIVER ACCESS door.

g. Remove caps from receiver inlet and outlet service valves and close valves by turning valve stemsclockwise.

h. Remove caps from compressor suction and discharge service valves and close compressor suction and discharge service valves by turning stems fully clockwise.

i. Remove suction service valve pneumatic valve cap.

j. Bleed refrigerant pressure in compressor to atmosphere by opening suction service valve pneumatic valve.

k. Disconnect capillary lines from compressor 1WP 009 00).

AG-l$OAO- 008 00 Page 63

To prevent injury, removal of power source must be completed before solenoids are disconnected.

I. Remove solenoids from compressor (1. ligure 7) and secure.

NOTE

Compressor suction and discharge valves remain connected to system piping.

m.Dionnect compressor suction service valve from compressor by removing screws and washers.

n. Remove screws. washers and gasket from eompressordisehargeservice valve.

0. Remove ~erews from compressor terminal jumper cover and remove cover.

p. Tag and disconnect electrical wiring.

q. Remove screws (2 and 3) washers (41 and spacers (5). from compressor ( I ).

r. Cap refrigerant tittings on compressor t 1 I

NOTE

To prevent condenser coils from’ damage, a cover may be fabricated from plywood or cardboard and placed between compressor and condenser coil.

s. Attach sling to compressor (1) and carefully remove.

63. INSTALLATION.

To prevent injury, be careful when positioning spacers (5. figure 7). washers (4). screws (2 and 3) and compressor t I).

a. Position spacers (5, figure 7) on chassis.

b. Using sling position compressor (1) on chassis.

c. Apply antis&e compound to screws (2 and 3).

d. Install washers (4) and screws (2 and 3) securing compressor (1) to unit.


f. Position terminal jumper cover in place and install four screws.

g. Remove caps from lines and fittings on compressor (1).

h. Install capillary lines (WP 009 00).

i. Install screws, washers and gasket securing compressor discharge service valve to compressor (1). Torque screws 80-90 ft.tbs. (QA)

j. Install compressor suction service valve with screws and washers. Torque screws 80-90 ft.lbs. (Qh)

k. Install solenoids on compressor (1).

I. Install duct storage rack (this WP, paragraph 71.

m.Install condenser fan (this WP. paragraph 1).

n. Check compressor oil. Service if required (WP 007 00).

a. Replace filter drier core (82. iigure 6).

p. Add refrigerant (WP 007 00).

q. Operate unit (WP 005 00) at low air conditioning load. Monitor oil level, sight glasses and performance. Replace filter drier core (82. figure 6) ifcontamination is evident. If oil foams or sight glasses are cloudy, shut down unit (WP 005 00) and determine cause.

r. Install cabinet top (64. figure 2).

64. FRONT WHEELASSEMRLY.


Part Number ?lomenelature

Jack, O-5000 Ihs. Chock Wrench, Torque (O-200 ft.lbs.1

AG-180AO- 00800 Page 64

‘6

D APPLY ANTISEIZE COMPOUND TO THREADS PRIORTO ASSEMBLY.

54 52 51

Figure 8. Chassis and Wheel Assemblies (Sheet 1 of 6)

AG-180AO-MMM-000

INDEX I I PART UNITS NO NUMBER, DKSCRIPTIOIV PER ASSY

008 00 Page 65

SIM & R CODE 1

9 10

II

12

13

14 15

16 17 18 19

24

21

22

23

NO IVUMRKR

1603AS104

1603AS233 MS171656

1603AS577

1603AS575 MS27183-23 MS171656

1603AS576

MS35O’i-263 MS27183.8

I603AS574

1603AS618

1603AS619

. CIIASSIS AZID WIIEKL ASSKMHLIKS /SICK FIGURE 1 FOR NIIN

. - TOWRARASSKMHLY _ . _ /ATl’ACIIINC PARTS’

PI.V,TOWHAR . _ _ . . . : : PIS.SPRINC . _ _ . _ _ .

t.. _ . . I1ODY,TOWBAR . . _ .

/A7TACIIINC PARTS/ . . . PIN.IIINCE.. _ . _ _ . . - . WASllER.FLAT _ _ . _ . . . PIN.SPRINC. _ . . .

1.. . . . PIN. HALL LOCK,

WITIICAHLK . _ _ . _ IAlTACIIING PARTY

. _ . SCREW.MACIIINK . . .

. . . WASHKR.PLAT . . _ . t..

_ . _ PIN. BALL LOCK /39428/983201\771/ . . _

. . - CABLE. NYLON COATED /99862lCI.-2-C-xX/. _ . _

_. . FERRULE. CABLE /99862/Cl.-4-k’/ _ _ _ . _

1603AS585 _ _ _ ARM, TOWHAR. . _ _ . 1603AS458 - . _ WIIERLASSKMHLY. FRONT

101083/SH114S4016-44/ . _ . IAI-I’ACIIING PARTSI

MS90725.167 _ _ SCREW. CAP. _ _ . _ _ _ MS90725.165 _ _ SCRKW.CAP. . _ _ . . _ MS27183.21 _ . WASIIER, FLAT . _ . _ . MS51922.49 . _ NUT.SE:LF~I.OCKINC . . .

t . _ - I’LATK, TOP

101083/SI’-23/ _ _ . . . I3KARINC.TIMKb;~~ . .

CUI’#15245/01083/ llOs/. . - . . . . . .

_ . . HEARING.TIMKKN CONK #15123/01083/ 1109/ . . . . . . . . .

. . . NUT. KING PIN, I-114-12 /01083/1036/. _ . . . _

XI3GCG

MCCZZ PA%%%

XBC7.Z

MGGZZ I’AGZZ PAGZZ

I’AG%%

I’AG%% I’AG%%

XAGZZ

Figure 8. Chassis and Wheel Assemblies (Sheet 2)

AC-180AO-MMM-000 008 00 Page 66

INDEX PART UNITS USABLE SM &R NO NUMBER DESCRIPTION PER ASSY ONCODE CODE

24

25

. . .

. . .

26 . . .

27 . . .

28 . .

29 . . .

30 . . .

31 . . .

32 . . .

33 . . .

34 . . .

35 . . .

36 . . .

37 . . .

38 . . .

39

40

41

42

43

. . .

. . .

. . .

. . .

. . .

PIN, ROLL, 3116 X I-13/4/01083/1033/. . . . CUP, GREASE, /01083/1360/ . . . . . .

BEARtNG,TIMKEN THRUST, #T-581 /01083/1107/ . . . . . . SWIVEL LOCK AND DAMPENER ASSEMBLY 101083/HM-27Al. . . . . SWIVEL LOCK HOUSING /01083/HM-27-U. . . . . SLEEVE, STL 101083/HM-27.21. . . . . PLUNGER /01083/HM-27-51. . . . . SPRING, PLUNGER 101083/SLS-1002/ . . . . HANDLE1010831 EMH-5-5Al. . . . . . . PRESSURE PIN ASSSEMBLY101083 IHM-21-3Al . . . . . . SPRING - PRESSURE PIN/01083/HM-27.41.. . .

PIN - ROLL - 3/32 X 5/8/01083/1019/. . . . . FITTING, GREASE /01083/1182/ . . . . . . FITTING, GREASE 101083/1196/ . . . . . . YOKE -FABRICATED STEEL/. . . . . . . .

101083/SBl14-11 BEARING, OILITE 101083/10021 . . . . . . FOKK - L.H. 16 IN 101083/C%91 . . . . . . FORK R.H. 16 IN /01083/C4-IO/. . . . . . PIN, HINGE /01083/K-1266/ . . . . . NUT-IIEX, 1-14X INSR/01083/144/ . . .

1

1

1

1

1

1

I

I

1

2

2

2

1

1

1

4

1

1

I

1

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XAGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBCZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBCZZ

XBGZZ

XBGZZ


AG-180AO-MM M-000 008 00 Page 67


I DESCRIPTION 1 P:?%Y 1 ,“,““cf%! ( %:E” 1

44

45

46

47

48

49

50

51 52

53

54

55 56

57 58

59

60 1603AS176

61 MS90725-67 62 MS27183.14 63 MS51922-9

. .

. .

. .

. .

. .

. .

. _

. .

. .

. .

. .

. .

. .

. .

. .

. .

f .

. .

. .

. .

64 1603AS427-100 . .

65 MS20392-5C3t . . 66 MS27183.14 . . 67 MS24665.283 . .

PIN. STOP/O1083/ R-1267/ . . . . . . . . NUT, HEX - 314 -16 NYLON INSERT /01083/1414/ . . . . . . BEARING. OILITE, .875 O.D. X 750 ID X 1 /01083/R-1042-2-9/. . . . WHEEL - 16 IN DIAX4IN RUBBER /01083/16-441 . . . . . . NUT, HEX 3/8 16 NC/01083/1568/. . . . . WASHER, LOCK SPLIT 3/8/01083/1219/. . . . . ASSEMBLY, HUB /01083/1650/ . . . . . . CAP, DUST . . . . . . NUT. JAM, SLOTTED HEX, 5/8-18/01083/1655. .

PIN. COTTER, 118 X I-l/2/01083/1064/ . . . . WASHER- BEARING TONGUE/01083/1656/ . . BEARING, CONE-OUTER. BEARING, CONE INNER.. . . _ . . . . SEAL, GREASE. . . . . SPRING - BLUE/010831 A-5000/ . . . . . . . . SPRING - GRAY1010831 A-50251. . . . . . . .

LEVER, BRAKE /ATTACHING PARTSI . . . SCREW,CAP . . . . . . WAStIER,FLAT . . . . . NUT,SELF-LOCKING . . .

* CABLE ASSEMBLY, BRAKE . . . . . . . . . /ATTACHING PAKTSI PIN.STRAlGtlT . . . . . WAStlER,FLAT . . . . . PIN,COTTER . _ . . . .

*

1

1

2

2

10

IO

2 2

2

2

2 2

2 2

2

2

1 2 2 2

1

I 1 1

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBCZZ

XBGZZ

XBGZZ XBGZZ

XBGZZ

XBGZZ

XBGZZ XBGZZ

XBGZZ XBGZZ

XBGZZ

XBGZZ


AGGGG

PAGZZ PACZZ PAGZZ


AC-180AO-MMM-000 008 00 Page 68

INDEX SO

PART NUMBER DESCRIPTION DESCRIPTION

UNITS USABLE SM &R PERASSY OSCODE CODE

68 c 1603AS426.1

69 1603AS449

70 MS35691.21 71 1603AS450 72 1603AS451 73 1603AS452

74 X390725-62 75 MS27183.14 76 MS51922.9

77 1603AS453

78 MS16562.71

79 - 1603ASJ27.IO1

80 MS20392.5C31 81 MS27183.14 82 MS24665.283

83 1603AS449

84 MS3569 I-2 1 85 1603AS426.2 86 1603AS341

87 MS90725.32 88 MS27183.12

89 1603AS670

90 1603AS670

91 MS90725.6 92 MS27183.IO 93 MS51922.I

. .

.

. .

. .

. .

. .

. .

. .

. .

. .

.

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

.

. CABLE,BRAKE . . _ . 192867/16474602/

. YOKEEND, . . . . . . ADJCSTABLE

. NUT,FIEX. . . . . . . StlAFT,CROSS. . . . . . COLLAR, SHAFT, CROSS. . BLOCK, PILLOW . . . . . /ATTAClIING PARTS/ SCREW,CAP. . . . . . WASIIER.FLA’r . . . . SUT.SK1I.F.I.OCKISG . . .

I.. AR.M, LEVER . . . . IATTACIIING PARTS/ PIS,SI’RING. . . . . . IATTACIIING PARTS/ CARLE ASSEMBLY, . . . k3KAKE ~ATTACIIING PARTS/ I’IN,STRAIGtlT . . . . . WASlIER.FLAT . . . . PIN, COTTER . . . . . .

. YOKEEND. . . . . . . ADJUSTABLE:

. NUT, HEX . . . . . CABLE,BRAKE . .

kNDER,ROADSIDE: : . . /ATTACHING PARTS/ SCREW,CAP. . . . . . . WASHER,FLAT . . . . .

.-*- BRACKET, PRESSCRE SWITCH . . . . . . . . BRACKET, PRESSURE SWITCH . . . . . . . . /ATTACIIING PARTS/ SCREW,CAP. . . . _ . . WAStlER,FLAT . . . . NCT,SF:LF-LOCKING . ,

1

2 PAGZZ

PAGZZ ~lGG%Z PAGZZ

MGGZZ

PAGZZ f’AGZ% PAGZZ

PAGZZ

PAGZZ

AGGGG

I’AGZZ I’AGZZ PAGZZ

PAGZZ

PAGZZ XBGZZ

MGGZZ

PAGZZ PAGZZ

MGGZZ

MGGZZ

PAGZZ PAGZZ


AC-180AO-MMM-000 008 00 Page 69


94 1603AS342 _ .

95 MS90725-32 . . 96 MS27183-12 _ .

97 1603AS460 . .

98 1603AS459 _. .

99 MS35489-79 100 MS35489-78 101 MS90726-185 102 MS35691.61 103 1603AS796

104 MS35207.263 105 MS3533843 106 1603ASl90

. .

. .

. .

. .

. .

. .

. .

. .

FENDER,CURBSIDE . . _ 1 IAlTACHINC PARTS/ SCREW,CAP. _ . . . . . 5 WASHER.FLAT . . . . . 5

..*- WHEEL ASSEMBLY, . . . 1 ClJRBSIDE/01083/B8000-44 RH /SEE FIGURE 9 FOR BREAKDOWN1 WHEEL ASSEMBLY, . . . 1 ROADSIDE/01083/B800044 LH /SEE FIGURE 9 FOR BREAKDOWN

GROMMET . . . . . . - 2 GROMMET . . . . . . . : SCREW.CAP. . . . . _ . 2 NUT,PLAlN . . _ . _ . . 2 WELDMENT. BRACKET, CHARGINGGAS . . . . . 1 IATTACHISG PARTS/ SCREW,MACHINE . . . . 1 WASHER,LOCK . . _ . . 1 CHASSIS, WELDMENT . . 1

*

MGGZZ

PACZZ PAGZZ

XBGCG

- XBGGG


MGCXZ

PAGZZ PAGZZ

MDGZZ

Figure 8. Chassis and \;Vheel Assemblies (Sheet 6)

AG-180AO-MMM-000 008 00 Page 70

Materials Hequired

Spccificution or Part Sumher

65. REMOVAL.

Nomenclature

Antis&e Compound

a. Remove cabinet top (64, figure 2).

b. Chock rear wheels of unit.

c. Usingjack raise front wheelsoffground.

d. Place jack stands under each front ccrner of the unit.

e. Support front wheel assembly (15, figure 8).

f. Remove scrc~s 116). washers (181 and nuts (19).

g. Remow screws ~171, washers (181 and nuts 119).

h. Lower front wheel assembly (1.5)~

66. INSTALLATION.

a. Support front wheel assembly (15, figure 81 in position under chassis.

b. Apply antiseize compound to screws (16 and 17).

c. Install screws (161, washers (18) and nuts (19). Torque screws (16) to 180 ft-lbs (QA,.

I

d. Install screws (17), washers (18) and nuts (19). Torque screws (17)to 180 ft.lhs (QA).

e. Lower unit

f. Install cabinet top (64, figure 21

67. ROADSIDE AND CURBSIDE REAR WHEEL ASSEMBLIES.


Pal‘t. Sumher Nomenclatlm Jack, (O-5000 Ihs.) Chock Wrench. Torque (O-200 ft.lhs.)

Materials Required

NOW

68. REMOVAL.

a. Chock rear wheels of unit.

b. Using jack raise front wheels off the ground.

c. Place jack stands under each front corner of the unit.

d. Using jack raise rear wheels off the ground.

e. Place jack stands under each rear corner of this unit.

f. Remove cotter pin (82, figure 81, washer (81) and pin (80).

g. Support rear wheel assembly (1, figure 9).

h. Remove screws (3 or 7), washers (4 or 8) and nuts (5 or 9).

i. Lower front wheel assembly (15).

69. INSTALLATION.

a. Support rear wheel assembly (1, figure 9) in position.

b. Install screws (3 or 71, washers (4 or 8) and nuts (5 or 9). I

c. Torque screws (3 or 7) in a ctiss-cross pattern to 95 ft.lbs. (QA)

d. Position yoke end (83, figure 8) on cam lever (23, figure 9).

e. Install pin (80, figure 8). washer (81) and cotter pin (821.

f. If necessary, adjust brakes (WP 007 00)

g. Lower unit and remove chocks

AG-180AO-MMM-OOQ 008 00 Page 71

>P~ACECOILS~RINGS~~~~ON SPRING SEATS.P~ACE SPRING CA (41) ON SPRINGS (39) WITH SCREW (43) FACING OUTEOARO. BACK OFF JAM NUT(42)ON CENTERSCREW(40)TO ALLOW BOLT 140) To BE THREAOEO INTO CONNECTING Roo (33). wm NO LOAD ONWHEELTlGHTEN SCREW 140) UMTILSPRINGS (39)ARE StlGHTLY PRELOAOEO. WITH CENTER MARK ON SCREW (40) FACING SPRING CAP SCREW (43). TlGHTEN JAM NUT (42). TIGHTEN SPRING CAP SCREW143).

Figure 9. Rear Wheel Assemblies (Sheet 1 of rl)

AG-180AO-MMM-000 008 00 Page 72

I . . . WII~El.ASS~?tlMRI.Y, CUKI1SII)K /01083/K8000 44KHI . _ .

. . . Wlilclil,ASSIcMIHI,Y, KOAIXIDWO1083 /118000-K441.111 . . . . . IATTACIIING PAKTSI

2 . . . SCREW.CAP 112-20 x l-114 /01083/1658/ . . . . . .

3 . . . SCKEW, CAP 1/2-20x I12 20 X 1 /01083/1659/ . . . . . .

.WS27183 19 MS51922 37

. . . WASIIl-ZR . . _ . . . .

. . . NCT _ _ . . . . . _ . *

. . . . IIlJls AND I)KLhl ‘, ASSImI1I.Y/O108:1 /1650/v . . . . . . . IATTACIIINC PARTS/

. . . . SCKEW. CAP, 318 X 16 X l/01083/1440/. . .

. . . . WAStIER, LOCK, 3/8/01083/1219/ . . . .

. . . . NUT- IIEX, 3/8~16/01083/1442/ . . .

* 10

11

12 13

I4

15

I6

I7

. . . . . IIUI%ASSHMRI,Y /01083/1650/ . . . .

. . . . . DRUM, IH<AKE /01083/1657/ . . . .

. . . . . SEAI.,CKHAS~ . . .

. . . . . IIKAKING, CONKINNPX . . .

. . . . . I%I:ARINC, CONK oc’rl+:li. . . .

. . . . . WASlIISK,TONGUE: 5/8/01083/165fi/ _ . .

. . . . . NUT, IIEX. 5 8 18/01083/l655/ . . .

. . . . . PIN Co’rTlSR l/8 DIA X l/01083/ 1125.. . . . . _ .

18 . . . . . CAI’,I)UST . . _ .

NO NCMBISIi

1

1

2

2 4 .I

I

4

4

4

1

1 I

1

1

1

I

1 1

XHC%%

XHCU

XI%G%%

XBC%% IJAG%% I’AC%%

XHCU

XBC%%

XISGU

XHG%%

Figure 9. Rear Wheel Assemblies (Sheet 2)

AG-180AO-MMM-000 008 00 Page 73


I DESCRIPTION

19

20 21

22

23

24

25

26

21

28

29

30 31

32

33

34

. . . . . WHEEL, RUBBER /01083/16-441 . . _ . /ATTACHING PARTS/

. . . . . WASHER. . . . . _

. . . . .NUT.. . . . . . . ..*-

. . . . . BRAKE AND ACTUATING LEVER /01083/1370/ . . . .

. . . . . CAMSHAFT ACTUATING LEVER /01083/1606/. . . . .

. . . . . BRACKET, L.H REARSPINDLE /01083/UAS-7.44A/. .

/ATTACHING PARTSI . . . . BRACKET, R.H

REARSPINDLE /01083/UAS-7.44A/. .

. . . . . RETAINBR, APERTURE 101083/UBM-5N . . .

. . . . . SCREW, LOCKING /01083/1405/. . . . .

. . . . . WASHER, RETAINER 5/16 /01083/1540/. . . . .

*..

. . . . . BEARING /010083/1181/ . . . .

. . . . . RETAINER ASSEMBLY/O1083/UCR-3/. /ATTACHING PARTS/

. . . . . PlN . . . . . . . .

. . . . . WASHER 506 101083/1428/. . . . .

. . . . . PIN-ROLL 3/32 DIA X 5/8/01083/1019/. . .

*..

. . . . . ROD ASSEMBLY, CONNECTING/O1083/USR-2/, IAITACHING PARTSI

. . . . . SCREW,StiOUI,I~ER 101083/UCl.-11. . . .

1 XBGZZ

4 XBGZZ 4 XBGZZ

1 XBGZZ

1 XBGZZ

1 XBGZZ

1 XBGZZ

I PACZZ

1

XBGZZ

XBGZZ

XBGZZ

XBGZZ

PAGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ


AG-180AO-MMM-000 008 00 Page 74

ISDEX PART UNITS USABLE SM &R NO NUMBER DF:SCRIPTION PERASSY ONCODE CODE

I 35

36

37

38 -

39

40

41

42

43

. . . . . BEARING, .750 ID X940ODX I

/01083/1199/. . . . . . . . . . WASHER, LOCK

/01083/1174/. . . . . . . . . . NUT- HEX , JAM l/2-20 NF

/01083/1437P/. . . . . . BRACKET, L.H. iEii

HlNCE/01083/ UPR-7-44BI. . .

. . . . . BRACKET, Ri. REAR SPINDLE/01083/ UAS-8.44BI.

. . . . . SPRING101083; ’ . . UA-8501 . . . . . . /ATTACHING PARTS/

. . . . . SCREW, CAP, l/2 -20 X3/01083/1176/ . . .

. . . . . CAP - STEEL /01083/USL-IN . . .

. . . . . NUT, HEX JAM l/2-20 NF/01083/1437P/.

. . . . . SCREW, SET, l/4-20/01083/1 124/.

-I..

1 XBGZZ

1

2

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ


AC-1 80AO-MMM-000 008 00

70. BRAKE ASSEMBLY.


Part Number Nomenclature Jack Chock

Materials Required

NO”C

71. REMOVAL.

a. chock rear wheels of unit.

b. Using jack raise front wheels off the ground.

c. Place jack stands under each front corner of the unit.

d. Using jack raise rear wheels off the ground.

e. Place jack stands under each rear corner of this unit.

Page 75/(76 Blank)

g. Remove cotter pin, (17) castle nut (16), washer (15) and outer cone bearing (14) from axle.

h. Pull wheel and drum (6 and 19) off spindle.

i. Remove springs and brake shoes.

j. Remove brake assembly (22).

72. INSTALLATION.

a. Position brake shoes on backing plate.

b. Install springs

c. Position wheel and drum (6 and 19) on spindle.

d. Install bearing (14) washer (15), and castle nut (16).

e. Install cotter pin (17).

f. Install dustcover(l8).

g. Ad,just brakes (WP 007 00)

f. Remove dust cap (18, figure 9). h. Lower unit and remove chocks.

AC-180AO-MMM-000 15 way 1991

009 00 Page 1 of 22

ORGANIZATIONALAND INTERMEDIATE MAINTENANCE

PRESSURE SWITCHES AND CAPILLARY INFORMATIVES

ASSEMBLY AND DISASSEMBLY INSTRUCTIONS

AIRCONDITIONER,AIRCRAFTGROUNDCOOLING

AiMBZC-21


Heference Material

Adjustment.............................................,......... IVPOO700 Removal and Installation WI’008 00

Alphabetical Index Subiect m

Hlower Airflow Delta Pressure Capillary Informative .......................... ............ 5 Rlower and Iklivered Airflow Differential Pressure Switches (PSI, PSZ, PS3). .................. 3 Compressor Suction Pressure Capillary Informative. ......................................... 13 Delivered Airflow Delta Pressure Capillary Informative ....................................... 7 Differential Pressure Switch IPSl. 1’52, PS3). ................................................ 2

lnstallution ......................................................................... 9 Materialsfkquired ................................................................. 2 Removal ............................................................................. 2 Support Equipment Kequired .......................................................... 2

Differential Pressure Switch, Close on Pressure Rise (PS4). ..................................... 9 Installation .......................................................................... 15 MaterialsKequired....~ .............................................................. 9 [lemoval ............................................................................ 9 SupportEquipmentRequired ......................................................... 9

Differential Pressure Switch, Close on Pressure Rise (PS5). ..................................... 15 Installation ... .................................................................... 15 Materials Kequircd ................................................................... 15 llcmoval ............................................................................ I5 Suppol.tEquipmentl~equired ......................................................... 15

AG-180AO-MM M-000

Alphabetical Index (Cont%li

DiNerentiaI Pressure Switch. Open on Pressure Rise(PS6) ...................................... I6 Insl?IIation .......................................................................... I6 ,~ateriaIsRequired ................................................................... 16 Removal ............................................................................ I6 SupportEquipmentRequired ......................................................... 16

FanCyclingSwitch ........................................................................ 20 Insl.aIIation ......................................................................... 20 Mat&alsRequired ................................................................. 20 ~moval ............................................................................. 20 Support Equipment Required. ......................................................... 20

HighPressureSwilch ...................................................................... 19 Installation ......................................................................... 19 MaleriaIsRequired ................................................................... 19 Removal ............................................................................. 19 Support Equipment Required. ......................................................... i9

LowPressureSwi~h ....................................................................... 18 Inst.allntion ......................................................................... 18 MaterialsRequired ................................................................. 18 Removal ............................................................................. 18 Support Equipment Required. ......................................................... 18

OilPressureSwitch ....................................................................... 17 Installation ......................................................................... I7 MaterialsRequired ................................................................. 17 Removal ............................................................................. 17 Support Equipment Required. ......................................................... 17

PressureSwitehes .......................................................................... 10

Record of Applicable TecRnical Directives NOW

1. DIFFERENTIAL PRESSURE SWITCH (Psi. PS2. PS2).

Support Equipment Required Shutdown and removal of newer

NOIW

Materials Required

N0ne

source must be completed before removing differential pressure switches. Failure to comply could result in injury or death.

2. REMOVAL.

a. Shut down unit (WP 005 00).

b. Open BLOWER/FILTI~:R DRIER ACCESS door.

c. Remove nut (2, ligure 1)

AG-18OAO-MMM-000 009 00 Page 3

1603AS670 PRESSURE SWITCH BRACKET

603AS670 PRESSURE WITCH BRACKET

PS 2 ITYPICAL)

Figure 1. Blower and Delivered Airflow Differential Pressure Switches (PSl, PS2, PS3) (Sheet 1 of 2)

AC-180AO-MMM-000

UNITS USABLE SM &R NUMBER DESCRIPTION PERASSY ON CODE CODE

I I NO NUMBER DIFFERENTIAL PRESSURE

SWITCHEStPSl, PS2, PS3) ISEE WP 008 00 FOR NHAI

1 1603AS146 . SWITCH, PRESSURE DIFFERENTlAW /1823-2-MIW . . . . . . . . 1 /ATTACHING PARTS/

1603As147 . SWITCH, PRESSURE DIFFERENTItW85274l /1627-I-MIIJ . . . . . . . . 2

2 - . NUT (SUPPLIED WITH SWITCH) . . . . . . . . . 3

3 - . WASHERKSUPPLIED WITH SWlTCH)/85274/1823-266/. . . 6 *

4 1603AS683-2 . BUSHING, UNIVERSAL /28520/2089/ . . . . . . . . 6

*

PAGZZ 1

PAGZZ I

NIA

N/A

NIA

009 00 Page 4

1

Figure 4. Blower and Delivered Airflow Differential Pressure Switches (Psi, PS2, PS3) (Sheet 2)

AC-180AO-MMM-000 009 00 Page 5

AFTERCOOLER MODULE lG03AS106

., . . . . ..uLE AS625

PRESSURE DIFFERENTIAL SWITCH /PSZI iSOSAs147

&)3a PRESSURE DIFFERENTIAL SWITCH (~~31

1 W3AS147

%3

I I

DSECURE TUBING TO STRUCTURE WITH TIEOOWN STRAPS AS NECESSARY TO PREVENT BINOING. CHAFING OR KINKING.

D SERIALNOS 51 ANDSUBSEQUENT

-

Flgure 2. Slower Alrflow Delta Pressure Caplllary lnformatlve (Sheet 1 of 2)

AG-180AO-MMM-000 009 00 Page 6

INDEX NO

PART NUMBER DESCRIPTION

UNITS USABLE SM &I? PERASSY ONCODE CODE

1603AS558

1603AS545.1

1603X5564-1

1603AS818.1 1603AS564.5

1603AS545.2

1603AS818-2 1603AS564-9

1603AS564.10

BLOWEK AIR FLOW DELTA PRESSURE CAPILLARY INFORMATIVE . ELBOW, MALE1303271

269-P-02X02/. . . . . . . _ . TUBING, POLYETHYLENE,

,125 OD X 48.OOLt +.25), PEDSPEC LP-39OC, TYPE I, CL L, GR2. CATEGORY 41 /30327/22-P/ . . _ . . . . .

. TEE/30327/272-P-02X02/ . . .

. TUBING. POLYETHYLENE, .250 OD X 48.OOL ( zk .25), FED SPEC LP39OC. TYPE I, CL L, CR2. CATEGORY 4/ /30327/22-P/ . . . . . . _ .

. ELBOW, MALE /30327/269-P-04X02 . . . . _

. TEE/30327/272-P-04X02/ . . .

. TUBING, POLYETHYLENE, ,125 OD X 12.OOL (+ .25), FED SPEC LP-39OC, TYPE I, CL L, GR2, CATEGORY 41 130327/22-PI . . . . . . . .

. TUBING, POLYETHYLENE, ,250 OD X 12.OOL If .25), FED SPEC LP-39OC, TYPE I, CL L, GR2, CATEGORY 41 /30327/22-P/ . . . . . . . .

2 PACZZ

2 XBGZZ 2 PAGZZ

2 XBCZZ

2

XBGZZ

PACZZ PAGZZ

XBGZZ

Figure 2. Blower Airflow Delta Pressure Capillary Informative (Sheet 2)

AG-180AO-M M M-000 009 00 Page 7

I AFTERCOOLER MODULE 1603AS106

COll. EVAPORATOR, AFTERCOOLEA 1603ASl45

AFTERCOOLER CABINET 1603AS416 "",,I "...JLI.IYLI, I LLAlYLL

AIR HOSE 1603AS625

PRESSURE DIFFERENTIAL SWITCH IPSII 1603ASl46

INSTRUMENT PANEL SUBASSEMBLY 1603AS333

OELIVEAEO AIR PRESSURE GAUGE 1603AS156

DSECURE TUBING TO STRUCTURE WITH TIEOOWN STRAPS AS NECESSARY TO PREVENT EINOING. CHAFING OR KINKING.

~SERIAtNOS.51ANDSUESEOUENT

Figure 3. Delivered Airflow Delta Pressure Capillary Informative (Sheet 1 of 2)

AG-180AO-MMM-000 009 00 Page 8


1603AS563

1 1603AS545-1

2 1603AS564-1

3 1603AS564.2

4 1603AS567-1

5 1603AS564.3

6

7

8

9

10

11 . .~

1603AS568.1

1603AS565

1603AS545-2

1603AS567-2

1603AS568-2

1603AS564.5

12

13

1603AS564-6

1603AS564-7

DELIVERED AIRFLOW DELTA PRESSURE CAPILLARY INFORMATIVE . ELBOWIhlALE130327

1269-P-02X 02. . . . . . . . . TUBING, POLYETHYLENE,

,125 OD X48.00L(f.25), FED SPEC LP-39OC, TYPE I, CL I,, CR2 CATEGORY 4 /30327/22-P . . . . . . . .

. TUBING,POLYETHYLENE, ,125 OD X 24.OOL (k .25), FED SPEC LP-39OC, TYPE I,

CL L GR2. CATEGORY 4 130327/22'1'/ . . . .

. TEE, UNIOS/ /30327/2G4~1~~0“/. . . . . .

. TUBING, I’Ol.YI~TIIYl.ESE, .125 01) X 54 001. f + 251, FEDSPEC 1.1’ 39OC,‘I‘YPE I, CL I., CR2 CA’I’EC01~Y 4 /30327/22-l'/ . . . . . . .

. CONSECTOR. FEMALE/30327/ 1266-P-02X 021 . . . . . . .

. ADAPTER /3-327/120-B-04X02/.. . . . .

. ELBOW/MALE130327 1269-P-04X021 . . . . . .

. TEE, UNION/ /30327/264-P-04. . . . . _

. CONNECTOR, FEMALE/30327/ /266-P-04X021 . . . . . . .

. TUBING,POLYETHYLENE, ,250 OD X 48.OOL (+ ,251, FED SPEC LP-39OC, TYPE I, CL L, CR2 CATEGORY 4 130327122-P . . . . . . .

. TUBING, POLYETHYLENE, ,250 OD X 24.OOL (k .25). FED SPEC LP-39OC, TYPE I, CL L, CR2 CATEGORY 4 130327122-P . . . . . . .

. TUBING, POLYETHYLENE, ,250 OD X54.OOLt +_.25), FED SPEC LP-39OC, TYPE I, CL L, GR2 CATEGORY 4 /30327/22-P . . . . . .

*

I 2 PAGZZ

1 XBCZZ

2

I

1 XBGZZ

I

1

xlv.xz

f’AGZ%

XBCZZ

FAG%%

PAGZZ

PAGZZ

PAGZZ

PAGZZ

XBGZZ

XBCZZ

Figure 3. Delivered Airflow Delta Pressure Capillary informative (Sheet 2)

AC-1 80AO-M M M-000 009 00 Page 9

d.

e.

f.

Remove switch (Il.

Tag and remove capillary lines from elbows.

Remove elbows.

Remove screw from cover.

Remove cover.

Tag and disconnect wiring from switch (1)

3. INSTALLATION.

a. Adjustswitch(l,figure l)(WPOO700)

b. Connect wiring as tagged to switch (1, figure 1).

c. Position cover on switch (11

d. Install screw.

e. Install elbows

f. Install capillilry lines as tagged on elbow fittings.

g. Position switch (1) in bracket.

h. Install nut(Z).

i. Leak test lines.

j. Close and secure RI.OWER/FlLTER DRIER ACCESS door.

4. DIFFERENTIAL PRESSURE SWITCH, CLOSE ON PRESSURE RISE (PS4).

Support Equipment Kequired

None

Materials Required

None

5. KEMOVAL.

a. Shut down unit (WPOO5 001

To prevent injury to personnel or damage to equipment, unit shutdown and removal of power source must be completed before removing pressure switch PS4.

b. Open PRESSURE CONTKOLSdoor.

c. Remove condenser fan panel assembly (WP 008 00).

d. Remove caps from compressor discharge valve and compressor suction service valve. Close valves by turningstemsclockwise.

Kefrigcranl is toxic. To :tvoid in.jwy to personnel, avoid breathing or L’Y- posure to skin or eyes. Do not expose refrigerant to open flame.

e. Bleed excess refrigerant pressure to atmosphere hy loosening pressure switch (10, figure 4) connection at pressure switch tee (10, figure 5).

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced.

f. Remove pressure switch line from tee fitting (101.

g. Remove screw and COYCI‘ from pressure switch (IO, ligurc 4).

h. Tag and disconnect wiring from pressure switch PS4(10).

i. Kemovc SCI‘E\YS (14) ilnd wshers (151.

,j. Kemove pressure switch I’S4 (IO) from bracket (13) by removing screws (2) and washers (3).

AG-180AO-MMM-000 009 00 Page 10

Figure 4. Pressure Switches (Sheet 1 of 3)

009 00 Page 11

PART NUMBER

I DESCRIPTION

1603ASllO

1 1603AS163

-

.MS35207-261

.MS27163-42

1603AS617

7 8

9

10

%35207-261 MS27183.42

1603AS683.4 . BUSHISG. UNIVERSAL/28520

1603AS174

11 DELETED 12 DELETED 13 1603AS402

14 15

16

MS35207.261 MS27183.42

1603AS175

17 DELETED 18 DELETED

PANEL, CONTROLS, PRESSURE /SEE WP 008 00 FOR NHAJ _ SWITCH, OIL PRESSURE

192576lP45NCA.%?I . . . . . /ATTACHING PARTS/

. SCREW, #10(.190)-32 (SUPPLIED WITHSWITCH) . . _ . . .

. WASHER, LOCK (SUPPLIED WITHSWITCH) . . . . . .

. SCREW,MACHINE . . . . .

. WASHER, FLAT . . _ . . . *..

. BRACKET SUI’PORT- WELDMENT . . IATTACIIINC P.AKT& .

. . .

. SCRISW, MACtIINE . . . . .

. WASIIEK,FLAT . . . . . . *..

2 PAGZZ

N/A

N/A PAGZZ PAGZZ

MGGZZ

PACZZ PACZZ

/2119/. .~ ‘. DIFFERENTIii Pi&S&ii ’ SWITCH, CLOSE ON PRESSURE RISE, PS4/92578/P70GA-6/ . . /ATTACHING PARTS/

4 PAGZZ

2 PAGZZ

. BRACKET, SUPPORT SMALL . _ . . . . . . . . /ATTACHING PARTS

_ SCREW,MACHINE . . . . . . WASHER, FLAT . . . . . .

..*- . SWITCH, PRESSURE,

DIFFERENTIAL, OPEN ON PRESSURE RISE /92576/P70CA-11 . . . . . .

3

12 12

MGG”

PAGZZ PAGZZ

1 PAGZZ

I

Figure 4. Pressure Switches (Sheet 2)

AG-180AO-MMM-000 009 00 Page 12


19 1603AS403

20 MS35207.261 21 Ms27183.42

22 1603ASl59

23 MS35206.228 24 MS35333.37

25 1603AS160

26

27

28

-

MS35333-37

1603AS158

29

30

-

MS35333.37

BRACKET, SUPPORT /ATTACtIINCPARTS/ . . . . SCREWMACHINE . . . . . WAStIER,FLAT . . . . . .

..*.. SWITCH, LOW PRESSURE /80439/AF24-10831. . . . . . /ATTACIIINCPARTS/ SCREW,MACHINE . . . . . WAStIER, LOCK . . . . . .

* tIIGtI PRESSURE SWITCtI /9257a/PZODA-l21/ _ . . /ATTACHING PARTS/ ’ SCREW, #6(.13ab32 (SUPPLIED WITH SWITCH). . WASHER, LOCK _ . . . . .

..*-. SWITCH, FAN CYCLING /9257a/PZOEA-351. . . . . . /ATTACHING PARTSI SCREW, ~6 t.13ab32 (SUPPLIED WITH SWITCH). . WASHER,LOCK . . . . . .

*

1 4 4

I PAGZZ

2 NIA 2 PAGZZ

I

2 NIA 2 PAGZZ

MGCZZ PAGZZ PAGZZ

PAGZZ

PAGZZ PAGZZ

PAGZZ

Figure 4. Pressure Switches (Sheet 3)

AG-180AO-MMM-000 009 00 Page 13

PRESSURE CONTROLS PANEL ,6031\~110

C

.

INSTRUMENT PANEL SUBASSEMBLY 1603AS333

Figure 5. Compressor Suction Pressure Capillary Informative (Sheet 1 Of 2)

AG-180AO-MMM-000 009 00 Page 14



I

2

3

4

5 6

I 8 9

IO 11

12

13 14

15

16 17

18

19

1603AS597

1603AS821

1603AS796

1603As589.a

1603AS590

1603AS795 1603AS798

1603AS789 1603AS749 1603AS592

1603AS591 1603AS589-3

1603AS234

1603AS593

1603AS747 1603AS592

1603AS590

1603AS788 1603AS591 1603AS595

1603AS596

COMPRESSOR SUCTION PRESSURE CAPILLARY INFORMATIVE. . . . . . .

. VALVE, PNEUMATICl41947I /AA-1713Y

. WELDMEST,‘BtiiCiE~,’ ’ ’ CHARGING,GAS . . . . . .

. TUBE, COPPER - .25 IN ODX24.00 (+.25)LG . . . . . . . . .

. NUT, StIORT/30327/ 1511.GS-04/ . . . . . . . .

. CROsSl30327/652.F‘-041. . . .

. COCPLING, FEMALE1303271 646~I’.04X04/. . . . . . .

. ‘I’UB~.CAPII.I.AI~Y . . . . .

. TI:H~,CAPII.I.ARY . . . .

. COSNECTOR, I’EMAI,E/31J327/ /646-F-04X04/ . . . . . . .

. ‘I‘K’:E, UNION/30327/644-F-041 .

. TUBE, COPPER-.25 IN 01) X 4.00 (f.25)

. COMPRtiSiOk I%C;IiR&?’ ’ PRESSURE CAPILLARY INFORiMATIVE. . . . . . .

. TEE, MALE BRANCH /30327/ 645-F-04X04/. . . . . . . .

_ CAPILLARY. . . . . . . . CONNECTOR, FKh1At.E

/30327/646-F-04X04 . . . . . . NUT. SHORT

130327/511-GS-041 _ . _ _ _ . . TUB~,CAPIl,l~ARY . . . . . . TEE, UNION/30327/644-F-04/ . . COMPRESSOR OIL PRESSURE

CAt’ILLARY IKFORMATIVE . . CONNECTOR, MAI.E/30327/

648~F~04X04 . . . , . . , . . TEE, OIL 1’KE:SSURE ACCESS

(SUPPI,IEt~ wm1 COMPRESSOR). . . . . . .

1

1 PAGZZ

1

XCGCG

PACZZ

.MG%%%

XDG%%

XBCZZ XnC%%

XHG%% XUC%% XBC%%

XHGZZ xnwz

xmzz

XCGCC

xnczz XHGZZ

xnczz

XBGZZ XBGZZ XBGZZ

N/A

Figure 5. Compressor Suction Pressure Capillary Informative (Sheet 2)

AG-180AO-MMM-000 009 00 Page 15

6. INSTALLATION.

a. Install pressure switch PS4 (IO. ligurc 4) on bracket (13) with screws (2) and washers (3).

b. Install washers (I 5) snd screws ( 14)

c. Connect wiring as tagged to terminals on pressure switch PS4(10).

d. Position cover on pressure switch (10) install screw.

Do not allow kinks or binds in

I capillary line. If this should occur, switch must be replaced.

e. Install pressure switch line to tee filling (10. ligure 5)

f. Evacuate unit (WP 007 00).

g. Leak test connections

h. Adjust switch (10) (WP 007 00) Kneccssary

i. Open compressor suction and discharge service valves by turning stems counterclockwise.


k. Install condenser fan panel assembly (WI’ 008 00).

I. Close and secure PRESSURE CONTROLS door.

7. DIFFERENTIAL PRESSURE SWITCH. CLOSE ON PRESSURE RISE (PS5).


NO”f!

Materials Required

NO”C

8. REMOVAL

a. Shut down unit (WPOO5 00).

piizGE(

To prevent injury to personnel or damage to equipment. unit shutdown and removal of power source

must bc completed before removing pressure switch PS5.

b. Open PRESSURE CONTROlSdoor,

c. Remove condenser fan panel assembly (WP 008 00.)

d. Remove stem caps from compressor discharge service valve and compressor suction service valve. Close valves by turning stems clockwise.

(WARNING\

Refrigerant is toxic. To ovoid injury to personnel, ;lvoid breathing or exposure to skin or eyes. Do not expose refrigerant to open flame.

e. Bleed excess refrigerant pressure to atmosphere by loosening connection at pressure switch (IO, ligwc4l tee(lO,ligure5).

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. I

f. Remove pressure swit,ch line from tee fitting (IO).

g. Remove screw and cover from pressure switch I’S5 (10, ligure 4).

h. Tag and disconnect wiring from pressure switch PS5 (10).

i. Remove screws (14) and washers (15).

j. Remove pressure switch PS5 (IO) from bracket (13) by removing screws (2)’ and washers (3).

9. INSTALLATION.

o. Install pressure switch I’S5 (10, figure 4) on hwcket (131 with washers (3) and screws (2).

h. lnstull bracket (13) with washers (15) and scrc?ws (14).

c. Connect wiring ils tagged to terminals on pressure switch (101.

AC-180AO-MMM-000 009 00 Page 16

d. Position cover on pressure switch (10) and install screw.

_~~~~~~~~~~~~~~~ Do not allow kinks or binds in capillary line, If this should

I occur, switch must be replaced.

e. Install pressure switch line to tee fitting (10, figure 5).

f. Leak test connections.


h. Adjust switch (10) (WP 007 00) if necessary.

i. Open compressor suction and discharge service valves by turning stems counterclockwise.


k. Install condenser fan panel assembly (WP 008 00).

1. Close and secure PRESSCRE CONTROLS door.

10. DIFFERENTIAL PRESSURE SWITCH, OPEN ON PRESSURE RISE (PSI3

Support Equipment Required None


1 I. REMOVAL.


To prevent injury to personnel or damage to equipment, unit shutdown and removnl of power source must be completed before removing pressure switch PS6.

h. Open PRESSCRE CONTROLS door.

c. Kemove condenser fan panel assembly (WI’ 008 00).

d. Remove stem caps from compressor discharge service valve and compressor suction service wlvc. Close valves hy turning stems clockwise.

Refrigerant is toxic. To avoid injury to personnel, avoid breathing or exposure to skin or eyes. Do not expose refrigerant to open flame.

e. Bleed excess refrigerant pressure to atmosphere by loosening connection at tee (10, figure 5).

Do not allow kinks or hinds in capillary line. If this should occur, switch must be replaced.

f. Remove pressure switch line from tee (10).

g. Remove screw and cover from pressure switch PSI? (16, figure 4).

h. Tag and disconnect wiring from switch PS6 (161.

i. Remove screws (14) and washers (15)

j. Remove pressure switch PS6 (16) from bracket (13) by removing screws (2) and washers (3).

12. INSTALLATION.

a. Install pressure switch PS6 (16, figure 4) on bracket (13) with washers (15) and screws (14).

h. Install bracket (13) with washers (15) and screws (14).

c. Connect wiring as tugged to terminals on switch PS6 (16).

d. Position cover on switch PS6 (16) and install screw.


e. lnstull pressure switch line to pressure switch tee fitting(l0, figure 5).

AG-180AO-M M M-000 009 00 Page 17

f. Leak test connections.


I h. Adjust switch(lG)(WP 007 00) if necessary

i. Open compressor suction and discharge valves by turning stems counterclockwise.



I, Close and secure PRESSCRE COSTROLS door.

13. OIL PRESSURE SWITCH.


None

Materials Required

None

14. REMOVAL.

a. Shutdown unit (WP 005 00).

To prevent injury to personnel or damage to equipment, unit shutdown and removal of power source must be completed before removing oil pressure switch.

b. Open PRESSURE CONTROLS door.


d. Remove stem caps from compressor discharge service valve and compressor suction valve. Close valves by turning stems clockwise.

Refrigerant is toxic. To avoid injury to personnel, avoid hreathing or ex. posure to skin or eyes. Do not expose refrigerant to open flame.

e. Bleed excess refrigerant pressure to atmosphere by loosening oil pressure switch connections at compressor (I 8 and 19, figure 51.


f. Tag and disconnect oil capillary lines from compressor.

g. Remove screw nnd cover switch 11, ligure 4).

pressure switch

from oil pressure

h. Tag and disconnect wiring from switch (1)

i. Remove screws (7) and washers (8)

j. Remove bracket (6).

k. Remove oil pressure switch (1) from bracket by removing screws (2 and 4) and washers (3 and 5).

15. INSTALLATION.


a. Route lines thru pressure control p”ncl to compressor. Position oil pressure switch (1, figure 4) on bracket (6).

h Install pressure switch I I) on bracket (6) hy instulling %crcws (2 and II and washers (3 and 51.

c. Install bracket 16) with washers (8) and 5cI‘c’w5 17).

d. Connect wiring as tagged to terminals on oil pressure switch (I I.

e. Position cover 01 oil pressuw switch (1) and insttill screw.

BAG-1 0-MMM-000 009 00 Page 18

Do not allow kinks or binds in capillary line. If this should

P d occur, switch must be replaced.

f. Install oil pressure switch capillary lines on compressor (18 and 19, figure 5).

g. Leak test connections.

h. Evacuate unit (WP 007 001.

i. Adjust switch (WP 007 00) if necessary.

j. Open compressor suction and discharge valves by turning stems counterclockwise.

k. Install stem caps

I. Install condenser fan panel assembly (WP 008 00).

m.. Close and secure PRESSURE CONTROLS door.

16. LQW PRESSURE SWITCH.


None

Materials Required

None

17. EWiOVAL.


piiiik-(

To prevent injury to personnel or damage to equipment, unit shutdown and removal of power source must be completed before removing low pressure switch.

b. Open PRESSURE CONTROLS door.


d. Remove valve stem caps from compressor discharge service valve and compressor suction service valve. Close valves by turning stems clockwise.

pik-~

Refrigerant is toxic. To avoid injury to personnel avoid breathing or exposure to skin or eyes. Do not expose refrigerant to open flame.

e. Bleed excess refrigerant pressure to atmosphere by loosening low pressure switch connection at tee (IO, figure 5).


f. Remove low pressure switch capillary line from tee(10).

g. Tag and disconnect wiring from low pressure switch (22, figure 4).

h. Remove screws (20) and washers (21) from bracket (19).

i. Remove screws (23) and washers (24) from low pressure switch (221.

j. Remove low pressure switch (22).

18. INSTALLATION.

a. Position low pressure switch (22, figure 41 on bracket (19).

b. Install screws (23) and washers (24).

c. Position support bracket (19) in pressure c”“trols panel.

d. lnslall support bracket (19) by installing washers (21) and screws (20).

e. Connect wiring as tagged

AG-180AO-M M M-000 009 00 Page 19

Do not allow kinks or binds in capillary line. If this should

I occw, switch must be replaced.

f. Connect low pressure switch capillary line to tee (10, figure 5).

g. Leak testconnection,

h. Evacuate compressor (WP 00’7 00)

i. Open compressor discharge and suction valves by turning stems counterclockwise.

j. Install stem caps on compressor discharge and suction valves.

k, Close ilnd S~CUI‘V I’KlX3URE COSTROLS door.

I. Install condenwr fan panel assembly (WP 008 00).

19. HIGH PRESSURE SWITCH.


Materials Required

SO”e

20. REMOVAL.


To prevent injury to pcrsonncl or damage to equipment, unit shutdown and removal of power source Inut he completed before removing high pressure switch.

b. Open PRESStiRE CONTROLSdoor,

c. Remove condenser fan panel asselnhly (WI’ 008 00).

d. Remove stem caps from compressor discharge valve and compressor suction valve. Close valves by turning stems clockwise.

Refrigerant is toxic. To avoid injury to personnel avoid breathing or exposure to skin or eyes. Do not expose refrigerant to open flame.

e. Bleed excess refrigerant pressure to atmosphere by loosening high pressure switch (25, figure 4) capillary line at tee (17, ligure 5).


f. f<cmove high pressure switch capillary line from tee (17).

g. Tag and disconnect wiring from high pressure switch (25, ligure 4).

h. Remove screws (20) and washers (21) from 1 support bracket (191.

i. Remove screws 1261 and washers (27)

j. Remove high pressure switch (251,

21. INSTALLATION.

a. Position high pressure switch (25, figure 4) on support bracket (19).

h. Install washers (27) and screws (26).

c. f’osition support bracket (19) in pressure co”trols panel.

d. Install support bracket (19) by installing washers (21) and screws (20).

AG-180AO-MMM-000 009 00 Page 20


[=]

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced.

f. Install high pressure switch capillary line on tee (17, figure 5).

g. Leak test connection


i. Open compressor discharge and suction valves by turningstemscounterclockwise.

j. Install stem caps to compressor discharge and suction service valves.


I. Close and secure PRESSURE CONTROLS door.

22. FAN CYCLING SWITCH.


None

Materials Required

None

23. REMOVAL.

a. Shutdown unit (WP 005 00).

To prevent injury to personnel or damage to equipment. unit shutdown and removal of power source must he completed before removing fan cycling switch.

h. Open PRESSURE CONTROLSdoor


d. Remove valve stem caps from compressor discharge service valve and compressor suction service valve. Close valves by turning stems clockwise.


e. Bleed excess refrigerant pressure to atmosphere by loosening fan cycling switch capillary connection at tee (17, figure 5).


f. Remove fan cycling switch capillary line from tee (17, ligure 5).

g. Tag and disconnect wiring from fan cycling switch (28, ligure 4).

h. Remove screws (20) and washers (21) from support bracket (19).

i. Remove screws 129) and washers (30).

j. Remove fancyclingswitch (28).

24. INSTALLATION.

I

a. Position fan cycling switch (28, ligure 4) on support bracket (19). I

h. Install washers (30) and screws (29)

c. Position support bracket (19) in pressure 1 controls panel.

d. lnslall support bracket by installing washers 121) and sc~‘ews (20).


e. Connect wiringas tag@ h. Leak test connection

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced.

f. Install fan cycling switch cupillary line lo tee (17, figure 5).

g. Evacuate compressor (WP 007 00).

i. Open compressor discharge and suction servicing valves by turningstemscounterclockwise.

j. install stem caps to compressor discharge and suction service valves.

k. Close and secure PRESStiRE COYTROLS door.

I. Install condenser fan panel nssembly (WP 008 00).

AG-180AO-MMM-000 mb3 00 15 May 1991 Page 1 of 34


ELECTRICAL CONTROLS PANEL, FUSE BOX, INSTRUMENT PANEL, AND WIRING


AIRCONDITIONER.AlRCRAFTGROUNDCOOLINC

AIM32C-21


Reference Material

NOIll?

Sub&t Alphabetical Index

Cable and Connector Assemblies ..................................... Electrical Controls Panel ........................................... Electrical Controls Panel ...........................................

Assembly ..................................................... Disassembly. .................................................. Materials Required. ............................................. Support Equipment Required. .....................................

FuseBow ........................................................ FuseBox .......................................................

Assembly ..................................................... Disassembl Materials dquired.

......... ......................................................................................

Support E uipment Required. ?

................ .................... Instrument anel. ................................................ InstrumentPanel .................................................

Assembly ..................................................... Disassembly. ................................................ Materials Required. ........................................... Support Equipment Required. .....................................

Wiring ......................................................... From ........................................................ Index~o ...................................................... Strip Insulation ................................................. To ........................................................... WireLg ....................................................... WireRunNo ...................................................

Wiring List.Table 1. .............................................. Wiring Schematic .................................................

Record of Applicable Technical Directives

NolIe

1. ELECTRBCALCONTROLS PANEL.


2. DISASSEMBLY.

NOW

Materials Required

NOW3

To prevent injury or death, make sure electrical power source is OFF and power cable is disconnected before working inside electrical controls panel.

AG-180AO-M M M-000 010 00 Page 2

8. Open controls panel access cover by turning grip latches (15, figure I).

u. Remove screws (29) and washers (30) from main service circuit breaker (28).

b Kemove rivets (16) securing grip latches (15) to controls panel nccess cover (10) and remove grip latches (15).

c, Remove starter reset buttons (27).

d Remove lens (25) from indicator light (22)

c Rcmo\~ bulb (261

f. Tag and disconnect wiring from indicator light 122)

g I~rmove indicator light (221,

h. Remove rivets (181 and instruction plate (17).

i. Remove screws (211 and washers (201 from operating handle (19)

j. Remove operating handle (19)

k. Remove screws (9) washers (8) and remove c”“tr”ls panel wxx!ss cover (7).

I. Tag and disconnect wiring from starter assemblies Kl (41), K2 (50) and K3 (61).

m.Kemove screws (42,51,62) washers (43,52.63) from starter assemblies, Kl 1411, K2 (50) and K3 (61),

n. Remove starter assemblies Kl (411, K2 (50) and K3 (61).

v. Remove main service circuit breaker (28).

w. Remove relays K4 (31) and K5 (57) by pulling out ofelectriccll receptacles (32 and 53).

3. ASSEMBLY.

3. Install relays K4 (31, ligurc 1) and K5 (571 by 1 pushing into electrical receptacles (32 and 53).

b. Position main service circuit breaker (28) in place and install washers (30) and screws (29).

c. Install wiring as tagged on main service circuit breaker (28).

d. Position voltage control transformer (64) in place and install four washers (66) and screws (65).

e, Install wiring on control voltage transformer (64).

f. Install ivxess cover (67) and screw (68).

g. Position starter relays Kl (411, K2 150). and K3 (61) in place and install washers (43, 52, 63) and screws ~42,51,62).

h. Install wiring on starter assemblies Kl (41), K2 (50) and K3 (61).

i. Position grip latches (151 on controls panel xcess cover (7) and install rivets (16).

j. Install starter reset buttons (27)

o. Remove screw (68) from access cover (67).

p. Remove nccess cover (67)

q. Tag and disconnect wiring from voltage control transformer (64).

k. Install indicator light (22).

I. Install wiring as tagged on indicator light (22).

m.lnstall bulb 126) and lens (25).

r. Remove screws (65) and washers (66) from voltage control transformer (64).

n. Position instruction plate (17) in place and in&all rivcts(l8).

s. Remove voltage control transformer (64).

t. Tag and disconnect wiring from main service circuit breaker.

o Position operuting handle (19) and install washers (20) and screws (21).

p. Position controls panel access cover (7) in place and install washers (81, and screws (9).

AG-180AO-MM M-000 010 00 Page 3

I ,,: A.‘\

__ _’ ,A

DAPPLY LACOUEA THINNER TO GASKETS TO ACTIVATE AOHESIVE. ~;%lC&CUlT BREAKER TO INDEX 2% BY ROTATING ADJUSTMENT

DSET EtEcmxt POWER PHASE toss RELAY TO MINIMUM RY ROTATING AOJUSTMENT SCREW COUNTERCLOCKWISE

Figure 1. Electrical Controls Panel (Sheet 1 of 6)

AC-180AO-MMM-000 010 00 Page 4

Figure 1. Electrical Controls Panel (Sheet 2)

AG-180AO-MMM-000 010 00 Page 5

INDEX SO

PART NU.MBER i)ESCRIPTION


1 1603ASl12

2 1603AS298

3 MS35207.263 4 MS27183.42

5 1603AS322.3

6 1603AS322.4

7 1603AS295

8 MS27183.42 9 MS35207.264

10 1603AS297

II 1603AS296

12 MS35207-264 13 MS27183.42 14 MS21044N3

15 1603AS323

16

17

M242431 6-A403H

1603AS316

I8 M24243/ 6.A403H

PANEL, CONTROLS. ELECTRICAL ISEE WP00800FORSIIN . . .

COVER, SIDE, LEFT, PA~EI.,CONTROIS. . . . . IATTAC~IIZ’IC PARTSI SCKEW.mwHINE . . . . . WASHER, FLAT . . . . . .

I.. GASKET, PANEW86730 14111NDBl. . . . . . . . . GASKET, PANEIJ86730 14111NDBl. . . . . . . . . ACCESSCOVERASSEMB1.Y

CONTROLSPANEL _ . . . /ATTACHING PARTS/

WASHER, FLAT . . . . _ SCREW,hlACHINE . . . . .

COVER, ACCESS, PASKI., CONTROIS

IIINGE, COVER A&;$& . PANEL.CONTROLS. . . IATTACIIING PARTS/ SCREW,MACHINE . . . WASHER,FLAT . _ . . NUT, SELF-LOCKING . .

..*.. LATCH, GRIP194222 /43-1-16-O/. . . . . , . /ATTACHING PARTS/

RIVET, POP . . . . . .

1

1

14 14

5 5

I

1 MGCZZ

6 PAGZZ 12 PAGZZ

6 PAGZZ

5

10

ADGGG

MCCZZ

PACZ PAGZZ

XBGZZ

XRGZZ

A DGGC

PAGZZ PAGZZ

MGGZZ

PAGZZ

PAGZZ

PLATE, lNSTRUCTlON, WARNING . . . . . . . IATTACIIING PARTS/

. RIVET, POP . . . . . . .

1

2

MGGZZ

PAGZZ


AG-180AO-MMM-000 010 00 Page 6

INDEX PART NO SUMBER DESCRIPTION


19 I I I I I

1603AS317 . HANDLE, OPERATING MECtlANISkt/28432/

20 MS35338-43 21 x35207-259

22 1603AS325.1

23

24

25

26

27

28

1603AS326

1603AS313

1603ASl50

29

30

31

32

MS35333-38

1603ASl61

1603AS162

33 MS27183.6 34 MS35333.37 35 MS51849.34

TEFHM41. . . . . . . . /ATTACHI.UC PARTS/

. WASHER, LOCK . . . . . .

. SCREW, MACHINE . . . . . *

. LIGHT, INDICATOR, REDI 72619180.6701.0511-303/ . . . /ATTACHING PARTS/

. WAStIER, LOCK (SUPPLIED WITH LIGHT) . . . . . . . SLIT, .MOCSTtNG (SCPPLIED WlTtI LIGtIT) . . . . .

* . LESStSCPPLIED WITH

LIGti’r) . . . . . . . . BULB-125 VOl.T/72619 6S6-125V/ . . . . . . . .

. BUTTOS, PASEL MOL.-ST- STARTERRESET. . . . . .

, CIRCUIT BREAKER, MAIN SERVlCE/28432/ TEC36100FPI. . . . . . . . /ATTACHING PARTS/

. SCREW (SUPPLIED WITH CIRCUITBREAKER) . . . .

. WASHER,LOCK . . . . . . -*-.

. RELAY, TIME DELAY1773421 CDA-3B-700141 . . . . . . .

. SOCKET, RELAY, TIME DELAY/77342/27E122/ . . . . /ATTACHING PARTS/

. WASHER, FLAT . . . . . .

. WASHER, LOCK . . . . . .

. SCREW,.MACHINE . . . . . *

3 PAGZZ

1 PACZZ

3 N/A 4 PAGZZ

PAGZZ

PAGZZ PAGZZ

NIA

N/A

N/A

PAGZZ

PAGZZ

PAGZZ

PAGZZ

PAGZZ PAGZZ PAGZZ


AC-180AO-MMM-000 01000 Page 7


UNITS USABLE S.M &R PERASSY ON CODE CODE

36 1603AS274

31 1603AS213

38 1603AS716

39 40

41

MS35206.217 MS21044N4

1603AS280

42 43

4-1

45 46

47

MS51849-64 MS27183.42

1603AS710

MS35206.217 MS21044N4

1603AS712

48 49

50

MS35206-217 MS21044N4

1603AS278

51 MS51849.64 52 MS27183.42

53 1603AS188

CABLE SEALING, GRIP 1.50 INCH1577971 CG1281501. . . . _ . . . .

IATTACHIXG PARTS/ LOCKNUT, CONDUlT/57797/ BLl50/ . . . . . . . . . _

CONNt?CTORASSEMBI.Y, ELECTRICAL, 54 . _ . . . .

/ATTACHtZIG PARTS/ SCREW.MACtlINE . . . . . NUT,SELF-LOCKING . . . _

.-*-. STARTER ASSEMBLY- BLOWERMOTOR. _ . . . _ /ATTACHING PARTS/ SCREWMACtIlNk: . . . . WASHER, FL/\T . . . . .

*.. CONSECTORASSEMBLY, ELECTRICAl.. Jl . . . . . SCRF:W,MACiIINE . . _ . NtiT.SE1.F.LOCKING . . . .

I..

COSNECTOR.4SSE.MBLY. ELECTRICAL, 52 . . . . . /ATTACtIING PARTS/ SCREW, MACHINE SUT:SELF-LOCKING : : : :

-*.. STARTER ,ASSEMBLY- COMPRESSORMOTOR . . . /ATTACHING PARTS/ SCREW,MACHINE . . . . . WASHER, FLAT . . . . . .

*..

SOCKET, RELAY151 IO’?/ RD.08/ . . . . . . . . . .

1 PAGZZ

I PAGZZ

1 AGGGG 4 PAGZZ 4 PAGZZ

1

3 3

1 PAGZZ

AGGGG

PAGZZ PAGZZ

PAGGG

PAGZZ PAGZZ

AGGGG

PAGZZ PAGZZ

PAGGG

PAGZ% PAGZZ


AG-18OAO-MMM-000 @ IQ

Page 8

-~.--__ -- INDEX PART UNITS USABLE SM &R

NO NUMBER DESCRIPTION PER ASSY OS CODE CODE

54 MS51849.54 55 MS35333-38 56 MS27183-41 57 1603AS167

58 1603AS714

59 MS35206.217 60 MS21044N4

61 1603AS279

62 MS51849.64 63 MS27183.42

64 1603AS149

65 66

67

MS51849.95 MS27183.IO

68

69 1603AS683-I

/ATTACHING PARTS/ SCREW,!vlACtItSE . , . . WASHER,LOCK. . . . . . . WAStlER,FLAT . . . . . . RELAY ELECTRICAL POWERPttASE I.OSS/511071 SLA-440-t%% . . . . . . . CONNECTORASSE;MBLY, ELECTRICAL-J3 . . . . _ . SCREW,MACtItSE . . . . NLT,SELF-LOCKING . . . .

* STARTER, ASSE~~t~LY- CONDESSEK FAN !vloTot~. . . . . . . . . . /ATTACtIISC PARTS/ SCREW.MACIIISF: . . _ . WAStII:R, FI.A’I‘ . . . . .

* ‘rRANSFOR.MI:R. VOLTAGK CONTROL/035l2/ 9T51B1003/ . . . . . . . /ATTACtItNG PARTS/ SCREW,MACtlINt? . . . . . WASIIER, FLAT . . . . .

* ACCESSCOVER(SUPPLIED WITIITRASSFORMER) . . IATTACIIINC PARTS/ SCREW (SCPPLIED WITIt TRASSFOR.MER) . . . . . .

* BUStlING,UNIVERSAL . . .


I

PAGZZ

AGGGG t’AG%% PAG%%

I’AGGG

I’AC%% I’AG%%

PAGZZ

PAGZZ PAGZZ

NIA

N/A

PAGZZ


AG-180AO-MMM-000 010 00 Page 9

4. FUSE BOX


Materials Required

5. DISASSEMBLY.

a. Remove ~erews (3, figure 2) and washers (4) from controls panel top cover (2).

b. Remove controls panel top cover (2) from fuse hox (I).

To prevent injury or death, make sure electrical power source is OFF and power cable is disconnected before working inside fuse hox.

c. Remove fuses (5) from fuse holder (6)

d. Tag and disconnect wiring from fuse holder (6).

e. Remove screws (7) from fuse holder (6)

f. Remove fuse holder (6) from fuse box (1).

g. Remove fuse (8) from fuse holder (9)

h. Tag and disconnect wiring from fuse holder (9).

i. Remove screws (IO) and washers ( I1 1 from fus;c holder (9).

j. Remove fuse holder (9).

k. Removcfu~es(l2)from fuse holder (131

I. Tag and disconnect wiring from fuse holder (13).

m.Removc screws (14) and washers (15) from fuse holder(l3).

n. Remove I-use holder (I 3) from fuse box (1)

o. Remove fuses (I 6) from fuse holder (17).

p Tag and disconnect wiring from fuse holder (17).

q. Remove screws (18) from fuse holder (17)

r. Remove fuse holder (17) from fuse box (I).

s. Remove fuses (19) from fuse holder (20),

t. Tag and disconnect wiring from fuse holder (20).

u. Remove screws (21) and washers (22) from fuse holder (20).

v. Remove fuse holder (20) from fuse hox (1).

6. ASSEMBLY.

a. Position fuse holder (20, figure 1) and install washers (22) and screws (21).

b. Install wiring as tagged on fuse holder (20).

c. Install fuses (19) in fuse holder (20).

d. Position fuse holder (17) and install screws (18).

e. Install wiringon fuse holder(l7).

f. Install fuses (16) in fuse holder(l7).

g. Position fuse holder (13) and install washers (15)andscrews(l4).

h. Position fuse holder (9) and install washers (Il)andscrcws(lO).

i. lns~all wiring as lagged on fuse holder (9)

j. Install fuse (8) in fuse holder (9).

k. Position fuse holder (6) and install screws (‘7).

AC-18OAO-MMM-000 010 00 Page 10

D APPLY LACUUER THINNER TO GASKETS TO ACTIVATE

Figure 2. Fuse Box (Sheet 1 of 3)

AG-18OAO-MMM-000 010 00 Page 11


I DESCRIPTION

1 1603AS288

2 1603AS299

3 MS35207.263 4 MS27183.42

5 1603AS320.2

6 1603ASl64-2

7 MSl6997.58

8 1603AS321.2 9 1603AS319

10 MS35206.230 11 MS35333.37

12 1603AS321-1 13 1603ASl66

14 MS35206.230 15 MS35333.37

16 1603AS320.I

17 1603ASl64.1

18 MSl6997.58

19 1603AS165

. BOX, FUSE-WELDMENT /SEE FIGURE I FOR NHAI . .

COVER, TOP, PANEL, . .

. .

. .

. .

. .

. .

. . .

.

.

. .

. .

. .

. .

. .

. .

. .

. .

CONTROLS . . . . . . . /ATTACHING PARTSI SCREW,MACHINE . . . _ WASHER,FLAT . . . . .

* FUSE,TIME DELAY, 600 VOLT/‘71400/JHC-251 . . HOLDER, FUSE111873 /J60030-30 . . . . . . . /ATTACHING PARTS/ SCREW,CAP. . . . . . .

* FUSE/71400/FNQ-3.2/10/ . . HOLDER, FUSE, ONE POLE /71400/2807/ . . . . . . . /ATTACHING PARTS/ SCREW,MACEIINE . . . . WASHER,LOCK . . . . .

*

FCSEI71400/FSQ-11 . . . . HOLDER, FUSE, THREE POLE/71400/2809/. . . . . /ATTACHING PARTS/ SCREW,MACHINE . . . . WASHER,LOCK . . . . .

* FL-SE, TIMI? DELAY, 600 VOLT /71400/JHC-601 . . . . . . HOLDER, F’USEIll873 lJ60060.30 . . . . . . . /ATTACHING PARTS/ SCREW,CAP. . . . . .

* FCSE,TIME DELAY/71.t00/ JIIC-so/ . . . . . . . . .

1

1

10 10

3

1

3

1

1

3

1

3

3

MGGZZ

MGGZZ

PAGZZ PAGZZ

PAGZZ

PAGZZ

PAGZZ :

PAGZZ’

PAGZZ

PAGZZ PAGZZ

PACZZ m

PAGZZ

PACZZ PAGZZ

PAGZZ

PAGZZ

PACZi!

PACZZ

Figure 2. Fuse Box (Sheet 2)

AC-1 80AO-MMM-000 010 00 Page 12

INDEX I I PART NO NUMBER ,DESCRIPTION

20 1603AS318 . .

21 MS35207-263 . . 22 MS35333.39 . .

23 1603AS322.6 . .

24 1603AS322.5 . .

HOLDER, FUSE, CLASS J /11873/J60100-30 . . . . IATTCHING PARTS/

I PAGZZ

SCREW,MACHINE . . . . WASHER,LOCK . . . . .

*

2 PAGZZ 2 PAGZZ

GASKET, PANEL186730 /4lllNDB/. . . . . . . . GASKET, PAIUEL186730 /4lllNDB/. . . . _ . . .

2 XBGZZ

2 XBGZZ

Figure 2. Fuse Box (Sheet 3)

AG-180AO-MM M-000 Page 13

1. lnstz~ll wiring as tagged on fuse holder (6).

m.lnstall fuses (5) in fuse holder (6).

n. Position controls panel top cover (2) on fuse box (1) and install washers (4) and screws (3).

7. INSTRUMENT PANEL


g. Capcompressordischarge pressuregauge line.

h. Remove two screws (40)

i. Remove compressor discharge pressure gauge (39).

j. Crack fitting at compressor suction pressure gauge (41) and allow refrigerant to bleed to atmosphere.

Non-2

Materials Required

k. Remove line from compressor suction pressure gauge (41). Cap compressor suction pressure gauge line.

None

8. DISASSEMBLY.

n. Open instrument panel door by turning grip latches (53, figure 3).

I. Remove two screws (42).

m.Remove compressor suction pressure gauge (41).

b. Remove rivets (54) securing grip latches (53) to instrument punel door (8) and remc~ve grip latches(53).

n. Remove and tag wiring from elapsed time meter (43).

o. Remove screws (44).


d. Remove caps from compressor suction and discharge service valves and close suction and

p. Remove elapsed time meter (43)

q. Remove air temperature sensing bulb from spring clips (48) and remove from aftercooler module.

discharge service valves by turning valve stems clockwise. r.Remove two nuts (47) and clamp (48) and

removG air temperature gauge (45). I

s. Remove line from air pressure gauge (51)

Refrigerant is toxic. To avoid injury to personnel, avoid breathing refrigerant or exposing skin or eyes to refrigerant. Do not expose refrigerant to open flnme.

u. Remove cap and bulb (17) from instrument panel lights (37).

v. Remove and tag wiring from light (37) and remove nut (38).

e. Crack fitting at compressor discharge pressure gauge (39) and allow refrigerant to bleed to atmosphere.

w. Remove instrument panel lights (37).

x. Remove lens (23) and bulbs (17) from indicator lights (22).

f. Remove line from compressor discharge y. Remove and tag wiring and remove indicatot pressure gauge (39). lights (22).

t. Remove screws (52) and remwe air pressure gauge (51).


ELAPSEDTIME METER WIRING

CAPILLARY INFORMATIVE wP00900

PRESSURE CAPILLARY INFORMATIVE

COMPRESSORSUCTIO PRESSURECAPILLAR INFORMATIVE

..’ /

56

57

56

1. APPLY LACOUER THINNER TO GASKETS TO ACTIVAl ” 1:

7 -1 - 2. COIL EXCESS SENSING LINE.SECtlRE AN0 STOW ON TOP OF PRE-

.E ADHESIVE.

.¶ COOLER MODULE.

Figure 3. Instrument Panel (Sheet 1 of 5)

AG-l80AO-MMM-000 010 00 Page 15



1 1603ASlll

2 1603AS327

3 MS35489-20 4 1603AS333

5 MS51922-9 6 MS27183.12

7 1603AS350

8 1603AS348

9 10 11

12

MS90725.6 MS27183.10 MS21044N4

1603AS347

13 MS35333-39 14 MS35207.264

15 1603AS325-1

16

17

18

1603AS326

1603AS343

PANEL, INSTRUMENT /SEE WP00800FORNHAI . . . . PANEL, INSTRUMENT

WELDMENT. . . . . . . . . GROMMET,RUBBER . . . . . PANEL, INSTRUMENT,

SUBASSEMBLY . . . . _ . /ATTACHING PARTS/

. NUT,SELF-LOCKING . . . .

. WASHER, FLAT . . . . . .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

*.. PANEL, INSTRUMENT, SUB-ASSEMBLY WELDMENT. . . . . _ DOOR-PANEL, INSTRUMENT. . . . . /ATTACHING PARTS/ SCREW,MACHINE . . . WASHER,FLAT . . . NUT, SELF-LOCKING . .

-*.. BLOCK,TERMINAL/26405/ 1314SPSEI . . . . . . . /ATTACHING PARTSI WASHER,LOCK . . . _ SCREW,MACHlNE . _ .

*.. LIGHT, INDICATOR, RED /‘726’19/80-6701.051 l-303/ . /ATTACHING PARTS/ FLANGE RING AND LENS (SUPPLIED WITH LIGHT)

..*- BULB, 125V172619 /6S6-125VI. . . . . . . SWITCH, PUSHBUTTON, START/02288/H33FSG4/ . /ATTACHING PARTSI

1

1

5 10

5

1 PAGZZ

1

6 PAGZZ

I f’AG%Z

AGGGG

MGGZZ PAGZZ

XBCGG

PAGZZ PAGZZ

MGGZZ

XBGZZ

PAGZZ PAGZZ PAGZZ

PAGZZ

PAGZZ PAGZZ

S/A

Figure 3. Instrument Panel (Sheet 2)

AG-180AO-M M M-000 010 00 Page 16

INDEX NO

PAKT NUMBER

CNITS USAK1.E SM &K DESCRIPTION PER ASSY OS CODE: CODl?

19

20

. .

1603AS344 . .

21

22

. .

l603AS325-2 . .

23 .

24 1603,\Sl68 .

25

26 . .

27 28 1603AS512 . .

29

30

31

32

. .

MILR~94-KV4 . N,\YSD-352A 1603AS346 . .

33

1603ASL75

FLANGE RING (SUPPLIED WITHSWITCII). . . . . .

* SWITClI, PUSHBUTTOS, STOt’102288lI 133ESRZ . . IATTACIIISG PAKTSI FLANGE RISG(SUI’I’I.I~I~ WIT11SWITCIII. . . . I.IGIIT. ISI~ICATOK YEI.I.OW /72619/80-6701-0513-303 /ATTACIIISC I’AK’rSi FLASCE RING ASI) I.l<ZS ~suI’Pl.II:I~\c’II‘II I.lcIIT)

SwI’I‘ctI, .\101)Hs2121/ 121303AZ1 . . . IATTACIIISG t’i\Kl’Si SCKI’W, ,191) 2.I CSC2AX 5111. (suPt’I.II:I)\vI’rtI swl’rctl).

KSOK, OV/\l., I~‘I.USII /82121/01040-11. . . . . /ATTACll ISG I’AKTS/ SCREW/82121/02016-91. . SWITCtl ASS1:Ml~I.Y. OS-Ob’l‘. DlM4lEK . . . . . . . /ATTACtllSG I’AKTSi SLT (SCPPI.IKD WlTtI SWITCII) . . . . . . . .

* $WI’I’CII, f’O’rl’s’rI0. . . !dK’rE:K . . . .

. sWlTctl, OS-OFF, I~I~lMEl~/04061/.~S-I/ . .

KNOt%, cosTl~ol.~9029l /368-l/ . . . /ATTAcIIIsG I’AKTSI s.m:w ~sui~t~l.IIsl)wl~rli KS0111 . . . .

*

I

I I’AGZZ

I

3

I t’AG%%

1

I

I S/A

N/A

PAGZZ

‘/A

N/A

t’AG%%

t’AG%%

AGCGG

N/A

SRG%%

I’AG%%

I’AGZZ


01000 Page 17

DESCRIPTION UNITS USAHLE SNI &R

PER ASSY ON CODE CODE

34 MS24523.27

35

36

__

__

31

38

1603AS169

__

39 I603ASI53

40 ._

41 1603AS152

42

43

44

45

-.

1603ASI51

-.

1603ASl57

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

SWITCIi.TOGGLE.ONE POLE. . . . . . . . . . /ATTACHING PARTS/ LOCKWASHER(SUPPLIED WITHSWITCH). _ _ . . . NUTfSUPPLIKD WITH SWITCH) . _ . . . . . _

-.*.. I.RXlT. PANEL, INSTRUMKNT l71744/900-006l _ . . - - . NUT (SUPPLIED WITH LBCIIT) . . _ _ _ . . . .

* GAUGE. DISCIIARCE PRES- SURE-COMPRESSOR /57098/25-300NDm02CK30/ o/150/. . . _ . . . . . . IAITACIIINC PARTS/ . SCRKW (SUPI’LIRD WITII

GAUGE) . . . . . . . -.*..

GAUGE, SUCTION/ FRESSURE. COMPRESSOR /57096/25-300ND02CK30/0/ 150/ . . . _ . . _ . . . /ATTACHING PARTSI SCREW (SUPPI.IED WITH GAUGE) _ _ . . . . _ _

t METER, ELAPSRD, TIME SYSTEM OPERATING /74400/20017/. . . . . _ _ IATTACHING PARTSI SCREW (SUPPLIED WIT11 METER). . . . . . _ _ _

* GAUGE, DELIVRRKD AIRTK.VPERATURK /14449/25uR3-2299 06PT-0.180FI. . . . . . .

1 PACZZ

I NIA

I NIlI

2 PAGZZ

1 NIA

I I’ACZZ I

I’AGZZ

N/A

PAGZZ

N/A

I’AC%%

NIA


AG-180AO-M MM-000 010 00 Page 18



46

47

48 NAS1464.044 -04c

49

50 51

M2424311-A403

X335489-345 1603AS156

52

53 1603AS323

54

55

56

57

58

MM24231 l-B402

1603AS322.7

1603AS322.8

1603AS177.1

1603AS177.2

/ATTACtIlNC PARTS/ . . CLAMPfSUPPLIED

WITH GAUGE). _ . _ . . . NUT (SUPPLIED

WITHCACCE) . . . . . . ..*..

. . CLIP, SPRING TENSION . . . . . . . . /ATTACHING PARTS/

. . RIVET,BLIND . . . . . . t..

. GROMMET . . . . . . .

. . CAL-GE, DELIVERED AIR PRESSURE 157098iW24DSB51 . . . . IATTACIIISC PARTS/

. SCREW (SUPPLIED WITH CACCE) . . . . . .

*.. . . LATCII, GRIP/94222/

43-l-16-01 . . . . . . . . /ATTACHING PARTS/

. . RIVET,BLISD . . . .

..*.. . . CASKET, PASKL186730

/4IllNDB/. . _ . . . . . CASKET, PANEL/86730 /41IlNDB/. . . . . . . .

. . ISOLATOR, SIIOCK /81860/A23-141-0011 . . . .

. . ISOLATOR, SHOCK 18186011222.142.OOI/ . . .

I

2

I PACZZ

2

5

10

N/A

N/A

PACZZ

PACZZ

PACZZ

N/A

PACZZ

PACZZ

XBCZZ

XBCZZ

XBCZZ

PACZZ


AG-180AO-M M M-000 010 00 Page 19

z. Disconnect and tag wiring from pushbutton 9. ASSEMBLY. start switch (18).

a. Position instrument panel subassembly

aa. Remove flange ring (19) and remove weldment (7, figure 3) in instrument panel

pushbutton start switch (181. weldment (2) and install washers 16), and nuts (5).

ah. Disconnect and tog wiring from pushbutton b. Position instrument panel door (8) on

stopswitch (20). instrument panel subassembly (7) and install washers (IO), screws (9) and nuts (II).

ac. Remove flange ring (21) and remove pushbutton stop switch (20).

ad. Remove screw (27) from knob (26)

se. Disconnect and tag wiring from MODE switch (24).

of. Remove four screws (25) and remove MODE switch (24).

ag. Remove screw (33) from knob (32) and remove knob (32).

ah. Disconnect and tag wiring from ON/OFF dimmer switch assembly (28).

ai. Remove nut (29) and ON/OFF dimmer switch assembly (28).

aj. Disconnect and tag wiring to AIR FLOW control toggle switch (34).

ok. Remove nut (36) and washer (35) remove AIR FLOW control toggle switch (34).

al. Tag and disconnect terminal block (12) wiring.

am. Remove screws (14) and washers (13)

c. Position terminal block (12) and install washers (13) and screws (14).

d. Connect wiring as tagged on terminal block (121.

e. Position air flow toggle switch (34) and install washer (35) nnd nut (36).

f. Connect wiring to AIR FLOW toggle switch (34).

g. Position OYIOFF dimmer switch assembly (281 in place and install nut 129).

h. Connect wiring as tagged to dimmer OK/OFF switch assembly 128).

i. Position knob (32) on ON/OFF dimmer switch assembly (28) and install screw 1331.

j. Position MODE switch 124) and install screws (25).

k. Connect wiring as tagged to MODE switch (24).

I. Position knob (26) on MODE switch (24) and install screw (27).

m.Position pushbutton STOP switch (201 in place and install flange ring(21).

on. Remove terminal block (12).

ao. Remove screws (9), ten washers (I 0) und live nuts(ll1.

op. Remove instrument panel door (8).

aq. Remove nuts(5) and washers(

sr. Remove instrument panel subassembly weldment 17).

n. Connect wiring to pushbutton STOP switch (201.

o. Position pushbutton START switch (181 in place and instoll llange ring ( 19).

p, Connect wiring as tagged to pushbutton START switch 1181.

q. Position indicator lights (221 and install bulbs (171 and lenscs(23).

AG-180AO-MMM-000 010 00 Page 20

r. Connect wiring as tagged to indicator lights WI.

s. Position instrument panel light (37) in place and install nut (38).

t. Connect wiring as tagged to instrument pnnel light (37).

u. Install bulb (17) and cap on instrument panel light.

v. Position air pressure gauge (51) in place and install screws (521.

w. Install line to air pressure gauge (51)

x. Route AIR TEMPERATURE gauge sensing bulb through aftercooler module and install on spring clips (48). Coil excess sensing line, secure and stow on top of precooler module.

1 y, Position AIR TEMPERATURE gauge 1451 in

place and install clamp(48) and nuts (47).

z. Position ELASPED TIME meter (43) and install three screws (44).

aa. Connect wiring as tagged to ELASPED TIME meter (43).

ab. Position compressor SUCTION PRESSURE gauge (41) in place and install screws (42).

ac. Remove cap from discharge pressure gauge line and install line to compressor SUCTION PRESSURE gauge (41).

ad. Position compressor DISCHARGE PRESSURE gauge (39) and install screws (40).

ae. Remove cap from suction prcssurc gauge line and install line to compressor DISC~IARCII PRESSURE gauge (39).

af. Position grip latches 153) on instrument panel door (8) and install rivets (54).

ah. Evacuate system (WP 007 00)

ai. install condenser fan panel assembly (WP 008 001.

IO. WIRING

11. This section contains information required for replacement of wiring. Repair of wiring should be accomplished in accordance with SAVAIR-Ol- l A-505.

12. Information in this work package is arranged in nine-column format. Columns are described in paragraphs below.

13. WIRE RUN NO.

14. This column lists the number used os o wire identifier. The wire run number is heat-imprinted on each wire installed on the A/M32C-21. When replacing complete wires, the wire must be marked with a wire run number.

15. INDEX NO.

16. The INDEX NO. corresponds to the index number listed in the Parts List.

17. STRIP INSULATION

18. The STRIP ISSULATIOS column lists the length of insulation to be removed before installation.

19. FROM

20. The FROM column lists the component(s) that ZI specific wire begins at.

21. ‘TO.

22. The TO column lists the component that il specific wire connects with.

23. WIRE LG

ag. Secure instrument panel door (8) hy turning grip latches (54).

24. ‘The WIRE LG column lists the length of wire rcquircd

AG-18OAO-MMM-000 010 00 Page 21

TABLE 1. WIKING LIS’I

I STRIP STRIP WIKE LG

WIRE RUN INDEX INSUL INSUL INDEX + 2.00

NO NO. IINCHESI FROM TO IINCHESI NO. .o.oo

AG-180AO-MMM-000 010 00 Page 22

TABLE 1. WIRIN

11

; LIST (Continued)

,,

F9-L 62

K3-LI .31 5

K%LZ 31 5

K3-L3 31 5

JZA 18

.J3-B 18

63-C IX

H3-T2 9

H%T, 9

RX-T3 9

FlO-1. 3, 5

F1 1-L .3, 5

F12-I. .3, 5

K5-3 .I8 6

TRI-HZ I .I72 I 10 TKl-HI I .62 I LO Fl3-L I .I8 I 6

I I 20 1 .18 1 6

KlX4.NO 1 28 1 7

IO.00 12.00

30.00

3 30.00

35.50

18.00

AG-180AO-MMM-000

TABLE 1. WIRING LIST(Continued)

QIOD 00 Page 23

AG-! Cl-MMM-000 01000 Page 24

TABLE 1. WIRING LIST(Continued)

I 98 99 3.6 3.6 .I" .I8 sw3.:1-12 sw3.u "S4 sw3-I.& 28 .1x 7 6 I4.00 4.00 1

AG-18OAO-MMM-000 010 00 Page 25

TABI,E 1. WIRING I,IST(Continued)

AC-1 80AO-M M M-000 010 00 Page 26

.

TABLE 1. WIRIk;

T

131 3.6 .18 PS4-Ml

132 3.6 .18 PS5-M2

133 3.6 .18 PSS-MI

134 3.6 .I8 TBL-5

135 3.6 .I8 TBL-4

136 396 .lS PSG-Ml

137 3.6 .18 PSG-ML

138 3.10 .62 S6

139 3. LO .62 53

143 3. IO .62 til

144 3.6 .I8 TBI-7

145 3.6 .18 TBI-8

149 3,6 .I8 K.5. I

150 3.7 .28 KIXS-COM

155

; LIST (Continued)

[-:

I”’ i.l:,

i os-2 .I8 6 2.00

sw4-11141 31 ISOLUERI 4.00

PS4.I.

PS5.L

.I8 6 2.00

.I8 6 2.00

AC-18OAO-MMM-000

LEGEND FOR TABLE 1

D IDENTIFY IN ACCORDANCE WITH MIL-W-5088 USING MACHINE HOT STAMPED MARKING PRIOR TOASSEMBLY.

!D USE INDEX NO. 9 (3 EACH) TO CONNECT MOTOR WIRES: B3-T4 & T7, B3-T5 & TS, AND B3-T6 & T9 TOGETHER, RESPECTIVELY.

D SOLDER PER MIL-STD.454, REQ 5

CD SOLDER AT,CAPACITOR Cl

&I SOLDER AT CAPACITOR C2

010 00 Page 27

AC-180AO-MMM-000 010 00 Page 28

INDEX I I PART SO NUMBER

I DESCRIPTIOS 1 Pk%Y 1 &%:Lo”E 1 “,“,:E” 1

1 2 3 4

5

6

I

8

9

IO

I1

12

13

14

15

I6

17

18

19

NO NUMBER

MILW-5086/2 MIL-W-5086/2 MIL-W-508612 MS25036.118

MS25036.I 12

MS25036-153

1603AS271

1603AS155.3

1603AS155.2

1603AS155.I

MS25036.108

1603AS717

MS25036106

1603AS709

I603AS710

1603AS712

I603AS711

1603AS714

1603AS713

WIRING LlSTlSEE WP 00800 FOR NHAI

WIRE, #8, WHITE. . WIRE, #12, WHITE . WIRE, #16, WHITE . TERMINAL LUG, CRIMPSTYLE . . . TERMINAL LUG, CRIMPSTYLE . . . TERMINAL LUG, CRIMPSTYLE . . . TERMINAL, WIRE 109922/PQ14R2588B / CONNECTOR, WIRE 130119/30-454/ . . . CONNECTOR, WIRE 130119/30-452/ . . . CONNECTOR, WIRE /30119/30-4511 . . . TERMINAL LUG, CRIMPSTYLti . . .

. . . .

. . . .

. . . .

. . .

. . .

. . . .

. . . .

. . . .

. . . .

. . .

. . . TERMINAL, ADAPTER, WIRE15650llF250TN . . . TERMINAL, LUG, CRIMP STYLE . . . . . . . CABLE ASSEMBLY-WIRE, ELECTRICAL- Pl (SEE FIG- URE 4 FOR BREAKDOWN) . . CONNECTOR ASSEMBLY, ELECTRICAL - Jl (SEE FIG- URE 4 FOR BREAKDOWN). . . CONNECTOR ASSEMBLY ELECTRICAL -J2 (SEE FIG- URE 4 FOR BREAKDOWN) . . CABLE ASSEMBLY-WIRE ELECTRICAL 1’2 (SEE FIG- URE 4 FOR BREAKDOWN) . . CONNECTOR ASSEMBLY ELECTRICAL - 53 (SEE FIC- URE 4 FOR BREAKDOWN) . . CABLE ASSEMBLY, -WIRE ELECTRICAL - P3 (SEE FIC- URE4 FOR BREAKDOWNI . .

AS LISTED PAGZZ AS LISTED PACZZ AS LISTED PACZZ

3 PACZZ

6 PAGZZ

102 PAGZZ

31 XBGZZ

3 XBGZZ

3 XBGZZ

29 XIX%%

5 PAGZZ

3 I’AGZZ

31 PACZZ

XBCZZ

AGCGC

AGCGG

XBCZZ

ACGCC

XRGZZ


INDEX I I PART NO NUMBER DESCRIPTION

20 1603AS716 . CONNECTORASSEMBLY, ELECTRICAL-J4(SEE FIG- URE4FORBREAKDOWNl

21 1603AS715 . CABLEASSEMBLY-WIRE, ELECTRICAL-P4(SEEFIG- URE4FORBREAKDOWN)

22 ,MS25036-109 . TtiRMINAL,LUC,CRIMP STYLE . . . . . . . .

1 AGGGG

1 ACGGG

3 PAGZZ

AG-180AO-MMM-000 010 00 Page 30

37

40. 39

\

1 26 27 28

Flgure 4. Cable and Connector Assemblies (Sheet 1 of 3)

AG-180AO-MMM-000 010 00 Page 31

1 INDEX 1 PART I I UNITS I USABLE )SM&R

I NUMBER DESCRIPTION PERASSY ON CODE CODE

NONUMBER . CABLE AND CONNECTOR ASSEMBLIES/SEE WP 008 00

.I

NO

4 5

6 7

8 9

10

11

12

13

14

15

16 17

18

19

20

21

22

FOR NHAI 1603AS709 . CABLE ASSEMBLY-

WIRE,ELECTRICAL-PI . . . MS3106R20.19P . . CONNECTOR . . . . . . (8771 1603AS692.7 . . TUBE, .75 ID X 68.00 LG/

IMIL-I-631,TYPE F, FORM U, GRADE C, CLASS I, CATE- GORY 1 . . . _ . . . . .

MIL-W-508612 WIRE, #8 WHITE, 8O.OOL . 1603AS710 . ’ CONNECTOR ASSEMBLY,

.

ELECTRICAL-J1 . . . . . . MS3102A20-19s . . CONNECTOR . . . . . TYPEFP301,.38 . TtiBING, HEAT SHRINK/

/2401 l/ . . . . . . . . . MII..W-508612 WIRE #8, WHITE, 6.OOL . . i603~s711 1 CABLE ASSEMBLY-WIRE,

ELECTRICALP . . . . . MS3106R20- . . CONNECTOR . . . . . . -19PW (877) 1603AS692.6 . . TUBE, .75 ID X 88.00 LGI

MIL-I-631,TYPE F, F0R.M U, GRADE C, CLASS I, CATEGORY 11 . . . . . .

MIL-W-5086/2 . . WIRE. #8. WHITE. 100.001, , . . . ‘.

1603AS712 . CONNECTOR ASSEMBiy, ’ ’ ELECTRICAL-.J2 . .

MS3102A20 . . CONNECTOR . . : : : : -19sw TYPE FP301 TUBING, HEATSHRINK, .38 ’ ’ 1.00 L/24011/. . . MIL-W-508612 WIRE #8,WlIITF,,6.dOI: . . 1603AS713 . ’ CABLE ASSEMBLY-WIRE,

ELECTRICAI..P3 . . . . . . MS3106R20.3P . . COSNECTOR . . . . . . (877) 1603AS692.8 . . TUBE, .38 ID X 48 LG/

MILI-631, TYPE F, FORM 4, GRADE C, CLASS I, CATE- GORY II. . . . . . , . .

MIL-W-5086/2 . . WIRE, #12, WHITE, 66.OOL . . . . . . .

1603AS714 . CONNECTOR ASSEMBLY, ELECTRICALJ3 ......

MS3102A20.3S .. CONNECTOR ......

1 1

1 3

1 1

3 3

1 1

1

3

1 1

3 3

1 1

1

3

1 1

XBGZZ PAZZZ

XAGZZ PAZZZ

AGGGG PAGZZ

XBGZZ PAGZZ

XBGZZ XACZZ

XAGZZ

PAZZZ

AGGGG PAGZZ

XBGZZ PAGZZ

XBGZZ PACZZ

XAGZZ

PAZZZ

AGCGG PAGZZ

Figure 4. Cable and Connector Assemblles (Sheet 2)

AG-180AO-M M M-000 010 00 Page 32

lSl)KX I’AI?I CSITS USAI~LE S!vl &K so SUMHIcK I)[ISCKI1”I‘I0N WK ASSY OS COD1s COI)K

23

z-1 25

26

‘27 28 ‘2 9 :111

31 32

33 34

3.5

36

37

38 39

-IO 41 42

43 44 45 46 47 48

~~1’1: 1‘1’301,.13 . . TUHISC, II~:ATSIIKISK. 1.00 I.I’L401 Ii . . . . . , .

.Vll.-\V-5086/Z \VIKF:, #I& WIII’I‘lc 6.00 I. . l603AS715 . c/we ASS~:~lI~l.Y-WIKI:.

[iLI~C’I’I~ICAI.-I’4 . . . . . . ~lS3106K22-l9P . C0NNI:C’I’0K . . . . . . (8771 MS3367.5 STKAP,‘I’IF:I)oWs . . I6lmwi92- I . ‘TUItE:, .38 II) X 17.OOl.1 . . . .\IIl.-\V-SO86/:! . . \VIKI:. #16,W~i1’1‘~:.22.001. llw3As692-2 . ‘I’UUI~:. .38 II) X 50.501.1

~111.-I-631.‘l‘YI’E: lJ, lwKM u, CKADl: C. CI.ASS I, CATF.GOKY Ii . . . . .

~III..W-508G12 . \VIKE, #l6, WII1’1‘~,60.001. . l603AS692-3 . . ‘I‘CISK, .38 II) X lU7.001.

/~lIl.-l-6:~l.‘l’YI’~: lJ, ~OKM u, GKADk: C, CLASS I. CAT1:COKY Ii . . . .

MII.-W-508612 . . WIRI:, #Ifi,WIIIT~. 112.001.. 1603AS692.4 . TUl%E, .38 X 145,00/

Mll..I-631,TYl’l: [:, k’OK!vl U, GRADE C, CLASS I, CATEGORY II . . . . .

.\lll.-W508612 . . \VlRF., #l6, WIIITIS. 148.001. . . . . . . .

lGO3AS692.5 . TCRE, 1.00 X 3.001 \III.-I-631,TYI’I: I:, FOKM U, GKAD11 C, Cl.ASS I, CA’I’k:COKY Ii . .

l603AS716 . COSS~CTOI~ASS~:~l~I.Y, I~:I.I:c’I’I~Ic/\I.-.~1 . . .

MS3102A22-19s . . COSNKCTOR . . . . . TYI’I< FP301,.12 . . TL’IHSG, tIEA’l’SllKlNK,

1.00L/2101 I/ . . . . . !vIII>-w-s086/2 . . WIRE, #lG, WIIITE, 23.00 I. . Mll.-W.508612 . . WIRE, #l6, WlllTE, 17.001, Mll..W-5086/:! . . WIRE:, #lG, WIIITE,

14.001. . . . . . . . . . ~III..W-s086/2 . . WIRE, #I6 WIIITE, G.OOL . . !vllI,-W-5086/2 . . WIRE, #IF, WllITE, 14.001. !vlll.-W-5086/2 . . WIRE, #l6,WlIITl~,9.00L MII.-W-5086/L . _ WIRE, #16, WIIITE, 12.001, . MIL-W-5086/2 . . WIRE, #I6, WIIITE, 16.001, . !dll.-W-508612 . . WIKE, #I6, WIIIT~,26.001~ .

3 XRCZZ 3 f’AG%%

I ACCGG I I’AGZZ

I I’AGZZ I XHGZZ 2 PACZZ

I XBGZZ -I PAGZZ

I

2

I

I I

IO I I

I I 2 I I I I

XBGZZ PAGZZ

SI<G%%

AGGCG PAGZZ

XBCZZ PAGZZ I’ACZZ

I’ACZZ PACZZ PAGZZ PAGZZ PAC%Z PAGZZ I’AGZZ

Flgure 4. Cable and Connector Assemblies (Sheet 3)

AG-180AO-M M M-000 15 May 1991

01100 Page 1 of 18

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS

AIRFLOW CONTROLLER MOTOR, AFTE’RCOOLER MODULE, PRECOOLER MODULE, AND WATER DRAIN PUMP



A/M32C-21

PART NUMBER 1603ASlOO

Subiect Airflow Controller Motor ............

Assembly. .................... Disassembly. .................. Materials Required ............. Support Equipment Kequired ......

Airflow Controller Motor. ........... Aftercooler Module. ................ Aftercooler Module. ................

Assembly ..................... Disassembly. .................. Materials Required ............. Support Equipment Required ......

Drain Pan Assembly. ............... Precooler IModule .................. Precooler Module ..................

Assembly. .................... Disassembly. .................. Materials Required ............. Support Equipment Required. .....

Water Drain Pump. ................ Assembly ..................... Disassembly. .................. Materials Required ............. Support Equipment Required ......

Reference Material

Alphabetical Index

...................

...................

...................

...................

...................

...................

...................

...................

...................

...................

...................

...................

....................

....................

....................

......

......

......

......

......

......

......

......

......

......

......

........

........

........

........

........

........

........

........

........

........

........

........

........

........

........

........

........

........

Record of Applicable Technical Directives None

AC-180AO-MMM-000 01100 Page 2

1. AFTERCOOLER MODULE. Support Equipment Required

Materials Required

Specification or Nomenclature Part Number

520 Adhesive, Insulation

2. DISASSEMBLY.

a. Remove screws (19, figure 1) and washers (20 and 21) from aftercooler cabinet inlet plenum (18) and aftercooler evaporator cabinet(l).

b. Remove elbows (17).

c. Remove after-cooler cabinet inlet plenum (18).

d. Remove insulation (16).

c. Remove screws (13) and washers (14 and 15) from aftercooler panel (12).

f. Remove aftercooler panel (12),

g. Remove screws (23) and washers (24 and 25) from bypass orifice plate (22).

h. Remove by pass orifice plate (22)

i. Remove insulation (4).

j. Remove screws (27) and washers (28 and 29) from aftercooler evaporator coil (26).

k. Remove aftercooler evaporator coil (26)

I. Remove screws (31) and washers (32 and 33) from delivered orifice plate (30).

I m. Remove delivered orifice plate (30).

n. Remove insu!ation (8).

o. Remove screws (6) from air outlet panel weldment (5).

p. Remove air outlet panel weldment (5)

3. ASSEMBLY.

a. Position air outlet panel weldment (5, figure 1) in place and install screws (6).

b. Position delivered orifice plate (30) in place and install washers (32, 33) and screws (31).

c. Position aftercooler evaporator coil in aftercooler evaporator cabinet (1) and install washers (28 and 29) and screws (27).

d. Position bypass orifice plate (22) in aftercooler evaporator cabinet (I).

e. Install washers (24 and 25) and screws (23).

f. Position aftercooler panel (12) in place and install washers (14 and 15) and screws (13).

g. Position aftercooler cabinet inlet plenum (18) in place and install washers (20 and 21) and screws (19).

h. Apply insulation adhesive to insulation (8 and 161, air outlet panel weldment (5), and aftercooler panel weldnxnt (12). When adhesive is dry to touch, install insulation (8 and 16).

i. Install elbows (17).

4. PRECOOLER MODULE.


Part Number Nomenclature _._ Torque Wrench

O-100 inch-pounds

Materials Required

Specification or Part Number

Nomenclature

520 613

5. DISASSEMBLY.

Sealing Compound Adhesive, Insulation Compound, Gasket Forming

a. Remove screws (36, figure 2) and washers (37 and 38) from precooler outlet plenum (35) and remove precooler outlet plenum (35i.

AG-1 $OAO- M-000 01100 Page 3

D APPLY INSULATION AOHESlVElP/N 520 AOHES,"E.FSCM 03938, TO INSULATION AND MATING SURFACE.WHEN AOHES,"E,S DRY TO TOUCH, INSTALL INSULATION.

D CUT ,750 OIA. HOLE IN INSULATION. BAPPLY CONTINUOUS SEA0 OF GASKET FORMING COMPOUNO

(P/N 6B. FSCM 623771 AAOUNO MATING SURFACES AND HOLES, ASSEMBLE PARTS AN0 TIGHTEN HAROWA"E.

~CUT.5OHOLESINlNSULATlON mSERIALNOS.51 ANOSUBSE[1UENT.

Flgure 1. Aftercooler Module (Sheet 1 of 3)

AG-180AO-MMM-000 631a OxI Page 4


UNITS USABLE SM &R PERASSY ONCODE

1603AS106

1603AS372

1603AS428

1603AS430.4

1603AS430.3

1603AS412

6 MS90’725.5

I 1603AS627

8 1603AS431

9 1603AS430.2

10 MS35489.345 11 1603AS430.1

12 1603AS461

13 MS907255 14 MS35333.40 15 MS27183.10

16

17

18

1603AS429

1603AS545.1

1603AS416

19 X390725-6 20 x35333-40 21 MS27183.10

22 1603AS410

23 MS90725.5

MODULE, AFTERCOOLER /SEE WP 00800 FOR NHAI CABINET, EVAPORATOR AFTERCOOLER . . . . . . INSULATION, 103939 MIL-P-15280/. . . . . . . . INSULATION, 1039381 MIL-P-15280/. . . . . . . . INSULATION, /03938/ MIL-P-15280/. . . . . . . . PANEL, WELDMENT, AIR OUTLET . . . . . . . . .

/ATTACHING PARTS/ SCREW,CAP. . . . . . . .

..*.. RECEPTACLE, 1/4TURN/94222/ 85.47.101.15/. . . . . . . . INSULATION, FRONT MIL-P-15280/ . . . . . . . INSULATION, /03938/ MIL-P-15280 . . . . . . . . GROMMET . . . . . . . . INSULATION 103928/ MIL-P-152801. . . . . . . . PANEL WELDMENT,AFTER- COOLER . . . . . . . . .

/ATTACHING PARTS/ SCREW,CAP. . . . . . . . WASHER, LOCK . . . . . _ WASHER, FLAT . . . . . .

t.. INSULATION, SIDE 1039381 MIL-P-15280 . . . . . . . _ MALE ELBOW1303271 269-P-02X02 . . . . . . . . PLENUM, INLET-AFTERCOOLER CABINET . .

/ATTACHING PARTS/ . . ’ SCREW,CAP. . . . . . . WASHER,LOCK . . . . . . WASHER,FLAT . . . . . .

*.. ORIFICE PLATE, BYPASS . .

/ATTACHING PARTS/ SCREW,CAP. . . . . . . .

1

1

1

22

2

1 XBGZZ

1 MGGZZ


1 XBGZZ

4 PAGZZ

1 XBGZZ


1 MGGZZ

16 PAGZZ

MGZZZ

XBGZZ

XBCZZ

XBGZZ

MGZZZ

PAGZZ

PAGZZ

XBCZZ

XBGZZ PAGZZ

Figure 1. Aftercooler Module (Sheet 2)

AG-180AO-M M M-000 01100 Page 5

INDEX NO

PART NUMBER

UNITS USABLE SM &R DESCRIPTION PERASSY ON CODE CODE

24 MS35333-40 25 MS27183.10

26 1603AS145

27 x390725-5 28 .ws35333-40 29 MS27183.10

30 1603AS409

31 32 33 34

35

36

MS90725-5 MS35333.40 MS27183.10 NAS1464. 044.04c

M24243/1- A403 1603AS545-2

. WASHER, LOCK . . . . . .

. WASHER, FLAT . . . . . . *..

. COIL, EVAPORATOR, AFTERCOOLER . . . . . .

/ATTACHING PARTS/ . SCREW,CAP. . . . . . . . . WASIIER,LOCK . . . . . . . WASHER,FLAT . . , . . .

*.. . ORIFICE PLATE,

DELIVERED. . _ . . . . . /ATTACHING PARTS/

. SCREW, CAP. . _ _ . . . .

. WASHER, LOCK . . . . .

. WASHER,FLAT . . . . .

. CLIP,SPRINGTENSION . . .

/ATTACHING PARTS/ . RIVET, BLIND . . . . . . .

. ELBOW, MALE /30327/269-P-04X02 . . . . .

*..

16 PAGZZ 16 PAGZZ

1 PAGZZ


1 MGGZZ


2 PAGZZ

2 PAGZZ

4 PAGZZ

Figure 1. Aftercooler Module (Sheet 3)


D APPLYlNSlJLATloN Al TO INSULATION AN0 TO TOUCH.INSTAtLl

@-- 27 *j yj/ip22a

lHESIVE(P/N 520 AOHESIVE.FSCM 039381 MATING SURFACE.WHEN ADHESIVE IS ORY NSUtATION. FA" "F GASKET FORMlNG COMPO"NO,P,N mASSEMoLE MOTOR TO MOUNTING BRACKET WITH ELECTRICAL -

LEAOS OOWN. ~hi~li-iLlN~fNOUS EL... -. -. .~~~ ~~~~

68. FSCM 62377) AROUNO MATING SURFACE AN0 HiLES. ASSEMBLE PARTSANOTIGHTEN HAROWARE.

DAFTER A~~EMSLY.TREAT EXPOSEO PORTION OF SHAFT PER MIL. P-116H TYPE p., USING MIL.C.161730 CORROSION PREVENTIVE COMPOUNG.SOLVENT CUT.EACK.COtO APPLICATION. GRI.

cs PRIOR

m INSTA AIR CONOITIONING UNIT.

>APPtYSEALlNG COMPOUNOTOTHREAOS 10 ASSEMBLY. LLAFTERPRECOOLERMOOULEISINSTALLEOIN

Figure 2. Precooler Module (Sheet 1 of 6)

AG-180AO-MMM-000 01100 Page 7

Flgure 2. Precook Module (Sheet 2)

AG-180AO-MMM-000 01100 Page a

INDEX PART UNITS USABLE SM &R NO NUMBER DESCRIPTION PERASSY ONCODE CODE

1603AS105 MODULE, PRECOOLERSEE WP 008 00 FOR NHAJ

1 1603AS737 .

2 1603AS657 .

3 1603AS658 .

4 1603AS661 .

5 1603AS736 .

6 1603AS733 .

7 1603AS735 .

8 1603AS734 .

9 1603AS430-11 .

10 1603AS430.12 .

11 1603AS556 .

12 1603AS519 .

13 x390725-3 . 14 MS35333-40 . 15 MS27183-10 .

16 1603AS430.5 .

17 1603AS518 .

18 MS90725.6 . 19 MS35333.40 . 20 MS27183.10 . 21 1603AS430-13 .

22 1603AS430.15 .

INSULATION, SIDE/039381 MIL-P-15288/. . . . . . . . INSULATION, BOTTOM /03938/MIL-P-152801. . . . . INSULATION, TOP /03938/MlL-P-152801. . . . . INSULATION, TOP CENTER /03938/MIL-P-152801. . . . . INSULATION, TOP FLANGE /03938/MIL-P-15280/. . . . . INSULATION, NOZZLE SIDE /03938/MIL-P-152801. . . . . INSULATION, CORNER /03938/MIL-P-152801 . . . . . INSULATION, CENTER SIDE /03938/MII.-P-152801. . . . . INSULATION, 103938/ MIL-P-15280/. . . . . . . . INSULATION,/039381 MIL-P-15280/. . . . . . . . INSULATIOK,/03938/ MIL-P-152801. . . . . . . . COVER,~~ILA~~E~S. . . .

/ATTACHING PARTS SCREW,CAP. . . . . . . . WASHER, LOCK . . . . . . WASHER, FLAT . . . . . .

* INSCLATION/03938/ MIL-P-152801. . . . . . . . COVER, DAMPER ACCESS . .

/ATTACHING PARTS/ SCREW,CAP. . . . . . . . WASHER, LOCK . . . . . . WASIIER, FLAT . . . . . . INSULATION/03938/ MIL-P-15280 . . . . . . . . INSULATION103938/ MIL-P-15280 . . . . . . . .

8 8 8

1 1

10 10 10

I

1

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ

XBGZZ MGGZZ

PAGZZ PAGZZ PAGZZ

XBGZZ MGGZZ

PAGZZ PAGZZ PAGZZ

PAGZZ

Figure 2. Precooler Module (Sheet 3)

AC-1 80AO-MMM-000 Page 9


23 1603AS430-14

24 1603AS430.6

25 1603AS517

26 MS90725.3 27 MS35333-40 28 MS27183-10

29 1603AS430.10 30 1603AS430-8 31 1603ASBOO

32 MS90725.8 33 MS35333:40 34 MS27183-10

35 1603AS699

36 MS90725.3 37 MS35333-40 38 MS27183.10

39 1603AS392

40 MS90725.3 41 MS35333-40 42 MS27183.10

43 1603AS122

44 MS90725-3 45 MS35333.40 46 MS27183-10

. INSULATION/039381 MIL-P-15280 ........

. INSULATION/039381 MIL-P-15280 ........

. COVER,ACCESS ...... /ATTACHING PARTSI

. SCREW.CAP. .......

. WASHER,LOCK ......

. WASHER, FLAT ...... -*-

. INSULATION. ....... INSULATION.

: DRAIN PAN ASSEiliL; ’ ’ ’ (SEE FIGURE 3 FOR BREAK- DOWN) ..........

/ATTACHING PARTS . SCREW, CAP. ....... . WASHER, LOCK ...... . WASHER,FLAT ......

*

. PLENUM, OUTLET- PRECOOLER. .......

/ATTACHING PARTS/ . SCREW.CAP. ....... . WASHER, LOCK ...... . WASHER,FLAT ......

-* . . . MIST ELIMINATOR,

MODIFIED ........ /ATTACHING PARTS/

. SCREW.CAP. .......

. WASHER, LOCK ......

. WASHER, FLAT ...... *

. COIL, EVAPORATOR, PRECOOLER. .......

/ATTACHING PARTS/ . SCREW.CAP. ....... . WASHER, LOCK ...... . WASHER, FLAT ......

*

1

1 1

14 14 14

4 XBGZZ 1 XBGZZ

1 MGGZZ


1 XBGZZ


1

20 20 20

PAGZZ

XBGZZ MGGZZ

PAGZZ PAGZZ PAGZZ

PAGZZ PAGZZ PAGZZ

PAGZZ

PAGZZ PAGZZ PAGZZ


AC-1 80AO-MMM-000 01100 Page 10

1 INDEX PART UNITS USABL .E ISM&RI

NO NUMBER DESCRIPTION / PERASSY / ONCODE 1 CODE 1

47 1603AS102 DAMPER ASSEMBLY . .

48 MS90725-3 49 MS35333.40 50 MS27183-10

IATTACIIING PARTS/ SCREW,CAP. . . . . . WASHER,LOCK . . . WASIIER,FLAT . . . .

*

51 1603AS720 52 1603AS721

. DAMPER, WELDMENT

. BRACKET, MOUNTISG IATTACHING PARTS

53 54 55 56

57

58 59 60

61

62

63

64

65

MS90725-5 MS27183.IO MS35338.44 MS51967 2

1603AS555

MS35206.228 MS355338.41 X35649-262

SCREW,CAP. . . . . . . WASkIER. FLAT . . . . . WASIIER, LOCK . . . . SCT. PLAIN . . . . . .

* CAPACITOR/77228/CH70/ .

/ATTACfIING PARTS/ SCKEW,MACHINE . . . WASHER,LOCK . NUT, PLAIN . . . . . . .

*

1603AS148 MOTOR, GEAR, REVEKSIBLE /77728/4RK25GK-AA/ . . . SCREW, MACHINE, 5MM (SUPPLIED WITH MOTOR) . WASHER, FLAT, 5MM (SUPPIJED WITH MOTOR) . WASHER, LOCK, 5 MM (SUPPLIED WIT11 .MOTOR) .

‘NUT. PLAIN, 5MM tSCPI’I.IED WlTtI MOTORI

* 66 1603AS554

67 1603AS727

68 MS18066.20 69 1603AS672

70 MS24665.360

Gt?ARI~II?Al~/77228/ 4GKlBOKA . . . . . . TUBE, wELIndEsT. . . IATTACIIING PARTS/ SETSCREW, IiEXSGCKET . RETAINER, GRIP NUT/78553/ /C7969-1213.31~. . . . . PIN,COTTER,SPl.IT. . .

*

. .

. .

. .

.

1 AGGGG


I MGCZZ

1

4

4

4

4

FAG%% PAGZZ PAGZZ FAG%%

FAG%%

FAG%% PAGZZ PAGZZ

PAGZZ

NIA

N/A

NIA

N/A

PAGZZ MGGGZ

PAGZZ

FAG%% PAGZ%


OA0-MMM-000 01100 Page 11

INDEX NO

PART PART NUMBER NUMBER DESCRIPTION DESCRIPTION


71 1603AS722

72 NAS1298.3-3 73 MS27183.10

74 1603AS170

75 MS35206.234 76 MS35338-41 77 MS35649.262

78 1603AS683.1

79 1603AS674

80 1603AS525

. .

. .

. .

. .

.

. .

.

BRACKET, WELDMENT . . 1 MGGZ% /ATTACHING PARTS/ SCREW,BRAZIER . . . . 6 I’AGZZ WASHER.FLAT . . . . . 6 PAGZZ

* SWITCH, LIMIT/91929 IBZ-2RW855-A2-SI. . . . /ATTACHING PARTS/ SCREW,MACHINE . . . . WASHER,LOCK . . . . . NUT,PLAIN . . . . . . .

*

2 PAGZZ


. BUSHING, UNIVERSAL /28520/2077 . . . . . . . .

. PLUG, BUTTON/83058/ /SS48143K1611/ . . . . . .

. CABINET, EVAPORATOR, PRECOOLER. . . . .

1 PAGZZ

8 PAGZZ

I XBGGG


AG-180AO-MMM-000 01100 Page 12

~APPLYlNSULATlONAOHESIVE(P/N 520AOHESIVE.FSCM 03938) TO INSULATION ANO MATING SURFACE.WHEN ADHESIVE IS DRY TO TOUCH. INSTALL INSULATION

DASSEMBLiTUiE AND FASTENEA[SI:OOUBLE FLARETUBING PER1 L \b MS33583

mASSEMEtE WITH FLOW ARROW POINTING AWAY FROM PUMP mAPpLY A SMALL AMOUNT OF SILASTIC ADHESIVE (P/N 732RTV

DCUT 625 i 19 DIA HOLE IN INSULATION FOR DRAIN BEFORE INSTALLING INSULATION.

FSCM 719841 AROUND ORAIN TUBE. POWER CORD ANO DCUT 250 + 20 OIA HOLE IN INSULATION BEFORE INSTALLING GROMMETS ON OUTSIDE OF DRAIN PAN AFTER ASSEMBLY. INSULATION

BAPPLYLACOUER THINNER TO GASKETS TO ACTIVATE AOHESIVE

Flgure 3. Draln Pan Assembly (Sheet 1 of 2)

01100 Page 13



I 1603AS801 2 1603AS430.16 :

3 1603AS430.17 .

4 MS35489.39 . 5 1603AS430-18 .

DRAIN PAN ASSEMBLY /SEE FIGURE 2 FOR SHA/ . WELDMENT. PAN, DRAIN . . INSULATlON/03938/

MIL-P-15280/. _ . . . . . INSULATION/03938/

MIL-P-15280/. . . . . . GROMMET _ . . , . . . . lNSUl,ATION/039381

MIL-P-15280 _ . . . . . 6

7

8 9

10

11

1603AS807 .

1603AS793 .

MS35842-15 . MS24630.36 .

1603AS806 .

1603AS590 .

. PLUG, PIPE, ,125 NPTI 30327/121-B-02/. . . . .

. PUMP,DRAIN, WATER. . . /ATTACHING PARTS/

. CLAMP,HOSE . . . . . .

. SCREW,SELF-TAPPING . . *..

. TUBE, DRAIN, .25 OD X ,030 WALL. . . . . . . .

12 1603AS589.9 .

13 1603AS794 . 14 1603AS804 .

15 MS35489.36 16 MS21919.WDE4 : 17 MS35207266 . 18 MS21044-C3 .

. NUT, SHORT .25 ODTUBE SIZE, 45”FLARE/30527/ 511.GS-041. . . . . . . .

. TUBE, COPPER, 1.75 LX .02500X.030 WALL. . . .

. VALVE,CHECK . . . . .

. ELBOW, FEMALE, 90”/30327/ /650-F-044-04/ . . . . . .

. GROMMET . . . . . . .

. CLAMP, LOOPTYPE . . .

. SCREW,MACHINE . . . .

. NUT,SELF-LOCKING . . . I..

19 MS25036.153 . . TERMINAL, LUG . . . . 20 1603AS812 . . GASKET,PAN . . . . . 21 1603AS811 . . GASKET, PAS . , . . . .

1603ASSOO .

1

1 XBGZZ

3 XEGZZ

1 1

1 1 1 1 1

3 2 2

MGZZZ

PACZZ

PAGZZ PAGZZ

XBGZZ

XBGZZ XBGZZ

PAGZZ PAGZZ

XBGZZ PAGZZ

XBGZZ PAGZZ PAGZZ PAGZZ PAGZZ

PACZZ XBGZZ XBGZZ

Figure 3. Drain Pan Assembly (Sheet 2)

AC-180AO-MMM-000 01100 Page 14

b. Remove insulation (16 and 24) from precooler evaporator cabinet.

c. Remove screws (26) and washers (2’7 and 28) from access cover (25).

b. Apply thread locking compound to setscrews (68).

c. Align motor shaft and tube (67) and install setscrews (68). Torque setscrews (68) to N-inch pounds (QA).

d. Remove access cover (25).

e. Remove screws (13) and washers (14 and 15) fromcoil accesscover(l2).

d. Treat exposed portion of motor shaft per MIL- P-116H, type P-l using MILG16173D Corrosion Preventive Compound. Solvent Cut-Back Cold Application, GRl.

f. Remove coil access cover (12).

g. Remove screws (44) and washers (45 and 46) from precooler evaporator coil (43).

e. Position mounting bracket (52) on damper weldment (51) and install screws (53), washers (54and 55) and nuts (56).

h. Remove precooler evaporator coil (431,

i. Tag and disconnect damper motor wiring at terminal blockTB-1.

j. Remove screws (48) and washers (49 and 50).

k. Remove damper (47)

1. Remove screws (40) and washers (41 and 42) from mist eliminator (39).

m. Remove screws (53) and washers (54 and 55) from mounting bracket (52).

n. Remove mounting bracket (52)

o. Remove setscrews (68) from tube (67).

p. Remove screws (62), washers 163) and (64) and nuts (65) from motor (61).

q. Remove motor (61).

r. Remove screws (32) and washers (33 and 34) from drain pan assembly (31).

s. Remove drain pan assembly (31)

6. ASSEMBLY.

a. Position motor (61, figure 2) (with electrical leads down) against gearhead (66) and mounting bracket (52) and install screws (62), washers (63) and (641 ilod nuts (65).

f. Position damper (47) in cabinet (79) and install screws (48) and washers 149 and 50).

g. Position mist eliminator 139) in cabinet (79) and install screws (40) and washers (41 and 42).

h. Position precooler evaporator coil (43) in cabinet (79) and install washers (45 and 46) and screws (44).

i. Apply a continuous bead of gasket forming compound around coil access cover (12) mating surface and holes.

j. Position coil access cover (12) on module and install washers(l4and 15)andscrews(l31.

k. Apply adhesive to insulation (16) and coil nccess cover (12). When adhesive is dry to touch, install insulation (16).

I. Apply continuous bead of gasket forming compound around damper access cover mating surface and holes.

m. Position damper access cover (25) in place and install washers (27 and 28) and screws (26).

n. Apply adhesive to insulation (24) and damper xcess cover (25). When adhesive is dry to touch, install insulation (24).

o Apply continuous bead of gasket forming compound around precooler outlet plenum (35) mating surface and holes.

AG-180AQ-MMM-000 01100 Page 15

p. Position precooler outlet plenum (35) on module and install washers (37 and 38) and screws (36).

7. AIRFLOW CONTROLLER MOTOR.


Part Number -

Nomenclature Wrench, Torque (O-50 inch-pounds)

Materials Required


Compound, Sealing

8. DISASSEMBLY.

a. Remove screws (2, figure 4) and washers (3).

b. Remove protective cover (1)

e. Remove setscrews (14) and washers (3) actuator weldment (13).

d. Remove screws (9), washers (10 and 11) and nuts (12).

e. Remove gear motor (ZZ), decimal gearhead (21), gearhead (20) and weldment (8).

9. ASSEMBLY.

a. Position decimal gearhead (21, figure 4) on motor (22).

b. Position gearhead (20) on decimal gearhead (21).

c. Position panel weldment (8) on gearhead (20).

d. Install motor (22) in mounting plate weldment (19).

e. Install screws (9), washers (10 and 11) and nuts (12).

f. Install actuator weldment (13) on gearhead (20).

g. Apply sealing compound to setscrews (14).

h. Install setscrews (14) and torque to 33 inch- pounds (QA).

i. Adjust limit switches (15) to actuate at approximately 90’actuator weldment (13) travel hy loosening screw (16). (Final adjustment will he made when airflow controller is installed on next higher assembly).

j. Position protective kover (1) on mounting plate (19) and install washers (3) and screws (2).

IO. WATER DRAIN PUMP


Part :Vumher Nomenclature Jack, 0 5000 Ibs. Chock

Materials Required

Specification or Nomenclature Part Number

732 Adhesive

I I. DISASSEMBLY.

a. Lock front wheel assembly parallel with rear wheels.

b. Chock front wheel assembly of unit

c. Usingjack raise rear wheels off ground.

d. Place jack stands under each rear corner of the unit.

e. Tag and disconnect water drain pump wiring (19, figure 3) at terminal block TB-1.

f. Remove screws (32, tigure 2) and washers (33 and 34).

g. Remove drain pan assembly (31)

h. Remove hose clamp (8, figure 3).

i. Remove screws (9).

.i. Remove elbows (14) from pump.

k. Remove pump.

12. ASSEMBLY.

a. Position pump in place and install elbow (14, figure 3).

b. Install screws (9).

c. Install hose clamp (8).

d. Position drain pan assembly (31, figure 2) in place and install screws (32) and washers (33 and 34).

e. Reconnect drain pump wiring (19, figure 3) to terminal block ‘E-l.

f. Apply adhesive around power cord.

g. Lower unit and remove chocks

\

AG-180AO-MMM-000 01100 Page 17/(18 Blank)

INDEX I I PART NO NUMBER, I~ESCRIPT10N 1 P&i%&’ 1 f%??Ifi: 1 :i?; 1

1603AS482

MS35207.261 MS35338-43

16093AS.555

MS35206.228 MS35338.41 MS35649.262

1603AS475

10

11

12

13 1603AS477

14 MS18063.13

15 1603AS170

16 MS35206.234 17 MS35338.41 18 MS355649.262

19 1603AS486

20 1603AS-554

21 1603AS553

22 1603AS148

1603AS487 CONTROLLER, AIR FLOW /SEE WP 008 00 FOR NHA/

COVERPROTECTIVE . . . . 1 IATT,\CI1ISC PARTS/

SCREW,MACHINE . . . . . WASIIER, I.OCK . . . . _

*.. CAPACITOW77228/CH70. . .

IATTACIIINC PARTS/ SCREW,MACHINE . . . . . WASHER, LOCK . . . . . . NUT,PLAIN . . . . . . . .

2 I’AGZZ 2 I’AGZZ 2 I’ACZZ

PANEL, WELDMEST . . . . /ATTACHING PARTS/ SCREW, .MAClIINE, 5 MM (.I95 DIA) X 90 MM (3.50) tSUPPL.IED WIT11 MOTOR) . . . . . . . . WASHER, FLAT, 5 MM (.l9S DIA) (SUPPLIED WITtl MOTORI . . WASHER, LOCK, 5 MM (.I95 DIAI (SUPPLIED WIT11 MOTOR) . . NUT, PLAIS, 5 MM (.I95 DIA) (SUPPLIED WITH MOTOR) . .

I

4

*.. ACTUATOR, WELDMENT . . I

/ATTACILING PARTS/ SETSCREW _ . . . . . . 2

*.. SWITCtl, LIMIT/91929/BZ-2RW855 A2-SI /ATTACI;IiC;PiiTS, . . ’ ’ SCREW,MACHINE . . . . WASHER, LOCK . . . . . . NUT,PLAlS . . . . . . . .

WELDMENT. .MOCNTING PLATE . . . . . . . . . . GEARHEADl77228 /4GKl80KA/ . . . . . . . CEARIIEAD, DECIMAL/772281 4CKlOX/ . . . . . . . MOTOR, GEAR, REVERSIBLE 177228/4RK25CK-AN . . ,

~IGCZZ

I’ACZZ PAGZZ

PAGZZ

S/A

S/A

N/A

S/A

JlGC%%

PACZZ

PAGZZ

PAGZZ PAGZZ PACZZ

MGGZZ

PAGZZ

XBGZZ

PAGZZ

Figure 4. Airflow Controller Motor (Sheet 2)

AG-18OAO-MMM-000 012 00 15 May 1991 Page 1 of 6

ORGANIZATIONAL AND 1NTEKMEI)IATE MAINTENANCE

REFRIGERATION COMPKESSOR ASSEMBLY ANI)

COMPRESSOR CYLINDEK HEADTEMPERATUKE CUTOUT (CTCOI

AIKCONI)ITIONEK.AIKCRAFTCROUNI)C001.INC;

A/M32C-21


Keference Material

Operating Instructions. Servicing, Lubrication, Adjustment

Cleanup After Compressor 1lotor Rurnout.. Assembly and Disassembly Instructions. Aircraft Electrical and Electronic Wiring Practices

........ ....... WI’ 005 00

Wl’ 007 00 ............... WI’00800 ............... NAVAIKOI-IA-505

Subiect Alphabetical Index

2 Compressor Cylinder Head Temperature

cutout (CTCO). ..... Installation ..... 2 Materials Required ...... 2 Removal. ...... 2 Support Equipment Required. ...... 2

KefrigfrutionCompressor Assembly. ...... 4 Refrigeration Compressor Assembly. ...... 1

Installation ...... I YvIMaterials Required .... 1 Prcparationfor Installation.. ..... I Support Equipment Required. .... 1

Record of Applicable Technical Directives NOIll2

I. REFKIGERATION COMPRESSOR 2. PKEPARATION FOR INSTALLATION ASSEMRLY.

B. Remove and discard shipping plugs and Support Equipment Kequired packaging.

I’art No. Nomenclature b. Kemovc und discard suction and discharge

Wrench,Torque (O-150 ft-lbs) cover plates.

Materials Kequired c. Install gasket (5, figure 1) and suction service

wlve (3). Torque suction service valve screws (4) 90. NON! I20 ft-lbs (QAl.

AG-480AO-MMM-000 01200 Page 2

d. Install gasket (8) and discharge service valve 6). Torque discharge service valve screws (7) 80-90 ft.lbs (QA).

e. Open compressor junction box by removing screws and cover.

Install jumper bars (10) and nuts (11).

a. Shut down compressor (WP 005 00).

b. Pumpdown compressor (WP 007 OO),


d. Remove caps from compressor suction and discharge service valves.

g. Install two-screw connector (15) in compressor junction box e. Close compressor suction and discharge

service valves by turning valve stems clockwise.

h. Install bushings (14) on solenoids (2).

i. Install solenoid coils (2) on side cylinder heads.

j. Insure that oil sight glass is on left side of compressor when facing bearing head and pump assembly. If sight glass is on wrong side, drain compressor oil and move sight glass to left side. (Do not reuse oil after oil has been exposed to atmosphere.)

k. Remove pneumatic valve (13) from low pressure connection. Install in gas charging port 1WPOO9 00).

I. Install compressor (1) in air conditioning unit (WP 008 00).

m. Evacuate system (WP 007 00) and service oil (WP 007 00) if required.

3. COMPRESSOR CYLINDER HEAD TEMPERATURE CUTOUT (CTCO).

(WARNING 1

To prevent injury to personnel or damage to equipment, elect,rical power must be disconnected when working inside compressor junction box.

f. Open compressor junction box

g. Disconnect splices (NAVAIR 01.IA-505),

h. Remove armored cable



NOW

Materials Required

Specilication or Part No. Nomenclature

Tape, Teflon

4. REMOVAL.

NOTE

CTCO is generally removed with compressor assembly installed in air conditioning unit.

i. Carefully loosen switch (12) slightly and nllow refrigerant to bleed to atmosphere.

j. Remove switch (12, figure I).

5. INSTALLATION.

a. Apply teflon tape to switch (IO, figure 1)

b. Install and tighten compressor cylinder head temperature cutout switch (12) in cylinder head.

c. Install armoredcable

AG-180AO-MMM-000 012 00 Page 3

f. Evacuate system tWP 007 00).

g. Leak test system t WP 007 00).

To prevent injury ‘to personnel or damage to equipment, electrical power must be disconnected when working inside compressor junction box.

h. Open compressor suction and discharge service valves by turning valve stems counterclockwise.

d. Splice wiring into air conditioning unit i. Install caps on compressor suction and

wiring(SAVAIROl-IA-505). discharge service valves.

j. Install condenser fan panel assembly (WP e. Close and secure compressorjunction box. 00800).


1.lNSURETHAT011SlGHTGLASSIS ONLEFTSIOE OF COMPRESSOR WHEN FACING BEARING HEAD AN0 PUMP ASSEMBLY. IF COM. PRESSOR 0ltLEVEAISLOW.AOO OIt(WP 007 00).

2. REMOVE PNEUMATIC vAtvE FROM tow PRESSURE c0NNEcTl0~ AN0 INSTALL IN GAS CHARGING PORT. REFER TO SUCTION PRES- SURE CAPILLARY INFORMATIVE IWP 009 00).

3. OISCARO REMOVED PLUGS. SUCTION AN0 OISCHARGE COVER PLATES AN0 MOUNTING HARDWARE,

22 23 24

COMPRESSOR MOTOR82

8 HIGH PRESSURE

7 CONNECTION WPOO9 00)

ARMORED CA8lE

I e@

1 COMPRESSOR \ JUNCTIONBOX

GLASS / \ ' &oN \ Fy ~wpoogOO~ BEARING HEAO

ANOPUMP PLUG ASSEMBLY

Flgure 1. Refrlgeratlon Compressor Assembly (Sheet 1 of 2)


~~~ PART NUMBER

I DESCRIPTION 1 PifitkiY / ::“c”o”D”E 1 %:E” 1

7

8

9

10

I1

12

13

14

15

1603AS324

1603AS124

1603AB821

1603AS683-2

1603AS792

REFRIGERATION COMPRESSOR ASSEMBLY/SEE WP 008 00 FOR NHAI . COMPRESSOR, REFRIGERATION

/10855/06E38755001 . . . . COIL, SOLENOID . .

. .

. .

. .

. .

. .

. .

. .

.

.

.

110855/06DA401784/. . . . VALVE, SUCTION SERVICE, 2-l/8 ODF /10855/E1M13FA516/ . . . . /ATTACHING PARTS/ CAPSCREWi10855l AH06BR3351 . . . . . . . GASKET, SUCTION VALVE /10855/6665-1061/ VALVE, DISCIIARCE SERVICEil0855/ EN70EA0391. . . . . . /ATTACHING PARTS/ CAPSCREW110855l AA06BR297/ . . . . . . .

-*.. GASKET, DISCHARGE VALVE /10855/6D68-11311. . . . . TEE, OIL (WITH INTEGRAL PNEU.MATIC VALVE)/10855 /06EA402632/. . . . . . . BAR, JUMPER10855 /06EA50055/ . . . . . . . /ATTACHING PARTS/ NUT, HEX/10855 lATl4QA2411. . . . . .

f SWITCH, COMPRESSOR

CYLINDER HEAD TEMPERATURE CUT-OUT

/10855106EA5015231 . . . . . VALVE, PNEUMATIC1419471

/AA-1713lJ BUSHISG, UNIVERSAL

/28520/2089/ . . . . . . . . . CONNECTOR,TWO-SCREW

/56501/3305/. . . . .

1 PBCGD

2 PACZZ

1 PAGZZ

4 PAGZZ

1 XBGZZ

4 PACZZ

1 PAGZZ

1 PACZZ

3 PAGZZ

6 XBCZZ

1 PAGZZ

1 PAGZZ

2 PAGZZ

1 PAGZZ

Figure 1. Refrigeration Compressor Assembly (Sheet 2)

*“.s c~~LNlPRlNrwcoFFlcL: 1992.602.ill ,3m:

Documents

AG-180AO-MMM-000