AG-180AO15 May 1991

ORGAN! MAINTEN

ERMEDIATE RATED PARTS

DISTRIBUTION STATEMENT C. Distribution authorized contractors lo protect publications required for official use only, 15 May 1990. Other requesfs for this document shall technical sewicas facility, 700 Robbins Avenue, Philadelphia.

lo U.S. Government agencies and their or for administrative or operationalpurposes be referred to commanding officer, naval air PA 1911 l-5097.

DESTRUCTION disclosure

NOTICE For unclassified. limited documents. of contents or reconstruction of the document.

destroy

by any

method

that

will

prevent

0819LP6662352

NATEC ELECTRONIC MANUAL

AG-180AO-MMM-000
15May1991 NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES/PAGES Page A

originaI0

. . . . . . . . . . . 15 May91

dated Ody those work pa&ages assignsd to the menual arc listed in this index. Insert _ Dispose of superseded and deleted work packages/pages. Superseded and deleted classified work pacas shall ba destroyed in accordance with applicable regulations.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 liuc WA IPDR-1 00100 all 01 MllU2 00200 00300 00400 an00 al600 00700 WP Number 00800 Numerical In&x of Effcctivc woIkpadrages/wges List of Technical Pablicatimu ===qReportsAl~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 00900

Mle Removal and Instsllstion InstmctiOUS F resm-c Switches sad Capillary lafmmstives Assembly sad Disasscmbly lastmctioos Elcchicsl Controls Panel, Fuse Box, Illmomen1 F%mclaad wig Assembly sad Disassembly InstractiOOS Abilow contmuer Motor, Aflercooler Module and I recmlcr Module and Water Dmis Pump Assembly aad DisssscmbIy Instractions Refrigcmtioa Compressor Asscmbly sad Compressor Cylinder Head Temperature Cutout (C KO)

01000

01100

01200

Tocal numbez of pages ia this msaosl is 298 consisting of tbe following: WPmlg No. Change No. .O . 0 .O .o .o .O .o .O 0 .o 0 .o .O 0 .o .O WPlPege No. Change . ..O .o ..O .o .o .o .o .o .o .o .o .o .o .o .o .o No. WPlPage No. Change No. .O .o .O 0 .o .O .o .o .O .o .o .o .o .o .O

lWC_. ................ A.. ................... TPDR-1 ................ TPDR-2Bkmk ......... 00100.. .............. 1-3 ................ 4Bbmk.. ............ 00101 ................ 1-6 ................ 00102.. ............... l-2 ................ 00200.. ............... l-3 ................ 4Blaok.. ............ 00300 ................. l-9 ................ lOBlat&. ............

11 ................... 12Bbmk ............ 13-17 .............. 18Blaak ............ CHMOO ................ l-4 ................ 00500.. .............. l-7 ................ 8Bbmk.. ............ al6Ml.. .............. l-64 ............... 00700.. .............. l-28 ............... 00800.. .............. l-7 ................ 8Blaak.. ............ 9-41 ...............

42Blsak ............. 43-75 .............. 76Blaak.. ........... 00900 ................. l-21 ............... 22Blaok.. ........... 01000.. .............. l-33 ............... 34Blaak.. ........... 01100.. .............. I-17 ............... 18Blsak.. ........... 01200.. .............. l-5 ................ 6Blank.. ............

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

TECHNICAL

PUBLICATIONS AND

LIST OF I)EFICIENCY 1NTEHMEI)IATE AIRCHAFT A/M32C-21

REI OKTS

INCOKPORATEI) WITH IPB

OKGANIZATIONAL AIR

MAINTENANCE GROUND COOLING

CONI)ITIONER.

PART

NUMBER

1603ASlOO-1

Identification QA Sequence

No./ No.

Location (WP) 003 00 (Pg) 11 (F) 2 (WP) 010 00 Wg) 11 (F) 2

Identification QA Sequence

No./ No.

Location

NAS NORFOLK 0064/03169

NAS NORFOLK 0061/03152

AG-180AO-MMM-000
15 May 1991

001 00
Page 1 of 4

ALPHABETICAL ORGANIZATIONAL AIR CONDITIONER. AND

1NDEX MAINTENANCE COOLING

INTERMEDIATE AIRCRAFT A/M32C-21

GHOUND

Number 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) 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
WP Number 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 Filter Drier Front Wheel Assembly Fuse Box Fuse Testing Ilead Pressure Regulator Adjustment Head Pressure Regulator Valve lligh Pressure Switch 1tot Gas Bypass Valve Inlet Airflow Controller Adjustment Instrument Panel Instrument Panel, Electrical Controls Panel and Delivery Duct Introduction Leading Particulars Low Pressure Switch MainServiceCircuit Hreaker(CR1) Adjustment Main Service Circuit Breaker (CBl) Testing Motor 30 HP Blower Motor Starters (K I, K2, K3) Adjustment Oil Pressure Switch Operating Instructions Panel and Door Assemblies Panel Assemblies and Duct Storage Rack Precooler Module Pressure Controls Panel Preparation for Shipment Preparation for Storage Preparation for Cse Preparalion For Use, Storage and Shipment Pressure Controls Testing Pressure Differential Switches (PS4, I %, PS6) Adjustment Pressure Switches Pressure Switches Testing Principles ofOperation Conditioned Airflow Cooling Mode Dehumidification Mode tilectrical and Control Function Entering Airflow Refrigerant Function Ventilation Mod12

00100
Page 2

00900 009 00 00800 01100 00800 00600 00300 00700 00800 009 00 00700 00800 00800 01000 00600 00700 00800 009 00 008 00 00700 00800 00500 00200 00300 009 00 00700 00600' 00800 00700 009 00 00500 00800 00800 00800 00800 00400 00400 00400 00400 00600 00700 009 00 00600 00300 003 00 00300 00300 00300 00300 00300 00300

AG-18OAO-MMM-000
WP Number

001 00
Page 3/(4 Blank)

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

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 ORGANIZATIONALAND AIR CONDITIONER,

INDEX

OF PART

NUMBERS MAINTENANCE WITH IPB

INTERMEDIATE AIRCRAFT A/M32C-21 PART NUMBER

GROUND

COOLING

1603ASlOO-1 WORK PACKAGE/ FIGURE NO. INDEX NO 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

PART

NUMBER

WORK PACKAGE/ FIGURE NO. INDEX NO 008 008 01 I 008 008 008 011 008 011 008 008 008 008 009 008 008 008 010 008 008 008 008 008 008 008 008 01 I 008 012 008 008 008 008 008 008 008 008 008 00/1/l 00/2/161 00/2/47 00/4/32 00/8/l 00/5/33 00/2/0015169 OO/l/0016 00/2/l 00/l/9 00/4/l 00/4/00/4/19 0013/l 001414 00/l/5 0015/17 00/3129 00/3/l 001318 001314 00/3/12 00/3/16 00/7/10 00/2/43 001518 00/1/l 00/7/6 00/6/83 0015/22 00/5/13 0013124 00/6/129 00161120 00/6/l 17 00/7/20

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 1603AS129 1603ASl31 1603AS132 1603AS133

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

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/ FICUHE NO. 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

PAKT

NUMBER

WOKK PACKAGE/ FICUKE NO. INDEX NO 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

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

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

WORK PACKAGE/ FIGURE NO. INDEX NO 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

WORK PACKAGE/ FIGURE NO. INDEX NO 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/-

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

1603AS545.2 1603AS.553 1603AS554 1603AS555 1603AS556 1603AS558 1603AS559

AG-180AO-MMM-000

001 01
Page 4

PART

NUMBER

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 00131I 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

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

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

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

PART

NUMBER

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

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

1603AS667 1603AS669 1603AS670 1603AS671

1603AS713

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

W ORK

I ART

NUMBER

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

WORK PACKAGE/ FIGURE NO. INDEX NO 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

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

AG-180AO-MMM-000
15 May 1991

II01 02
Page 1 of 2

NUMERICAL ORCANI%A lTONALANLl

INDEX

OF REFERENCE

DESIGNATORS MAINTENANCE WITH IPB

INTERMEDIATE AIRCRAFT A/M32C-21 PART NUMBER

AIR CONDITIONER,

GROUND

COOLING

1603ASlOO-1 I

Ref Des

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 00/3/7 011 011 010 012 010 010 010 010 010 010 010 0012/57 00/4/4 0011128 00/l/10 00/l/22 0013122 00/3/22 00/3/22 00/u/37 00/3/37 00/l/22 l603ASl28 1603AS32-1 i603ASl29 1603ASl-18 1603ASl48 1603AS793 1603AS555 1603AS5.55 1603ASl50

Ref Des

WI No./Fig No./ Index No. OlJ9 OO/li Z 010 010 010 nl0 00/1!44 0011147 0011158 00/l/38

I iN

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, 13 E CS FSW

I I PC0 .J 1 ,J2 .J3 .J4 Kl K2 K3 K4 K5 I.PCO IS1 I.S2 IS3 IS4 OS

1603ASI 60 1603,\S710 1603AS7 12 1603,\s714 lm3x716 1603AS280 1603,1S278 1603AS279 1603ASl61 1603ASl67 1603ASl59 1603ASl70 1603AS170 1603AS170 1603ASl70 1603ASl63 1603AS709 1603AS711 1603AS713 1603AS715 1603ASl46 1603ASl47 1603ASl47 1603ASl74 1603ASl7-l 1603ASl75 1603ASl37 1603ASl37 1603ASl40 1603ASl42 1603ASl35 1603ASl38-2

010 00/1141 010 00/l/50 010 00/l/61 010 00/1131 0100011157 0090014122 01100/2/74 01100/2/74 01100/4/15 01100/4/15 009 00/4/l 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 008OO/G12 008 001612 00800/6/143 00800/6/155 008 0016176 008 olm5

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

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

I 1 P2 1'3 1'4 I S1 PS2 I S3 I S4 I S5 I S6 Sl 52 s3 s4 55 S6

AG-180AO-M

M M-000

001 02
Page 2

Krf Iks Kef Des WP No.iFie. No. Index No. 0l00013/18 n10 on/3/20 II IO 00/3ml 0 IO 00/3/28 0100013112 010 0011164 012001112 iN -I L.2 SW1 SW2 SW3 SW4 TRI TKI u1 I6l)3AS3-u I6ODAS3J-l 1603ASl68 1603AS512 1603AS317 I603AS119 VI V2 v3 v4 XI 52 x :3 s-l

WI No./E ig No./ Index No. 012 00/l/2 008 008 008 008 00/6/129 00/6/l 17 00/6/l 42 0016/lfl

y!J

1603AsI:%I l603ASI33 I603ASIII l603AS1-13 I603ASl:j8. I Ifio3AsI:15.l 16clnAsl:Is.~ 1603ASI:18 2

008 00/6/l 47 008 00/6/l 47 008 00/6/5 I108 00/6/5

AG-1 $OAO-M M M-000

15 May 1991

002 00
Page 1 of 4

1N I KOI)IJCTION OHGANI%A i IONAL WITH ANI) INT~KME:I)IA I I.: PARTS MAINTKNANCE

ILLI.!STHAT~I)

HHEAKDOWN GHOUNI) COOLING

AIR CONDITION~H.

AIHCHAFT A/.M02C-21

PART NUMBER 1. f CRPOSIC OE \IASLAI..

1603ASlOO-1 This listing is used 11)Iocat~ desired WI requlwd perform specific maintenance tusk. 5. QCAI.ITY ASSLRASCb: R~:t~LIRII!vl~:STS. Lo

2. This milnuill provides organizational and intermediate maintenance instructions with illustrated purts breakdown for the AiMRZC-21 Ail 1 Conditioner, part ~numhcr 1603ASlOO.1. 3. AKRASCE~lI<S f OF IIASUAI.,

6. Certain prwcduws or steps in the manual are follrwcd with QA in parcnthcsis. Improper pcr-

4. This manual contains an alphabetical index work package (Wf l, an introductory \Vf and tech. nictil content WPs. Technical WI s arc independent, self-contained procedures that ma? he used LIS handouts to support specific functional tahks. Kach WP is maintained 3s a separate entity: changes result in a reissue of the specific Wf . WPs are identified hv unique, five digit numbers appearing in upper rjght hand corner of each page. The numher provides a means of locating WI s that hove been storedon microfilm, permits rapid asscmhly of LL completc manutil, and is used for referencing within the manu:ll. I\ numwical index of effective WPs, listing all WI s, is pru\,ided on the A page. TvpeiNumber Date Title and ECI No.

a~suranw inspection of each auxmplishcd shall he made next st~.p unless it can hc inspection can he pcrformcd procedure. 7. RF:CORI) l)ltwx-fvt:s.

(QA) step previously prior to proceeding to determined that such after completing entire

OF APPI.ICAHI.E

TECHNICAL

8. Technical directives applicable to this manual are listed helow by directive type/number, date of issue, title, date of incorporation, and remarks. These technical directives also appear an title page of each suhscquent applicable WP. Date Incorporated Hemarks

AG-180AO-MMM-000
9. INTRODUCTION PARTS BREAKDOWN. TO THE ILLUSTRATED

002 00
Page 2 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 01series 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 0s 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.

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

AG-180AO-MMM-000

002 00
Page 3/(4 Blank)

:30. Iwm 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 pertaining 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:rencedesign~~tion. 112 Turn to the WP and Figure the index number refercncc. indicated itnd Iocatc

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

Known. (WI 001 note lhc and the

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
15 May 1991

M-000

003 00
Page 1 of 16

OKGANI%ATIONAI.ANI)

INT~KM~I)IATE

MAINTE:NANCE

AIK

CONI)ITIONEK.

AIKCKAFT AiMXX-21

CKOUNI)

COOLING

PART NUMBER Keference

1603ASlOO-1 Material

I
2 II 13 14 1; :t 17 16 15 17 15 15 1 15 15 15 15 15 I 15 6

Sane Alphabetical Suhiect ,\/\132C-21 Comprmcnt I.ocator ;\/\13LC-21 Elcctric~l Schcnutic : :: :: : : :: :: :: : :: .\/.U32C 21 Rcfrigcratian Contwl Sntetn Schematic .\/\I3!2C-21 Airflow Control System Schematic. Ikscriptiun. ., I.cadinz Particulars.. : : : : : : : : 1: : : : : : : : 1: : 1: 1: : : 1: : 1: 1:: 1: : 1: : I ~inci~~le~~~fOperiltion. Conditinwd Airflow. C,,olin~\I,,dc............,.,. ,..~,::I::::::::::::::::::::::::::::::::: :::: I)ehulni[lilicati~,n .\lodc I:lcclrical ;lnd Cnntwl Function.. ..~...................... kntcring Airflow.. Unit Operation. Ventil~ti~~n~Mode........,....,:::.::::::::.:::::~:::::::::~::::::::::::::::: System Description IllOWC~..................... ..~.......................................... CondenserCoils......................................................... CondenserFan. ... ... ... ... ... .. .... .. ... .. .... ... ... .. .. .... . .... . ... .. ... . Contr~,l~anrls............................................................... F.vaporalorCoil~.........~................................................... Kefrigor;lnt Compressor. Vehicle.................................................................... Tohlc I, I.cxling I articulars Kecord of Applicable Technical 1Vwlc IXrectives Index

I I I I

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 intended for, hut not limited to, air conditioning airplane cabins and aircraft equipment compartments.

4. The air conditioner (figure 1) is a mobile, troilermounted, clcctric-powered, self-contained air conditioner. The unit is powered by 440 volt, 3 phase (A, I%,Cl, 60 Hz electric motors. 5. K~FKIC~~KANT COMPRESSOR. The refrigerant system uses an accessible-hermetic, six-cylinder

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 I 2 3 4 5 6 7 a 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

NOMENCLATURE IDuct storilgc Access Do01 ondcnscr Fnn Panel Asscmhl.~ Rear Condcnscr Fan Pancl Cabinet Top Instrument Panel Cowr Assumhly I~lower Oil Fill Access I)oor !)uter Fuse Bos Cover Klectrieul Controls Panel Roadside Panel BlowzrlFiltcr Drier Access Door &down Ring Condenser Coil Grille Handbrake Lifting Ring Front Panel Front Condenser Fun Panel Pressure Controls Access Door Comp~cssorlReceiverl\cccss Door Condcnscr Coil Grille Curhsidc Panel Discharge Duct Cover Curhsidc Rear Panel Pressure Tap Access Doors Filter Access Door Sightglass Access Door Roadside Rear Panel Head Pressure Regulator Valve (VI) Unloader Solenoid Compressor Condenser Fan Bypass Valve Asscmhly Airflow Controller Blower Aftercooler Sightglass Precooler Sightglass Pressure Differential Switch (1 52, I S31 Pressure Diffcrcnlial Switch (PSI) 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

003 00
Page 6

3. CONI)bINSC:H

COklI ONE:N t S

CoIIdcIIscI.: .sxv.v I urt .so : Curtwide Rwdsidc I ypc Finned Dimensions Ixngth Width tlcight Circuits t asws: 7 Circuits 2 Circuits sut,coolcr: Circuits PilSSL1S 1)r.v Weight (11~)

(inl:

Rointion I I.wking at Outlet1 C~~ut~t~~~l,~c~wi~;e I)ilTct t)vivc t)iamctcr(in) 42.0 PI Ilushin!: savy Put so. l6O3AS7.50 Ibrc lin) l.62 Weight (with hushing) (11,s) 13.8 Fill1 51lltw saw I dIT so I603ASl29 T& 1 KFC I IoM!po\wl 7.5 Voltuge 230/460 60 Ilz 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 llorsepower Voltage 112 Phase Speed kpm) Weight (Ihs) 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

IXFC 30 460 60 3 (A.H,CI 3600 214

Phase w:

livuporator Pressuu! Kegulator (l<PlU: Navy Purl No. lG03ASl39 Open on rise i inlet pressxe Type I rcsww Adjustment (psig) 0 to 75 Pressure Sctpoint (prig) 55 lleadl ressurc Kcgulator(V1): .Uavy Part so. lfiO3AS131 Openso rise in inlet pressure l-.&W Pressure Adjustment (psig) 65 to 225 Prussurc Setpoint (psig) 225 Receiver blief(V2): Navy Part No. KeliefSetpoint tpsig) I lot Gas Bypass (V3): Navy Part No. TYPO

I 603AS138- I I603ASl38-2 Thcrwstulic 8 lf30i\Sl38-2 I hornwst~tic 8

1603ASl33 450

1603ASl37 Normnlly closed II0 60 1 1603ASl37 Sor~nally closed II0 GO 1 1603ASl40 Sormlly closed 110 GO I 1603AS142 Sorn~ally closed 110 GO I 1603ASl35 Sormally closed 110 60

1603AS141 Opens on drop in downstream pressure Pressure Adjustment ~psig) ,5.=J to 70 I rcssurc Setpoint (psig) 55 Quench (V4): Navy Part No. I603<\Sl43 Type Thermostatic Expansion 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 I inncd Dimensions Ixngth Width lleight

1603ASI 36.2 Green Yellow lG03ASl36-I Crccn Yellow

I603ASl34 163OASli2 163OAS125 96 130

Ic,O3/\Sl22 Tllk/l:i (ill): 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

COMPRESSOR SUCTION SERVICE VALVE COMPRESSOR DISCHARGE VlBRATlilN CONOENSERS

VIBRATION ELIMINATOR

FILTER DRIER

PRECO

F--

SIGHT GLASS

LEGEND
INLET-SERVICE VALVE OUTLET-SERVICE VALVE Sl- EVAPORATOR SOLENOID VALVE SZ-EVAPORATORSOLENOIO VALVE %I- HOT GAS SOLENOID VALVE S4- DUENCH SOLENOID VALVE SS-PUMPOOWN 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

003 00
Page 14

PAECOOLEA

AFTCR COOLER

ELDAMPER e BYPASS OAMPER

BLOWER

fi

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 111S\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 up, and ventilation air will bc delivered.

will start

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 IVceivcr, 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.

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 dchumidification 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, precooler 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 light, 11%. will illuminate. 29. Dehumidified tion is as rollows: air will bc dclivcrcd. I)liIICMII)

35. l hc u,nditil,ncd ilir Iravinr: thl, pwcooler cri\lIorxtl)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

l hc opera-

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 temperatures 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

ORGANIZATIONAL PREPARATION

AND

INTERMEDIATE

MAINTENANCE AND SHIPMENT COOLING

FOR iJSE. STORAGE, AIRCRAFT AIM32C-21 PART NUMBER

AIR CONDITIONER,

GROUND

1603ASlOO-1

Reference I reoperatiorul MGntenancc Requirement Cards. Alphabetical Subiect I rcpaution for Shipment.. Prepar:ltion for Storage Preparation For Use I reparationForUse,StorageandShipment Record

Material AC-180AO.MRC-000 Index r&& 2 2 1 3

.: ::::: of ApplicableTechnical Directives

1.

PKHPARATION Support

FOR USE Equipment NO"C! Required f. Remove condenser 008 00). fan panel assembly (WP

Materials

Required NO"t?

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 and outlet shutoff wives (1 and 2). Install O08J60,. k. Close COMPRESSOIURECEIVER door and secure with grip latches. Perform preoperational tions (AC-180AO-MRC-000). I. ACCESS func condenser fan panel assembly inlet

a. Remove all wrapping, packaging and adhcsive tape from unit. MMakesure that ducts, doors and grillesare free ofobstruction. b. unit. c. Inspect unit for damage. Kemove blocks or wheel chocks from under

(WP

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.

maintenance

AG-180AO-MMM-000

004 00
Page 2

2. PREPARATION Support

FOR STORAGE

j. Set CIRCUIT position.

BREAKER

CBl

(9) in OFF

Equipment Required None Materials Required Nomenclature Dessicant Bags Barrier Material Tape, pressure sensitive fan panel assembly (WP

Specification or Part No. MIL-D-3464 MIL-P-131C,Class 1 PPP-T-GO, Type Ill, Class I

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 compartment. flexible duct in duct stowage

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 Support FOR SHIPMENT Equipment None Materials Specification or Parl No. or N0me*&ture Required Required

a. Remove condenser 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 valve (1) and close valve by turning clockwise. f. Install valve cap (4) inlet shutoff valve stem

Barrier Material MIL-P-131C, Class 1 PPP-T-60, Type III, Tape, pressure sensitive Class 1 a. Perform paragraph 2). Preparation for Storage (this WP,

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 i. Install 008 00). valve caps (5 and 7). condenser fan panel assembly (WP

b. Wrap cabinet in MIL-P-131C, material. Secure with PPP-T-60, pressure sensitive tape. c. Block wheels

Class 1 barrier Type III, Class 1

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

ELECTRICALCONTROLS

I 4
POWER

k3
0

BLOWER

ILI

Figure 1. Preparation

for Use, Storage and Shipment

(Sheet 2)

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

005 00
Page 1 of 8

ORGANIZATIONAL

AND OPERATING

INTERMEDIATE INSTRUCTIONS

MAINTENANCE

AIRCONDITIONER.AIRCRAFl-GROUNDCOOLING AIM32C-21 PART NUMBER 1603ASlOO-1

Reference Preopcrational Maintenance RequirementCards. Alphabetical Subject Controlsand Indicators. Table 1. Instrument Panel, Electrical Controls Operating Instructions. Shutdown Instructions Emergency Shutdown Procedures. Normal Shutdown Procedures. Record

Material _. Index _. .AG-180AO-MRC-000

Panel, and Delivery

Duct.

of ApplicableTechnical NOIW

Directives

Table FIGURE/ INDEX IVO. l-l

1. Controls

and Indicators FUNCTION

CONTROWlNDlCATOR DISCHARGE PRESSURE gage

Indicatescompressor discharge pressure. During normal operation should indicate 140 to 365 psig. Provide instrument panel illumination.

2. 3.

Panel Lights SUCTION PRESSURE gage

Indicatescompressor suction pressure. During normal operation should indicate to 70 psig. Records unit running time.

20

4.

ELAPSEDTIME

meter

AG-180AO-MMM-000

005 00
Page 2

Table FIGURE/ INDEX NO

1.

Controls

and

Indicators

(Cont d)

CONTROL/INDICATOR

FUNCTION

5.

IR TEMPERATURE

gage

ndicates temperature ofconditioned air at elivered air outlet. During normal peration, gage should read as follows: VENT mode: 50F greater ambient. DEHUMID than

mode: 90F (minimum)

COOL !vlode: 45F( k5). 6. IR PRESSURE gage ndicatcs pressure ofconditioned air at clivered air outlet. During normal peration, gage should read 0 to 3.0 psig

7.

IRFLOW

CONTROL

switch

ncrenses or decreases conditioned lositioning inlet damper. Lheostat controlling ights. brightness

airflow

by

8.

ANEL

LIGHTSswitch

of panel

9. 10.

OOL light :ODE switch

rovides visual indication

ofCOOL

mode.

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

11.

EHUMID

light

rovides node. rovides

visual indication

of DEHUMID

12. 13. 14. 15.

ENT light TOP switch TART switch OWER light

visual indication unit,

of VENT

mode

jhuts down operating legins unit operation

rovides visual indicationofelectrical mat unit.

power

AC-180AO-MMM-000

005 00
Page 3

Table

1. Controls

and Indicators

(Cont d)

CONTROWINDICATOR Main Service Circuit Breaker (CBI)

FUNCTION Provides overcurrent shutdown capability. protection and rapid

POWER light

Indicates prcsenee of440 VAC, 3 phase 60 hz electrical power in ELECTRICAL CONTROLS panel. FAN motor starter Resets condenser fan motor starter circuit after starter open condition. Resets compressor motor starter starter circuit open condition. Resets blower motor starter starter circuit open. relay

CONDENSER reset button COMPRESSOR button BLOWER

motor starter

reset

relay after

motor starter

reset button

relay after

I. OPERATING a. Perform MRC-000)

INSTRUCTIONS preoperational checks (AC-180AO.

1. Condenser Fan (2 doors) 2. Instrument 3. Air Outlet Panel

b. Set main service Figure 1) to OFF.

circuit

breaker,

CBl,

(16,

c. Remove power cable (22) from storage rack. To prevent equipment, damage to the hose or ^ remove hose carelully. duct (24) from duct stowage duct (24) to delivered air

g. Remove flexible compartment. 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. (23) to power h. Connect outlet. flexible

e. Connect power cable connector source.

Do not operate duct connected.

without

flexible

i. Set power source circuit f. Open four doors marked OPEX BEFORE OPERATING AIR CONDITIONER DOOR I21 1. j. Set main service circuit

breaker to ON. breaker (16) to ON

AC-180AO-MMM-000

005 00
Page 4

k. Set .MOt)E switch (10) to VENT I. Press START button (14). 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 3. NORMAL INSTRUCTIONS SHUTDOWN PROCEDURES

d. PressSTOPswitch

(13). hreakcr (16) to OFF.

e. Set main service circuit f. Remove flcxihle stowage compartment.

duct (24) and store in duct

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 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 cqipment. il. Set DEIIUMID. h. c. MOIRE switch (IO, figure 1) to To prevent injury to personnel or damage to equipment, this procedure should be used under emer. gency conditions only. i. Close doors (21)

4. EMERGENCY

SHUTDOWN

PROCEDURES

Operate for 15 minutes. Set MODE switch 110) to VENT. NOTE Compressor will operate for approximately 30 seconds as refrigerant is pumped into receiver and will shutoff.

a. Set main service 1) to OFF.

circuit

breaker,

(16, figure

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

ELECTRICAL CONTROLS

*o\

19 -

18 -

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
15 May 1991

M M-000

006 00
Page 1 of 64

ORGANIZATIONAL TESTING AIR CONIlITIONER,

AND

INTERMEI~IATI?

MAINTENANCE:

ANDTROUBLESHOOTING AIRCRAFT AlM32C.21 GROUND COOLING

PART

NUMBER

1603ASlOO-1

Reference

Material . . . . . . . . . . . . , . . . . . . . WPOO5 00 WPOO7 00 WPOO8 00 WP 009 00 wP01000 WPOII 00 wl 01200 NAVAIKOI-IA-505 AC-ISOAO-MKC-000

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 . . . Alphabetical Subiect 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index

19 24 55 I 11 40 57 67. 21 27 16 33 2

I&cord

of Applicable

Technical NonI?

IXrectives

1. INTRODUCTION This work package provides tesling and troubleshooting information. Table 1 provides

trouble analysis in four-column format leading from symptom to remedy. Table 2 provides detailed information on testing individual components.

AC-1180AO-MMM-000

00600
Page 2

Table

1. Trol

bleshooting FAULT ISOLATION REMEDY 1. Correct Source Power 1. Re-Insert 1. Reset Connector

1. Power On Lights Fail ToLight -

1. No Source Power

1. Verify Power

Source

2. Improper Connection at Source Power 2. Main Service Circuit Breaker Open (Not Reset) 3. Failed Open Main Service Circuit Breaker 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

1. Replace (WPOlO 00)

4. Phase Reversal 5. Phase Loss 6. Low Source Voltage 7. Faulty Phase Loss Relay (K5)

1. Correct Phase 1. correct 1. Correct 1. Replace (WPOlO 00)

8. Failed Control Voltage Transformer

1. Replace (WPOlO 00)

9. Failed Open Fuses (FIO, Fll, F12) IO. Power On Lamps Burned Out 11. Faulty Light ReceptacIes 12. Faulty Wiring

1. Replace (WPOIO 00)

1. Replace (WPOlO 00) 1. Replace Light Receptacles (WPOlO 00) 1. Repair/Replace (NAVAIR 01.lA-505)

AG-180AO-M

M M-000

006 00
Page 3

Table SYMPTOM 2. Blower Does Not Operate When Start Button Is Depressed

I. Troublesh

lting(Continued) FAULT ISOLATION REMEDY 1

PHOBARLE CAUSE 1. Power On I.ights 0 Not

I. Refer to Symptom

2. IIlower Motor starter R day, K I, Open

I. Overload

Heater Trip

Reset Replace Starter clay (WP 010 00) Replace Starter NP01000) Replace starter clay (WPOlO 00)

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 I his WI ) Phase : lontacts, Loss Relay K5X1, Open

Replace starter k :clay(WPOl000) 3, I Replace Phase I ~08s Relay cWPOlO 00) Replace Switch :?&PO10 00)

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 This WP) 17,

Faulty Start Switch, i WI

5 Faulty Stop Switch, S,w2 6 Failed Open Fuses (Ii-1, F2, F3, Fl3l 7 Blower -Motor Open

1 Replace Switch WPOlO 00) ( 1 Replace (WPOIO 00)

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 J

1 Replace (WPOIO 001

1 Replace (WPOIO 001

1. Faulty Wiring E 9 Faulty Coupling

1 Replace/Repair YAVAIRO~.IA-505) (I 1 Adjust/Replace NPOO8 00)

00600
Page 4

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

1. Troublesb

oting(Continued) FAULT ISOLATION 1. Check Continuity of Coil (Table 2, Paragraph 9. This WP) 2. Check Continuity K4X1 Contact of REMEDY 1. Replace Relay (WPOIO 00)

PROBABLE CAUSE Time Delay Relay, 14. Faulty

1. Replace Relay (WPOlO 00) 1. Replace Temperature Cut-Out (WPO12 00) 1. Add Refrigerant (WP 007 00)

I_ Compressor Cylinder lead Temperature Cutht (CTCO) Open :_ Low Pressure Cutht (LPCO) Open

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. Adjust (WPOO7 00) 2. Replace (WPOO9 00) I. Bleed Refrigerant

I. High Pressure Cut)ut (HPCO) Open

1. Verify System Refrigerant Pressure Less Than 425 PSIG 2. Check HPCO for Continuity (Table 2, Paragraph 12, This WP)

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)

i. Oil Safety Switch OS) Open

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)

i. Compressor Motor itarter Relay, K2, Open

1. Replace Starter Relay (WPOlO 00)

1. Replace Starter Relay (WPOlO 00)

AC-I 80AO-M

M M-000

006 00
Page 5

Table SYMPTOM 4. Condcnscr Fan Does Not Operute ~l)EIIUMID, COOL Mode) When Compressor Discharge Pressure Greater Than 245 PSIC

1. Troubleshooting(Continued) FAULT ISOLATION I. Check Continuity IleLwxn FSW Terminals I and 3 (Table 2, Paragraph This WI ) 2. Keplacc (WPOO9 00) 3,

I RORAHLE CAUSE

2. Condenser Fan Motor Stxter. Kc&, K3,Opcn

I. Overload Heater Trip ( 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)

2. Kcplacc Starter K&y(Wl 0I000) I. Keplacc stxt.er Relay (WPOIO 00)

I. Kcplace starter Kf2llly

I. Keplace startc1 Kclay tWPOl0 00)

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

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

I. Keplacc (ligure 9)

I4

Condenser Fan Motor Open

1. Replace (WPOO8 00)

I. Keplace (WPOOS 00)

AG-180AO-MMM-000

00600
Page 6

Table SYMPTOM Not Operate (DEHUMID,COOL Mode) When Compressor Discharge Pressure Greater Than 245 PSIG

1. Troublesh

oting(Continued) FAULT ISOLATION I. isolate

1
REMEDY 1. Repair/Replace (NAVAIROl-IA-5051

6. Compressor Operating 5. No Air Flow Control

Not

1. Refer to Symptom

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

1. Inspect

1. Repair/Replace (WPOO9 00)

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 for Continuity with Switch in Closed Position

1. Replace (WPOO9 00)

1. Replace (WPOlO 00)

4. l.imit Switch, LSI, Defective 5. Limit Switch, LSZ, Defective 6. Faulty Capacitor, Cl

1. Replace (WPOll

00)

1. Replace(WF O11

00)

1. Check Continuity 1. Check Continuity

1. Replace (WPOll 1. Replace (WI 011

00) 00)

1 1

7. Main Air Damper Motor Open 8. Main Air Damper Linkage Loose/Broken

1. Inspect

, 1. Repair (WF Oll

00)

AC-180AO-MMM-000

00600
Page 7

Table SYMPTOM I. .Vo Air Flow Control Contd)

1. Troubles1

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 1. Check for Continuity with Switch in Closed Position 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 REMEDY 1. Replace(WP009 00)

PROBABLE CAUSE 9. Pressure Switch, PS3, Defective

10. Pressure Switch PSZ, Defective

1. Replace (WPOO9 001

11. Limit Defective

Switch, LS3,

I. Replace (WPOl 100)

12. Limit Defective

Switch, LS4.

1. Replace(WPO1100)

13. Faulty c2

Capacitor,

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

00) 00)

14. Bypass Damper Motor Open 15. Bypass Damper Linkage Loose/Broke 16. Faulty Wiring

17. Defective Delivered Air Pressure Gage 18. Ruptured Duct(s)

I. Replace (WPOO9 00) I. Replace 1. Remove Blockage

19. Blocked Conditioned Air Passage 20. Main Damper Damaged 21. Bypass Valve Damaged / 6. No Temperature 1Control (COOL Mode) 1. Low refrigerant Charge

1. Inspect 1. Inspect

1. Repair 2. Replace (WF Oll I. Repair 2. Replace (WPOll 1. Add Refrigerant :wp 007 00).

00: 00)

1. Observe Sight Glass(es)

AG-180AO-MMM-000

006 00
Page 8

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

1. Troubleshl

,ting(Continued) FAULT ISOLATION REMEDY Rcplacc (Wf OO9 00)

Pressure Switch, :&4, F aulLy

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

Pressure Switch, 55. Faulty

Replace (WPOO9 00)

Pressure Switch, PS6 a&y

I. Replace (WPOO9 00)

i. Defective Solenoid l&e, Sl

1. Replace Coil WPO12 00) I. Replace Solenoid Valve Sl (WPOO8 00) I. Replace Coil :wpo12 00) I. Replace Comprcssol YWP 008 00)

i. Defective Solenoid Jalve, til

1. Open Coil;check Continuity 2. Inoperable Valve

G-l 80AOPage 9

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

1. Troubles1

,ting(Continued) FAULT ISOLATION I. Open Coil; check Continuity (Table 2, Paragraph 20, This WP) 2. Inoperable Valve 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 (WPOO8 00) 1. Replace Coil (WPOO8 00) 1. Replace (WPOO8 00) I. Replace Coil (WPOO8 00) 1. Replace(WP00800) 1. Adjust (WPOO7 00) 2. Replace (WPOO8 00) 1. Adjust (WPOO 7 00) 2. Replace (WPOIO 001

P%%%LE 7. Defective Valve, s2 Solenoid

8. Defective Solenoid Valve, u2

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

9. Defective Solenoid Valve, S6

I. Open Coil; check :ontinuity (Table 2, ?aragraph 20, This WP) 1. Inoperable Valve I. Open Coil; check Continuity (Table 2, Paragraph 20, This WP) 1. Inoperable Valve I. Open Coil; check :ontinuity (Table 2, ?aragraph 20, This WP) !. Inoperable Valve

10. Defective Solenoid Valve, s3

11. Defective Solenoid Valve, 54

12. Faulty Head Pressure Regulator

(Vl)

I. Compressor Dis:harge Pressure not Maintained at 225 PSIG w Greater. t. FSW does not open at Compressor Discharge Pressure less 175 psig, Check Continuity heween terminals 1 and 3 I. Observe Suction Pressure for Lower fhan Normal Level t. Leak Check ,WP 007 00)

13. Faulty Fan Cycling Switch, FSW

14. Evaporator Pressure Regulator Valve Failed Closed 15. Refrigerant Leak 16. Faulty Valve(s) Piping

1. Test Valve, Repair/Replace (WPOO8 00) 1. Repair, add Refrigerant (WPOO7 00) 1. Replace (WPOO8 00) I. Replace (WPOO8 00) I. Replace (WPOO8 00)

Expansion

17. Damaged Faaporatorw 18. Damaged Condenser(s) 19. Faulty Wiring I. Isolate

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

AaG-l$OA0-MMM-000

Table SYMPTOM Unit Shuts Down Vhile Running POWER On Lights Ofll

I. Troublesh

vting(Continued) FAULT ISOLATION I. Verify Source Power

Power

PROBAHI.,E CAUSE No %1rce Power

REMEDY I. Corrccl Source

Circuit

Hreakcr Open

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. Reset I. Replace (WI 010 00)

I. Failed Open Circuit greaker

1. Failed Control Joltage Transformer

I. Replace ~Wl OlO 00)

i. Failed Open I uscs FllandF12) i. Faulty Wiring

I. Replace (WPOlO 00)

1. Repair/Replace INAVAIROI-lA-5051 1. Replacc(WPO10 00)

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

Failed Open Fuse, r13

I. Check Fuse for Continuity (Table 2, Paragraph 17,This WP) 1. Isolate 1. Overload IYip Heater

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

Wiring

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)

I Blower Motor Starter <day. K 1, Open

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

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

4.

1. Replace Starter Relay (Wf OlO 00)

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

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)

Table

1. Troublesh

100 ting(Continued) FAULT ISOLATION 1 Check for Continuity ( Cable 2, Paragraph 4, T his WP) 1 Check Switch for CContinuity (Table 2, P aragraph 5, This WP) 1 Isolate 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

PROBABLE CAUSE !. Phase Loss Relay Zontacts, K5X1, Open 3. Faulty Stop Switch, SW2 4. Faulty Wiring

IO. Condenser Fan Shuts Down during Operation (SOTE: Could Represent ~ormnl Operation During Low Imhient Temperature, 1.0~ Air Conditioning Loads)

1. Faulty Fan Cycling switch, FSW

1 Check Continuity Rletwcen FSW 1 erminals 1 and 3 with lI jischarge Pressure g water than 245 psig. 2 Check Continuity ELetween FSW I erminals 1 and 3 with I:jeweasing Discharge F ressure; Switch should .ot open until 175 psig

I. Adjust (WPOO7 00) 2. Replace (WI 009 00

1. Failed F&Motor 3ushing l. Refer to Symptom .l. Compressor Shuts Iown during Operation I. Low Compressor Level 2. Refer to Symptom 3. Failed Compressor 4 Oil

1 Observe

1. Replace (WPOOS 00

1 Check Oil Safety Slwitch Reset and c :ompressor Oil Level

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

3 I. Repair/Replace (WPOO8 00) 2 I Ohserve I Ohservc I. Keplace (Wf OO800) 1. Replace (WI 008 00)

t I12. Blower Shuts Down cluring Operation. I. Refer to Symptom

2. Failed Blowcr/.Motor Zoupling 3. Failed Blower

!-

AG-180AO-MMM-000

00600
Page 12

1 n,,rt:

1.

, I ul,rcJrlr,~,~,u,,rllrr;,

SYMPTOM 13. Unit Will Not Turn c MT

I KOBAHLE CAUSE 1. Faulty SW2 StopSwitch.

FAULT ISOLATION I. Check Switch for Open when Depressed (Table 2, Paragraph 5. This WI ) 1. Check Switch for Continuity when not Dcprcsscd (Tahlc 2, Paragraph 5,This WP) 1. Check Low Side system Pressure for 0 PSI 1. Ohserve Lamp Filaments 1. Check Continuity with Good Lamp 1. Check Continuity (Table 2, Paragraph This WP) I. Isolate 5,

KIXMEDY I. Replace~WP0l0 00,

I
\ 4. Panel Light(s) o Light Fails

2. Faulty SW1

Start Switch,

I. ~~~1~~~~wr~o~o001

3. Faulty LOW Pressure Cutout Switch I. Defective Lamp

1. Adjust

(WPOO7 00)

2. Replace (WPOO9 00 I. Replace iw1 010 001

2. Dcfcctive Panel Light Receptacle 3. Defective Panel Light Switch, SW4 4. Faulty Wiring

1. Rcplacc iWl O10 00) 1. Replace (WI 010 001

I. Repair/Replace (NAVAIROl-IA-505t I. Replace (WI 010 00) 1. Replace (WI 010 1. Keplxe 6, 1. Repair/Replace (NAVAIR 01.IA-5051 001

5. Mode Light(s) o Light

Fail

1. Defective 2. Defective Receptacle

Lamp Mode Light

1. Observe Lamp Filaments I. Check Continuity with Good Lamp 1. Check Continuity (Table 2, Paragraph This WP) I. Isolate

3. Defective Mode Switch, SW3 4. Faulty Wiring

(WPOlO 00)

16. Discharge Pressure :age Indicates Less rhan 140 Psig

1. Low Refrigerant Charge

I. Ohscrve Sight Glass(es1 for Ruhhlcs

I. Add Refrigerant (WP 007 00) 2. Test System for Leaks, Repair. Recharge (WPOO7 00)

AC-18OAO-MMM-000

006 00
Page 13

L ame

. .

. 1.

L rouo~esnoot~ng(tionrInuea,

. .

..

,-

..

. KEMEDY 1. Replace (WPOlO 1. Repair/Replace (WI 008 00) 1. Clean Coil(s) O(

SYMPTOM
1 16. Discharge Pressure 7 ( sage Indicates Less 1Phan 140 Psig ( ,Contd)

I KOBABLE CAUSE 2. Defective Cage 3. Defective Compressor

FAULT ISOLATION 1. Test Gage with Known Pressure Source 1. Observe Compressor Operation 1. Observe Condenser Coils 1. Observe Suction Pressure for Iligher Than Normal Level 1. Test Gage with Known Pressure Source 1. Ohserve Valve Stem Position 1. Observe Suction Pressure for Lower Than Normal Level 1. Observe Suction Pressure for Lower Than Normal Level 1. Observe Suction Pressure for Lower Than Normal Level 1. Observe Unit. 1. Check Filter/Drier 2. Observe Sightglass

c I17. Discharge Pressure (kge Indicates Higher r

1. Condenser Coil(s) Clogged or Obstructed

2. Overcharge

l han 365 psig

of

Refrigerant 3. Defective Cage 4. Receiver Shutoff Valve(s) Closed 5. Filter/Drier Clogged

1. Bleed Refrigerant from System. I. Replace Gage 1. Open Valve(s) I. Replace Filter/Drie, Core (WP 008 00). 1. Test Valve, Solenoid, S5, and Wiring 1. Rep&c I.ine

6. Pumpdown Solenoid Valve Failed Closed 7. Collapspd Refrigerant Lint

8. Panels Not in Place

1. Replace Panels 1. Evacuate and Recharge Unit (WPOO7 00)

9. system Contaminated 1 18. Suction Pressure (&ge Indicates Less 1fhan 10 psig L 1. Refer to 17.3 through 17.7 above

AG-180AO-MMM-000

006 00
Page 14

rahle

I. rl-ouhleshooting(Continued) I VA U I:r ISOLATION

SYM I TOM

I I HEMEIIY

I I

I HOHAHI;K CAUSE

2. Air liiltcr i (NOTE: Could j lb2prcsent Normal 0pcr;llion: c-g., I.ow And~icnl, I.ow I)clivcrcd

Dirty

I, lnspuct

Air Filtc~

I. Clean Ail lillcr(Wl OO7

00) I

I. Ohserve Sight Clasdcs) for llubhlcs

I. Add rcfrijicrant ( 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 ) 6. Itot Gas llypass and/or Quench Valvc(sl Faulty 7. Hlowcr Not Operating Properly I. Ohscrw 9. Air Circuit 10. Faulty Valve(s) 20. Suction Pressure i IndicatesGreutcl- l han j 7o pig 2. Compressor Loading Not I. Perform Test Procedures in Accordance with (WI 006 00) 2. Compressor Head Cold Cylinder Blocked Opfr*tion 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. Repair/Replace (WPOOS 00) 1. Clear Rlockage I. Keplace (WPOO8 001

I. lnspcct

&pansion Pwssure

I. Discharge Too High

1. Replace (WPOO7 00)

I. Replace Compressor (WPOOS 00)

AG-180AO-MMM-000

006 00
Page 15

Table SYMPTOM 20. Suction Pressure Indicates Greater Than 70 psig(Contd) I

I. Trouhleshooting(Continued) FAULT ISOLATION 1. Check for Power ON Solenoid Coil Sl and/or 52 1. Verify Power to Solenoid Valve(s) 53 and 54 1. Ohserve Compressor REMEDY I. Replace Coil (WPOO8 00) I. Adjust, Repair/ Replqe (WPOOS 00) I. Replace Comprcssot tWP008 00) I. Replace (Wf OO8 00)

PRORARLE CAUSE 3. Precooler Not &aging 4. Ilot Gas Bypass I.ine Open 5. Defective 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. Replace Valve/Replnce (WPOOS 00)

Coil

I. Rcplnce(WPOlO001

1. Check

Contacts

1. Replace (WPOlO

O(

AG-180AO-MMM-000

006 00
Page 16

Till

: 2. Testin NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE

1. MAIN 1(CBI)

SERVICE

CIRCUIT

BREAKER

; / I

Support Part x0.

Equipment Required Xomenclature Multimeter Required None

Materials

To prevent injury to personnel or damage toequipment, electrical power must be disconnected when working inside electrical controls panel. power is OFF and

a. AMake sure electrical 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) ! I I Materials Support Part No. Equipment Required Somenclature .Multimeter ! Zontinuity exists

teplace main service circuit ,reaker (WPOlO 00).

Eeplacc main servicecircuit 1reaker (WPOlO 00).

Required N0ne

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

00600
Page 10

Table

2.

;ting(Continuedl NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE

To prevenl injury to personnel or damage to equipment, electrical power must be disconnected when working inside electrical controls panel. Band /( a. Make sure external electrical connector is disconnected. power is

b. Open electrical controls panel (figure 2 : by turning grip latches counterclockwise. c. Removebolt( d. Remove cover (3). e. Disconnect wormer wiring. unit wiring from trans!ontinuity exists :eplace transformer WPOlO 00).

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 3. MOTOR STARTER K3) Support Part No. Equipment controls (KI. pane K2,

RELAY

Required Nomenclature Multimeter 110 VAC Power source

Materials

Required None

AC-180AO-MMM-000

00600
Page 19

ELECTRICAL -CONTROLS PANEL

-44 -4, . -42 -43 1

Figure 2.

Control

Voltage Transformer

AG-180AO-MM

M-000

006 00
Page 20

Table

2. Tl?!;ting(Continued) NORMAL INDICATION s tarter resets REMEDY FOR ABNORMAL INDICATION <eplace Overload WPOlO 00) Relay

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. c. Open grip latches securing electrical I controls panel. I / d. Disconnect wires from coil terminals. Check continuity between coil connections. e. Check heaters for continuity.

:ontinuity

exists

ieplace

Coil (WPOIO 001

iontinuity

exists

%eplace Starter WPOlO 00)

Relay

To prevent injury or death, do not touch electrical connections. f. Apply external terminals. g. Disconnect Checkcontinuity T2, L3 and T3. 110 VAC power to coil :ontacts close ieplace Starter WPOlO 001 ieplace Starter WPOlO 00) Relay

wires from Ll, 1.2,1.3. between Ll andT1, L2 and

fontinuity

exists

Relay

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).

bontinuity

erists

Ieplace Starter WPOLO 00)

Relay

Ipen exists (Kl) lontinuity exists (K2)

ieplace Starter WPO 10 00)

Relay

AC-18OAC.bMMM-000

006 00
Page 21

ELECTRICAL CONTROLS

<\-I
Y
STARTER RESET SUTTON

RESET SUTTON

~~

COMPRESSOR STARTER RESET 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

00600
Page 22

I uT3 I

-64 .156

STARTER RESET BUTTON

-5.0 -26 -21 16

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

AG-180AO-MMM-000

006 00
Page 23

Table

2.

,ting (Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION :eplace starter wl olooo) :eplace starter WPOIO 001 IWay

I
! ! k.

PROCEDURE

j. Removeexternal coil terminals..

I10 VAC power from

ontinuity

exists (K2)

Reconnect all w~ires.

Relay

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

Ir1. PHASE

LOSS

RELAY

Support art No.

Equipment Required Nomenclature iVIultimeter 3 phase, 60 Hz, 440 VAC Power Supply Required None

Materials

To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside electrical controls panel. a. Make sure electrical onnector is disconnected. lc power is OFF and

b. Open electrical controls panel by t urning grip latchescouterclockwise. c. Unplug phase loss relay (Figure 4) , d. Check continuity
L

between pins 8 and 1.

lpen circuit

teplace WPOlO

phase loss relay 00)

AG-180AO-MMM-000

00600
Page 24

GRIP LATCHES~

i : -

ADlUiTMENT SCREW

Figure 4. Electrical Phase Loss Relay (K5) Testing

00600
Page 25

Table

2. Testing I

(Continued) I NORMAL INDICATION REMEDY FOR ARNORMAL INDICATION I

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

440 VAC, 3 Phase, 60 Hz electrical power is dangerous. To prevent injury or death USCextreme 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. Indicator light on Replace phase loss relay (WPOIO 00)

3.0 voltage

i. Secure electrical controls pancl hy turning grip latches clockwise. 5. START(SWl)ANDSTOP(SWZ) SWITCH Support Equipment Part No. Required Nomenclature Multimeter

Materials

Required NOW

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

AG-180AO-M

M M-000

00600
Page 26

Table

2. Testing

(Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE

a. Make sure electrical connector is disconnected. I b. Open instrument

power is OFF and

panel door. grip

/ c. Open instrument panel by turning latchescounterclockwise. d. Disconnect wire 75or 77 from the ~START(SWl)switch(I,figure5). e. Check for continuity terminals (C and .X0).

between switch

Open circuit

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

f. Depress switch button. Check for continuity between switch terminals. 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 terminals (C and NC). between switch

Continuityexists

Continuity

exists

Replace switch. switch (WPOIO 00)

j. Depress switch button. Check continuity between switch terminals. I. Reconnect wires 76,86, or 77,78 to switxh terminals. m. Close and secure instrument turning grip latches clockwise. n. Close instrument 6. MODE SWITCH panel door. (SW3) Required Nomenclature Multimeter panel by Open circuit Replace switch. switch (WPOIO 00)

Support Part No.

Equipment

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. Testing

(Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

/ I

To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside instrument panel. a. Make sure electrical connector is disconnected. b. Open instrument power is OFF and

panel door, grip

c. Open instrument panel by turning 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 above to their respective terminals. i. Close instrument latchesclockwise. j. Close instrument in d. grip Continuity exists Replace switch. (WPOIO 00)

Continuity

exists

Replace switch. (wP01000)

Continuity

exists

Replace switch (wPo1ooo)

panel by turning

panel door.

AG-180AO-M

MM-000

00600
Page 30

Table

2. Testing

Khntinued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE

7. PANEL

LIGHTS

SWITCH

(SW4)

Support Part No.

Equipment

Required Nomenclature 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. a. Make sure electrical connector is disconnected. b. Open instrument power is OFF and

panel door. grip

c. Open instrument panel by turning latehescountercloekwise. d. Disconnect location TBl-2. wire 71 from terminal

block

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.

Open circuit

Replace switch. (WPOIO 00)

Continuity

exists

Replace switch. (WPOIO 00)

Continuity exists, while the resistance level changes.

Replace switch. switch (wP01000)

AG-180AO-MMM-000

006 00
Page 31

l ahle

2. Testing(Continued1 NORMAL INDICATION KEMEDY FOR AHNOKMAL INDICATION

PKOCEDUKE

h. Reknect

wire71

toTB1~2. panel by turning grip

i. Close instrument latches clockwise. j. Close instrument i 8. AIK FLOW

panel door. SWII CH~(FCSI Kequired Nomenclature Multimeter

CONTKOL Equipment

Support Part so.

Materials

Kequired None

To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside instrument panel. a. Make sure electrical connector is disconnected. b. Open instrument power is OFF and

panel door. grip

c. Open instrument panel by turning i latchescounterclockwise.

d. Disconnect wire 101 from terminal 2 of 1the 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. Continuity exists Replace switch. (WPOIO 00)

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

Continuity

exists

Replace switch. switch (WPOlO 00)

AG-180AO-MMM-000

00600
Page 32

. . ^ -

,^

. REMEDY FOR ABNORMAL INDICATlON

PROCEDURE

NORMAL INDlCATlON

g. Reconnect wire 101 to terminal h. Close instrument atches clockwise. i. Close instrument

2. grip

panel by turning

panel door. (K4) Required Nomenclature Multimeter 110 VAC Power source

I. TIME DELAY RELAY Support Equipment Part No.

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 :onnector is disconnected. power is offand

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 md 7. e. Check continuity between pins 2 Continuity exists Replace time delay relay (WPOIO 00) Replace time delay relay. (wP01000) Replace time delay relay. (wP01000)

between pins 1 and 3.

Open

f. Apply 110 VAC to pins 2 and 7. Check :ontinuity between pins 1 and 3.

Open for approximately 10 seconds after 110 VAC application; continuityaftcr 10 seconds.

Page 33

1
ELECTRICAL

I
CONTROLS PANEL

Figure 6. Time Delay (K4) Testing

AGd$OA0-MMM-000

006 00
Page 34

Table

2. Testing

(Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE

g. Install

relay in socket. controls READ (CTCO)

h. Close and latch electrical and. 0. COMPRESSORCYLINDER EMPERATURE CUTOUT Support Part No. Equipment

Required Nomenclature Multimeter Salt bath or oven

Materials

Required
NOW

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 325F and closed below 250F. 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 (70F), check continuity between wires 112 and 113. f. Place CTCO into a salt bath or oven md raise temperature, monitoring the emperature continuously. Continuity exists Replace Conipressor (WPOOS 00).

AG-I $OAO-MMM-000

006 00
Page 35

PROCEbURE

NORMAL INDICATION

REMEDY FOR ABNORMAL INDICATION

g. Check continuity between wires 112 and 113 as temperature exceeds 325F (nominal). h. Decrease temperature: check continuity between wires 112 and 113 as temperature drops below 250F (nominal) i. Install II. CTCO (WP 012 00) CUTOUT

Open

Replace Compressor (WP 008 00).

Continuity

exists

Replace Compressor (WP 008 00).

LOW PRESSURE (LPCOI Support Part No.

Equipment Required Nomenclature Multimeter Regulated Nitrogen Pressure Source Required None

Materials

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).

00600
Page 36

Table

2. Testing

(Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE

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 (5, figure 8) capillary line from LPCO

j. Disconnect wire 113 or wires 114 and 115 from LPCO. k. Check continuity and 3. between terminals 2 Replace LPCO (WP 010 00).

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

AG-180AO-MMM-000

00600
Page 37

l ahle 2. lestlng

(Gont~nued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION __----

PROCEI)URE

m. Increase the prcssurc. Monitor for bntinuity os the pressure rises ahove 17 jig. n. Decrease the pressure. Monitor for 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 r. Evacuate CONTKOLS 00). panel.

Continuity

exists

Replace I.PCO (WP 010 00).

open

Replace LPCO (WP 010 00).

system (WI 007

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 108 00). condenser fan assembly (WI

2. HIGH PRESSURE CUTOUT (HPCO) Support Equipment Required Part No. Nomenclature Multimeter Kegulated Nitrogen Pressure Source Materials
NOIW

Required

AG-180AO-MMM-000

006 00
Page 38

PRESSURE CONTROLS

3 RESET lIUTTON~\i

(SHEET 21

OS llG&$2 -129 -118

I 117

L-Jd

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
L

1xMl

131-

Figure 7. Pressure Controls

Testing (Sheet 3)

AC-1 $OAO-

-000

Cm
Page 41

Table

2.

iting (Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

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 :onnector is disconnected. g. Open PRESSURE power is off and

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.

AC-1 $OAO-M M M-000

006 00
Page 42

Table

2.

sting (Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE h. Bleed pressure from lines by loosening le capillary line litting to the HPCO (6. gure 7). i. Disconnect j. Disconnect capillary line from HPCO.

wire 114or 116 from HPCO. reset button. between terminals 1 :ontinuity exists &place HPCO (WP 010 00).

k. Depress manual I. Check continuity 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 monitor continuity. reset button and

)pen
Ipen :ontinuity exists

<eplace HPCO (WP 010 00). <eplace HPCO (WP 010 00). Xcplaee HPCO(WP01000).

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 t. Evacuate CONTROLS panel.

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.

AC-18OAO-MMM-000

00600
Page 43

Table

2. Testing

(Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE

3. OIL SAFETY SWITCH Support Equipment Part No.

(OS) Required

Nomenclature Multimeter Regulated Nitrogen Pressure Source 110 VAC Power Source Clamp-Around Ammeter Materials Required
NOW

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 WP 008 00). fan panel assembly

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 onnector is disconnected. power is off and

00600
Page 44

Table 2. sting (Continued) NORMAL INDICATION REMEIlY FOR ABNORMAL INI~ICA L ION

PROCEDURE

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

to

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 Z and 120. between terminals <eplace OS (WP 010 00).

n. Decrease the pressure to the HIGH ;ide port until the pressure drops below 5 xig. a. Check continuity and 120. between terminals 2 Zontinuity exists ieplace OS (WP 010 00)

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

AG-180AO-MMM-000

00600
Page 45

Table

2.

sting (Continued) NORMAL INDICATION REMEDY FOR ARNORMAL INDICATION <eplace OS (WP 010 00).

PROCEDURE

q. Check continuity /I and L.

between terminals

)pen

r. Depress manual reset button s. Check continuity .nd 120. between terminals 2 )pen kplace OS (WP 010 00).

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 .nd 120. M

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 ew minutes. heater to cool for a

:urrent flow for approimately 45seconds, hen open circuit.

teplace OS(WP 010 00)

y, Depress manual reset button, z. Monitor md L. current through terminals M hrrent flow ieplace OS (WP 010 00).

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

AG-180AO-MMM-000

006 00
Page 46

Table 2.

iting(Continued1 NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

I ROCEDURE

ab. Connect wire I16 to terminal wires 118;lnd 120 to terminal 120. ac. Connect capillaries LOW side ports. ! I I

;\rl and

to OS HIGII

and

ad. Evacuate system IWP 007 00). ae. Close PRESSURE pnnel. CONTROLS

of. Open compressor suction and : discharge service valves by turning stems counterclockwise. Install stem caps. ug. Open receiver inlet and outlet ,ervice valves by turning valve stems ,ounterclockwise. Install stem caps.

/I
I

ah. Close COMPRESSOWKECEIVER \CCESS door. ai. Install condenser fan panel assembly WP 008 00). 14. FAN CYCLING Support Part so. SWITCH (FSW)

Equipment

Required

Materials

Nomenclature Multimeter Keg&ted Nitrogen Pressure Source Required

NOnI?

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

AG-180AO-MMM-000

006 00
Page 47

Table 2.

sting (Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

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 :onnector is disconnected. g. Open PRESSURE power is off and 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 j. Disconnect capillary line from FSW

wire I15 or 1 I9 from FSW. between terminals 1 Ieplace FSW (WP 010 00).

k. Check continuity and 3.

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

AG-180AO-MMM-000

00600
Page 48

Table

2. Testing

(Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE
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. n. Decrease the pressure. Monitor continuity as the pressure drops below 175 psig. o. Disconnect pressure source and connect capillary line. p. Disconnect multimeter. Continuity exists Replace FSW (WP 010 00).

Open

Replace FSW (WP 010 00).

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).

AG-180AO-MMM-000

00600
Page 49

Table

2. TestingtContinued)

PROCEDURE

I
lPS4. I S5) Required

NORMAL INDICATION

REMEDY FOR ABNORMAL INDICATION

15. PRESSURE Support Part No.

SWITCHES Equipment

Komenclature Multimetal Regulated Nitrogen Pressure Source Materials Required NOW

a. Pump down unit.

(WP 007 00).

b. OpenCOMPRESSOR/RECEIVER ACCESS door. c. Remove stem caps from receiver inlet and outlet service valves and close valves by turning valve stems clockwise. d. Remove condenser fan panel assembly (WP 008 00). 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 connector is disconnected. g. Open PRESSURE power is off and CONTROLS panel.

AG-l$OAO-MMM-000

00600
Page 50

Table

2. Testing I

KZontinued) NORMAL INDICATION REMEDY FOR ABNORMAL 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 and PS5. j. Disconnect from PS5 capillary lines from PS4

I
wire 128 from PS4 and 129

k. Check continuity between terminals Land M2 of PS4 and PS5. respectively. I. Check continuity between terminals and Ml of PS4 and PS5, respectively. L

Open I Continuity exists

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

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. continuity between terminals PS4 and PS.5, respectively. Check L and M2 of PS5: Continuity above 50 psig Ps4: Continuity above 55 psig exists exists Adjust PS4 and/or PS5 (WPOO7 00). Replace PS4 and/or PS5 (WP 009 00). Adjust PS4 and/or PS5 (WPOO7 00). Replace PS4 and/or PS5 (WPOO9 00).

o. Decrease the pressure. continuity between terminals PS4 and PS5, respectively.

Check Land M2 of

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

OAO-MMM-000

00600
Page 51

Table

2. T tsting (Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION idjust PS4 and/or PS5 WP 007 00). Leplace PS4 and/or PS5 WP 009 00).

PROCEDURE

p. Increase the pressure. continuity between terminals I S4 and PS5, respectively.

Check Land :%I1of

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

q. Decrease the pressure. continuity between terminals ! PS4 and PS5, respectively.

Check Land Ml of

S4: Continuity )elow 30 psig 35: Continuity )elow 25 psig

exists

idjust PS4 and/or PS5 WP 007 00). leplace PS4 and/or PS5 WP 009 001.

exists

r. Disconnect pressure source and connect capillary lines. Disconnect multimeters. s. Connect wires 128 and 129. t. Close PRESSURE I I / CONTROLS panel.

u. Evacuate system (WP 007 00).

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. y Install condenser fan panel assembly I i (WP 008 00). / 16. PRESSURE I Support Part x0. SWITCH Equipment (PSI3 Required Nomenclature Multimeter Regulated Nitrogen Pressure Source

Materials

Required None

AG-180AO-MMM-000

00600
Page 52

Table

2.

sting(Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE

a. Pump down unit.

(WP 007 00).

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 janeI. CONTROLS

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

AG-18OAO-MMM-000

00600
Page 53

Table

2.

!sting

(Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE

j. Disconnect

wire 135 from PS6. between terminals Zontinuity exists. ieplace PS6 (WP 009 00).

k. Check continuity 1and M 1 of PS6.

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

c c

I. Apply a pressure source to the apillary connection of PS6. Monitor I. and M 1 of Ipen abovc 45 psig Idjust PS6 (WP 007 001. <eplace PS6. (WP 009 00)

m. Increase the pressure. ontinuity between terminals F56.

n. Decrease the pressure. Monitor between terminals Land Ml of PS6. o. Disconnect pressure source and C onnect capillary line. Disconnect nultimeter. p. Connect wire 135. q. Close PRESSURE r. Evacuate CONTROLS panel.

:ontinuity exists Elow 20 psig

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

system (WP 007 00).

s. Open compressor suction and d ischarge service valves by turning valve s 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).

AG-180AO-MMM-000

006 00
Page 54

Table

2.

ding

Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION I

PROCEDURE

17. FUSES Support Part Number Equipment Required Nomenclature Multimeter Required

Materials 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 connector is disconnected. power is off and

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 g. Position (1) screws (5) and washers (6) FUSES panel (3) on top. compound to screws Continuity exists Replace fuse (WP 010 00)

h. Apply antiseize

I I.. Install

screws (1) and washers (2)

AG-18OAO-MMM-000

00600
Page 55

AG-180AO-MM

M-000

00600
Page 56

r
c 1 18. PRESSURE Support f art No.

Table

2.

sting (Continued) NORMAL INDICATION REMI.:DY E OR ABNORMAL INDICATION

PROCEDURE

SWITCH Equipment

(PSI) Required

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) Materials Required None power is off and DRIER

a. Make sure electrical xxmector is disconnected. b. Open BLOWER/FILTER \CCESSdoor.

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

switch

PSl

(7) from

AG-180AO-M

M M-000
BLOWER~F~LTE~~ DRIER ACCESS OOOA

006 00
Page 57

SPRING LATCHES

9--

PS3 NC t69 NO

PSZ NC 107 -+

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

AC-180AO-MMM-000

006 00
Page 58

Table

2. Testing

K!ontiued) NOHMAL INDICATION HEMEDY FOR ABNORMAL INDICATION Replace PSI (WP 009 00).

PROCEDURE

h. Check continuity between terminals C and NC and C and NO, respectively.

C and NC: continuity exists C and X0: Open Open from 0 to 1.45 in. H2D; continuity e.xists at greater than 1.45 in. H20

i. Using an external pressure source with manometer teed into the pressure line, apply pressure to the HIGH side port of PSI Increase the pressure from zero to greater 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.

Adjust PSI (WP 007 00). Replace PSI (WP 009 00).

Open Open to approx 1.3 in. HzO; continuity exists at less than 1.3 in. Hz0 C Opt

Keplacc I S1 IWP 009 00). Replace PSI (WI 009 00).

k. Decrease the pressure to zero while monitoring the continuity between terminals C and NC. I. Check continuity and NO. m. Disconnect between terminals

Replace PSI (WP 009 00).

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 wire 101 to terminal NC, wire 102 to terminal NO. p. Replace cover (3) and tighten screw (2). C,

cover

q. InstaIl switch PSl (7) in compartment with nut (6) and washers (5). r. Close BLOWER/FILTER ACCESS door. DRIER

AG-180AQ-

MM-000

006 00
Page 59

Table

2.

sting (Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDtCATION

PROCEDURE

t 19. PRESSURE Support Part No.

SWITCH Equipment

(PS2, PS3) Required

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

To prevent injury to personnel or damage to equipment, electrical power must be off when testing pressure switches. a.. .Make sure electrical onnector is disconnected.
iP ,CCESS door by ounterclockwise. C

power is off and

b. Open BLOWER/FILTER DRIER turning spring latches S), washers

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

I

d. Remove

switch

PS2lPS3

(S/S).

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. g. Tag and disconnect the air pressure j lines rrom the HIGH and LOW side ports of / the switch housing.

AG-180AO-MMM-000

00600
Page 60

Table

2. Testing

(Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION Replace (WPOO9 00).

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

PS2: C and NCcontinuity exists; C and NO-open PS3: C and NCcontinuity exists; C and NO-open

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 terminals C and NC. between PS3 (9)

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

Adjust

PS3 (WPOO7 00).

Replace (WPOO9 00).

Open

Replace (WPOO9 00).

i I

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

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

Replace (WPoo9 00).

I. Checkcontinuity terminals C and NO. m.Repeat (8).

between PS3

open

Replace (WPOO9 00).

steps i. through

1. for PS2

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

Adjust

PS2 (WPOO7 001.

Replace (WPOO9 00).

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

Repluce (WPOO9 00)

AG-180AO-MMM-000

00600
Page 61

PROCEDURE

NORMAL INDICATION

REMEDY FOR ABNORMAL INDICATION

n. Connect air pressure lines as tagged.

co lver

o. Connect wiring as tagged and install (3) with screws (2). p. Position switch ( 7) on roadside fender.

witch 9,

q. Install nuts (6), washers (5) and PS2 (8) or PS3 (9) on Bkt (4). I . Close BLOWER/FILTER door. DRIER

ACCESS

1. SOLENOID VALVE 6, UI AND U2). Support Part No. Equipment

(SI THROUGH

Required Nomenclature Multimeter

Materials

Required NOtZ power is off and

a. Make sure electrical ccmnector is disconnected.

b. Remove condenser fan panel assembly DRIER ACCESS (( ,pen BLOWER/FILTER dm oar for S5). piiiiz-) To prevent injury to personnel or damage to equipment, electrical power must be off when testing pressure switches. c. Remove coil electrical junction box by the retaining screw/nut. IIDoseningiremoving d. Remove wire nut from one electrical le: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

00600
Page 64

Table

2.

stin

(Continued) NORMAL INDICATION REMEDY FOR ABNORMAL INDICATION

PROCEDURE

e. Remove wire nut from second electrical lead. f. Check continuity solenoid coil as follows: Solenoid Valve 31 52 $3 $4 55 j6 !Jl Li2 g. Join separated 1ut.s. between the leads to Zontinuity exists ?eplace coil (WP 008 00).

Wire 130 132 136 137 127 134 131 133

To

Wire 122 123 139 140 121 138 118,143 143

wires and replace wire

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).

OKGANI%A I7ONALAND SERVICING,

INTERMEDIATE LUBRICATION.

MAINTENANCE

ADJUSTMENT, MOTOK GROUND BUKNOUT COOLING

CLEANUPAFTERCOMPRESSOR AIR CONDITIONER, AIKCRAFT AiMR2C.21 PART NUMBER

1603ASlOO-1

Keference Operating Instructions. ILcmoval and Installation. Fabrication :tnd Inspection

Material WI 005 00 WI 008 00 SAVSEA 0900.1.1 .001-7000

of Hraxd

I iping

Systems

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 Suhiect Liquid Refrigerant Addition/Charging Pumpdown................................................................. SystemEvacuation........................................................... S~stemPmpdow..........................................,................... Record of Applicable

Index

(Continuedl m 7 3 3 4

Technical None

Directives

1.

REFRIGERATION INSTRUCTIONS. Support

SERVICING Equipment Required 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.

Part Number

tion system. High pressures are present which could cause serious injury. If a refrigerant leak is suspected, provide adequate ventilation and be careful not to inhale refrigerant vapors or allow any refrigerant to contact the skin. 2. LEAK TEST. condenser fan panel assembly (WP

a. Remove 008 00).

Materials Specification or Part Number

Required Nomenclature Refrigerant, R-113 Refrigerant. R-22 Charging Drum Oil, Compressor Rermlated Pressure Source (Nitrogen) Solvent Compound, Sealing Corrosion Preventive Compound, Grade I

To prevent injury to personnel, be careful when working near rotating components. b. Check all refrigerant valves for leaks. Iittings, couplings, and

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 f. Perform WP, paragraph empty 5). system 0900-LP-001-7000) pressure test (this

VV-L-825. P-D-680

Type IV

MIL-C-16173D

g. Evacuate system (this WP, paragraph 4) and add refrigerant (this WP, paragraph 6 or 7). I To prevent injury to personnel, use care when servicing the refrigerah. Install 008 00). condenser fan panel assembly (WP

AG-18QAO-MMM-080

Cm 0
Page 3

3. I UMI I~OWN.

4.

SYSTEM

EVACUATION. condenser fan panel assembly

NO I E I.PCO will stop comprcswr when suction pressure reaches 0 prig. a. open CO~PKESSoR/R~C~lv~:R door (figure I ). ACCESS

a. Remove (WP 008 00).

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 evacuunit must be pumped ated, 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 pneumatic valves (4 and 9) of gas port and EPR valve. 2) from charging

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, pumping 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 close valve (II by turning inlet service valve cap and valve stem clockwise. vnlve cap and tw3. ACCESS

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. g. Note and record vacuum indicated on

f. Install receiver inlet service receiver outlet service valve cap. g. door. Close COLIPKESSORIREC~IVER

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

ELECTRICALCONTROLS

i
Ej

COMPRESSOR

CONOENSERFAN

Figure 1. System Pumpdown

(Sheet 2)

AC-180AO-MMM-000
Page 6

Figure 2. Evacuation

and Charging

AC-180AO-MMM-000

007 00
Page 7

i. Charge WP, paragraph

system 7).

with

refrigerant

(this

h. Disconnect erant drum.

center charging

line from refrig-

j. Disconnect lines from pneumatic valves (4 and 9). Open compressor suction and discharge service valves fully by turning stems counterclockwise. k. valves Install caps (4 and 9). (5 and 8) on pneumatic

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

1. If required, outlet service valves m. Install (WP 008 00).

open receiver (1 and 2, figure fan panel

inlet 1).

and

condenser

assembly

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. from charging manifold and flow through

5.

EMPTY

SYSTEM

PRESSURE NOTE

TEST.

This procedure shall be used when there is no refrigerant in the system (systemcompletely empty). a. Remove condenser 00800). fan panel assembly (WP

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

o. lf any leaks were detected, repair leaks (VAVSEA 0900.LP-001-7000) and repeat pressure test. p. Remove charging valves (9 and 4). q. Install caps valves (9 and 4). r. Evacuate with refrigerant s. Install 00800). (5 lines from pneumatic

h. Connect center charging line of charging manifold to drum of refrigerant (R-22). Open valves on manifold. c. Purge charging refrigerant drum. lines by opening valve on

and

8)

on

pneumatic

system (WP 007 00) and charge (WP 007 00). fan panel assembly (WP

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

2) from charging

condenser

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. I f. Open refrigerant drum valve fully and allow refrigerant gas to flow into the system. Allow refrigerant to flow until stabilized. g. Close charging drum valves. manifold and refrigerant

6. LIQUID CHARGING.

REFRIGERANT

ADDITION/

a. Attach center hose of manifold refrigerant supply bottle (R-22). b. Place refrigerant

gage set to

supply bottle on scale. ACCESS

c. Open COMPRESSOR/RECEIVER door.

AC-180AO-MMM-000

007 00
Page 8

d. Remove valve cap from receiver valve and pneumatic valve. c. Close the receiver outlet turning valve stem clockwise. f. Open receiver outlet turn (counterclockwise). g. Open refrigerant

outlet service

c. Place refrigerant

supply hottle on scale. ACCESS

service valve

valve

by

d. Open COMPRESSOR/RECEIVER door. c. Rcmovc villve cap (8, figure charging port pneumatic valve (9). f. Open refrigerant

service

one full

21 from

gas

supply bottle valve.

supply hottle valve

h. While purging discharge side of manifold gage set, attach discharge hose to pneumatic wlve on receiver outlet service valve. i. Add liquid refrigerant until scale indicates desired amount has been added. (If necessary, refrigernnt supply bottle may be turned upside down to discharge liquid refrigerantI. j. valve. Close valve on refrigerant supply bottle

g. While purging discharge side of manifold gage set, connect discharge hose to gas charging port pneumatic valve. h. Open refrigerant supply bottle valve fully and add gaseous refrigerant until scale indicates desired amount has been added. i. Close refrigerant supply bottle v~lvc. gas charging

,i. Remove discharge hose from port pneumatic valve (9). k. Install cap (8) pneumatic valve (9). on gas

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. m. Open receiver outlet service valve completely by turning valve stem counterclockwise. n. install valve caps on receiver valve and pneumatic valve. a. Close and secure RECEIVER ACCESS door. p. 00). 7. GAS CHARGING. REFRIGERANT ADDITION/ outlet service

charging

port

I. Close COMPRESSOR/RECEIVER door. m. Shut down air conditioning 00). 8. COMPRESSOR OIL DRAIN. unit

ACCESS

IWP

005

a. Remove condenser 008 00).

fan panel assembly

(WP

COMPRKSSOR/-

h. Remove caps (3 and 5, figure and discharge service valves.

3) from suction

Shut down air conditioning

unit

(WP 005

c. Close compressor suction and discharge service valves I2 and 4) by turning valve stems clockwise.

a. Operate air conditioning or COOL mode (WP 005 00).

unit

in DEHU,MID To prevent injury to personnel, use cure when changing compressor oil. High pressure is present which could cause serious injury.

b. Attach center hose of manifold refrigerant supply bottle (R-22).

gage set to

AG-180AO-M

SIGHT GLASS

X\

\\

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 refrigcrilnt. I)0 not cupose refrigerunt to open flame.

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). hy f. Disconnect drain g. Install h. Install 008 00). plug 10. AIR hose from oil servicing port assembly (WP port (7).

(I. Rclcasc rcfrigcront from compressor dcpresiing pneumatic valve (9, figure 2). (5. l lxc holr Iwnted container under chassis beneath in floorboard.

cap (6) on oil servicing condenser fan panel

f. Remove oil drain plug (8) and drain oil g. Install oil drain plug (8). Torque 25 to 30 foot-pounds CQA,. h. Perform puragraph 9). compressor oil addition drain

FILTER Support

SERVICING. Equipment None Materials Required Nomenclature LubricatingOil Required

(this

WI ,

9. COMPRESSOR

OIL ADDITION.

Specification or Part Number W-I,-820R (or Equivalent) a. Remove cable storage rack (1). h. Open FILTER c. Remove filter

assembly

(2, figure

4) from

Do not add oil to compres:;or unless oil level is below 118 level of sightglass when compressor is operating. a. Hemove condenser 008 00). fan panel assembly (WP

ACCESSdoor (3).

NOTE Compressor oil will absorb moisture from the atmosphere. h. Remove cap (6, ligure port (7). 3) from oil servicing

d. Inspect lilter (3) for damage or deterioration. Replace Filter (3) if unserviceable. e. Wash filter water. Rinse. (3) with mild detergent and hot

f. Allow lilter (3) to dry lightly with lubricatingoil. g. Install lxter (3)

throughly

and oil

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

pump

to oil

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

ACCESSdoor. (I) on storage rack (2).

i. Place cable assembly

AG-180AQ-M

007 00
Page 11

Figure 4. Air Filter Serwicing

007 00
Page 12

Il.

BLOWER

OIL SERVICING. Equipment None Mabxials Required Required

Support

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

Specification or Part Number Dexron II

Nomenclature Automatic Fluid Transmission

Refrigerant is toxic. To avoid injury to personnel, avoid breathing or exposure to skin or eyes. Do not expose refrigerant to open flame. d. Loosen fan cycling switch capillary and allow captive refrigerant to bleed off. e. Disconnect Fitting. fan cycling switch fitting capillary I of the

il. Open BLOWER

OIL FILL door. 3) from top of gear below drain tube

b: Remove fill plug (9, figure

case.

c. Place a suitable container located on underside ofunit. d. Open oil drain gear ease. petcock

f. Disconnect wire fan cycling switch (1).

115 from terminal

and drain

oil from

g. Using multimeter. check continuity between switch terminals 1 and 3. An open circuit should exist. h. Connect pressure source valve to fan cycling switch capillary with gage fitting, and

e. Close oil drain petcock. f. Fill gear case through fill plug hole with automatic transmission fluid (ATF) until proper level is indicated on blower oil level gage and fill cold to cold fill line (4 to 6 pints). n g. Install fill plug(9). h. Close BLOWER 12. ADJUSTMENT. Support Part Number Equipment Required Somencluture Regulated Nitrogen SOUrCe Cage 0 to 300 psi Valve Multimeter Vacuum pump Materials Required NOnI2 13. FAN CYCLING SWITCH (FSW). OIL FILL door.

i. While monitoring the multimeter. slowly increase the pressure to the fan cycling switch. The switch should close at, nominally, 245 psig. j. While monitoring the multimeter, slowly decrease the pressure to the fan cycling switch. The switch should open at, nominally, 175 psig. NOTE Dcadband (differential between switch opening and closing) is 70 psi. Deadband cannot be adjusted. Rotation of the range adjustment screw one full turn clockwise increilses 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). I. Remove pressure source nnd gage from cycling switch capillary fitting. fan to

8. Open PRESSURE b. Remove condenser 008 001.

CONTROLSdoor. fan panel assembly (WP

m.Connect tee.

fsn cyclig

switch capillary

litting

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 cycling switch (1).

115 to terminnl

1 of the fan 4). 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 fitting. high pressure cutout capillary

o. Evacuate system (this WP, paragraph

p. Open compressor suction and discharge service valves completely by turning valve stems counterclockwise. Install caps (5 and 71. q. Install
00800).

condenser

fan panel

assembly door.

(WP

r. Close PRF:SSURE CONTROLS

14. HEAD (VI).

PRESSURE

REGULATOR

VALVE (WP

a. Remove condenser 008 00).

fan panel assembly

f. Disconnect wire 114 from terminal high pressure cutout switch (3).

C of the

b. Remove valve cap from valve !I, figure G). e. Start air conditioner (WP 005 00).

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

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 discharge presswe of225 psig. f. Shut down air conditioner g. Install h. Install
00800).

to maintain

(WP 005 00).

valve cap on valve (1). condenser fan panel assembly (WP

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.

15. HIGH PRESSURE (HPCO). a. Open PRESSURE b. Remove condenser

00800).

CUTOUT

SWITCH

COSTROLSdoor. fan panel assembly (WP

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

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 range adjustment screw. Repeat steps i. thru j. as necessary. If switch (3) cannot be adjusted, replace it (WP 00s 00). m.Remove cutout switch. pressure source from high pressure

g. Using multimeter, check continuity terminals 2 and 3. An open should exist.

between

h. Connect pressure source with gage and valve to low pressure cutout switch capillary fitting. i. While monitoring the multimeter, slowly increase the pressure to the low pressure cutout switch. The &itch should close & nominally. 17 psig. j. While monitoring the multimeter, slowly decrease the pressure to the low pressure cutout switch. The switch should open at, nominally, 0 psig.

II. Connect wire 114 to terminal ~prcssurc cutout switch (3). o. Connect capillary fitting high to tee. pressure

C of the high

cutout

switch

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

NOTE Deadband (differential between switch opening and closing) is 17 psi. Deadband cannot be adjusted. 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.

s. Close PRESSURE 16. LOW PRESSURE (LPCO). a. Open PRlZ%RE b. Remove condenser 008 00).

CO.UTROLSdoor. CUTOUT SWITCH

CONTROlSdoor. fan pwel assembly (WP

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

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 cutout switch. m.Connect source from low pressure 2 of the switch. capillary 4).

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 lary fitting. low pressure cutout switch cilpil-

wires 113 to terminal

n. Connect low pressure litting to tee.

cutout switch

o. Evacuate system (this WI, paragraph p. Open compressor service valve completely counterclockwise. Install q. Install 008 00). condenser

suction and discharge by turning valve stems caps (5 and 7). fan panel assembly (WP

f. Disconnect wire 113 from terminal low pressure cutout switch (2, figure 5).

2 of the

r. Close PRESSURE

CONTROLSdoor.

AG-180AO-MMM-000

007 00
Page 10

PRESSIJRECONTAOLS

5 4

LOW

HIGH

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. by rotating

switchces) 00).

cannot

be adjusted,

replace

it (WP 009

b. Set switches to close (cut in) adjusting screw (4, ligure 7) as follows: PS4 - 55 psig PS5 50 psig

o. Rleed remaining pressure from line(s) 1 ~1tnov~pressure source from PS4 and/or I % p. Connect wire 128 to terminal q. Install cover (2) and screw (3). r. Connect PS4 and/or PS5 capillary fittings 4), L of PS4

Lund

to

c. Set switches to open (cut out) BS follows rotating adjusting screw (5): PS4 30 psig PS5 25 psig d. Remove condenser 008 00). fan panel assembly

by

tees. s. Evacuate system (this WP, paragraph

(WP

t. Open compressor suction and discharge service valves completely by turning valve stems counterclockwise. Install caps (5 and 7, ligure 5). u. Install 008 00). condenser fan panel PRESSURE assembly (WP

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 allow captive refrigerant to bleed off. g. Disconnect PS4 and/or PS5 capillary fitting and

Y. Close and secure door.

CONTROLS SWITCH (PS6). door. by

IS. PRESSURE DIFFERENTIAL (OPEN ON PRESSURE RISE) il. Open PRESSURE CONTROLS

fitting.

h. Remove screw (3, figure 7) and cover (2) i. Disconnect wire 128 from terminal Lof PS4

b. Set switch to close (cut in) at 20 psig rotatingadjustingscrew (4, ligure 7)).

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. n. Adjust switch(es) as required per steps b. through g. Repeat steps n and o. as necessary. If

c. Set switch to open (cut out) at 45 psig by rotatingadjusting screw (7). d. Remove condenser 008 00). fan panel assembly (WP

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 refrigerant to bleed off. g. Disconnect fitting and allow captive

PS6 capillary

fitting.

h. Remove screw (3, figure 7) and cover (2). i. Disconnect wire 135 from terminal Lof PS6

j. Using B multimeter, between terminals L and Ml. exist.

check continuity Continuity should

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 increase the pressure to the switch. The switch should closeat, nominally, 45 psig. m.While monitoring the multimeter, slowly decrease the pressure to the switch. The switch should close at. nominally, 20 psig. 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 q. Install cover (2) and screw (3). fitting to tee. 4). L of PS6.

b. Adjust limit switches (8 and 10, figure 10) as follows: (1) Remove screws (1) washers (2) and nuts (3). (2) Loosen clamp (7) and slide clamp (7) and flexible duct off upper mount weldment (4). (3) Remove upper mount weldment (4)

r. Connect PS6 capillary s. Evacuate

To prevent injury or damage to equipment, exercise care when workir.g with electrical power applied to air conditioning unit.

system (this WP, paragraph

t. Open compressor suction nnd discharge service valves completely by turning valve stems counterclockwise. Install CBDS(5 and 7, fiwre 5). I u. Install 008 00). condenser fan panel PRESSURE assembly (WP

(4) Apply il 1 lOV, 60 Hz, single phase power supply across terminal C of the open limit switch, I.$ and ground (terminal block locations TBI-6 throughTBl-II). (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 limit switch (IO). actuator bypass sealing ilrm valve against (5) in full to coupling open open (61

Y. Close and secure door. 19. MAIN SERVICE

CONTROLS

CIRCUIT

BREAKER. panel. to 2: (2,

8. Open ELECTRICAL b. Set circuit figure 8). breaker

COSTROLS trip adjustment

c. Close ELECTRICAL 20. MOTOR STARTERS

CONTROLS (Kl, K2, K3).

panel (8) position. panel screw. (91 Position Apply

a. Open ELECTRICAL

CONTROLS

compound

NOTE If nuisance tripping of motor starters occurs, adjustment may be varied 90 to 110% of setpoint. b. With small blade screwdriver rotate adjustment screw (1, figure 9) as required. c. Close ELECTRICAL 21. BYPASS AIRFLOW CONTROLS CONTROLLER. fan panel assembly IWP panel. trip CQA)

(10) Torque

coupling

(6) screw

87 in-lbs.

(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.

il. Remove condenser 008 00).

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 RESET BUTTON

STARTER RESET BUTTON

STARTER RESET BUllON

Figure 9. Motor

Starters (Kl, K2, K3) Adjustment

AG-180AO-MMM-000
Page 23

FLEXIBLEOUCT

kLo.\

LS-4 CLOSED LIMIT SWITCH

\
COUPLING NOT SHOWN FOR CtARlTY

ACTUATOR ARM

mAPPLY SfALING COMPOUNO TO THREADS PRIOR TO ASSEMBLY. 2 TOROUEFASTENERSTO 87 INCH-POUNOS 8 3 TREAT EXPOSEDPORTION OF SHAFTS PER MIL-P-IIS. TYPE p.,, USING Mlt~C~l61730 CORROSIONPREVENTIVE 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 008 00). 22. INLET condenser AIRFLOW fan panel assembly (WP

controller frame. additional sliding Tighten screws (2).

Adjust plate

the switch to allow travel before shutoff.

(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. (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.

CONTROLLER (1, figure 4) from

a. Remove cable assembly storage rack ( 2.). b. Open FILTER

ACCESS door (8, figure 11) screws

c. Remove insulation

(7) Disconnect

power supply to the unit.

d. Remove access cover (5) by removing (7) and washers (8).

e. Apply continuous bead of gasket forming compound around access cover (3) mating surface and holes. f. Install xcess (61 and screws (7). cover (5) by installing washers

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 TBl2 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. (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

g. Apply insulation adhesive to insulation (8) and mating surface. When adhesive is dry to touch, install insulation (8). h. Close FILTER i. Replace cable storage rack (2) 23. BRAKE. Support Equipment None Materials Required None 8. Position position. b. Rotate tighten. brake lever (1, figure 12) in vertical Required ACCESS door assembly (1, figure 4) on

adjustment

screw

(2) clockwise

to

c. Apply brakes by positioning horizontal position.

brake lever (1) in

AC-1 80AO-M M M-000

007 00
Page 25

OPEN

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 MOTOR BURNOUT. Support Equipment None Materials Specilicationor Pm-t Number Required Noeclatre Refrigerant (R-113) COMPRESSOR

Required

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. h. Close compressor suction and discharge service valves and bleed refrigerant from compressor. e. Remove suction and d&ha.-ge shut-off valve bolts and all other connections to damaged cornpressor. 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 personnel avoid exposure to skin or expose refrigerant to

To avoid injury breathing or eyes. Do not open flame.

e. Replace filter

drier core (WP 008 00). breaker. CBI, OFF.

f. Set main service circuit

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

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 (5) Open INSTRUMENT grip latches countereloekwise. panel by turning

(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. h. Close compressor suction service valve supply to comOpen refrigerant system. under hole in lloor-

NOTE This procedure is difficult, timeconsuming and expensive. This procedure should be performed in the Field only if depot level facilities are unavailable or inaccessible. i. Connect R-113 refrigerant pressor discharge service valve. supply valve and flood refrigerant j. Place catchpan board. or bucket

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

Y. Close solenoid

valves as follows:

I. Close compressor ice valves. m. Replace filter/drier

suction and discharge

serv-

(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

core (WP 008 OO), (3) Remove three ,jumper wires from tcrminals 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 5) CONTROLSdoor 8)

n. Close R-l 13 refrigerant supply valve and disconnect supply from compressor discharge service valve. o. Discard R-113 refrigerant pan or bucket. collected in catch-

p. Evacuate system (this WI , paragraph q, Connect R~l13 refrigerant pressor discharge service valve valve. r. Open compressor discharge flood refrigerant system. s. Repeat stepsj. througho. t. Install new compressor compressor oil level. (WP 008 00).

w. Charge the system (this WI . paragraph

supply to comand open supply

service valve and

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. 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.

Check

u. Evacuate system (this WP, paragraph

5).

AG-180AO-MMM-000
15 May 1991

008 00
Page 1 of 76

ORGANIZATIONAL REMOVAL AIR AND

AND

INTERMEDIATE

MAINTENANCE INSTRUCTIONS

INSTALLATION AIRCRAFT AlM32C-21

CONDITIONER,

GROUND

COOLING

PART

NUMBER

1603ASlOO-1 I

Reference Material ............. ............................ Operating Instructions. Servicing. Lubrication. Adjustment, and Cleanup After Compressor Motor Burnout ........................... Fabric&m and Inspection of Brazed Piping Systems. ..................

WP 005 00 ...... WP 007 00 NAVSEA 0900.LP-001.7000

Alphabetical Index Subiect AftercoolerModule.. ..................................................................... .. .. ................. Installation. ................................................ .................................................................. Mat&&Required Removal ............................................................................ SupportEquipmentRequired ......................................................... Air Conditioner. Aircraft Ground Cooling, A/M32C-21 ....................................... Atmospheric Relief Valve (V2) ............................................................. ...... ....... Installation. ..... .................................................... .................................................................. Mat&&Required Removal ............................................................................ ......................................................... SupportEquipmentRequired ........................................................................ BlowerAssembly .................................................................. Installation.......: .................................................................. MaterialsRequired Removal ............................................................................ ......................................................... SupportEquipmentRequired Blower, Blower Motor, Precooler and Aftercooler Modules. ..................................... ......................................................................... BrakeAssembly ... .. ............. Installation. ..................................................... .................................................................. Mat&&Required Removal ............................................................................ SupportEquipmentRequired ......................................................... Chassis and Wheel Assemblies. ............................................................. ................................................................... Compressor Assembly Installation .......................................................................... .................................................................. MaterialsRequired Removal ............................................................................ SupportEquipmentRequired ......................................................... Compressor, Receiver and Condenser Coil Assemblies. ........................................ .......................................................................... CondenserFan Installation .......................................................................... .................................................................. MaterialsRequired Removal ............................................................................ Support Equipment Required .........................................................

m ..3 9 39 39 39 39 4 61 62 61 61 61 28 28 28 28 28 29 75 75 75 75 76 64 62 63 62 62 62 59 18 18 18 18 18

AG-180AO-MMM-000

008 00
Page 2

Alphabetical

Index

(Continued)

m Subiect 19 ........................................ ........ .. .... C,,ndc,,ser Fan md Motor ...................................................................... 16 Cl,,,dcnscr~anMol,,r 18 .......................................................................... installation .. ....... ........... ....................................... 16 .Matcriuls Kcquircd ........................................................... 18 .... .. ... I~c,nonl .. ..... .... ............................. .. 18 Support Equipment Kequircd ........ 37 Coupling, Illowcr to Mlotur ......................................................... 37 .......................................................................... lnstall;ltion 37 .................................................................. MaterialsKcquired 37 Kcmoval ............................................................................ ............................ ............................ 37 Support Equipment Kequired 22 ......................................................................... I)uctSto~agcHack 22 Instnllation .......................................................................... ........ .. ............................... 22 .. .. Materials Required ............ 22 ............................................................... .... Rcmoal ....... ... 22 Support Equipment Kequired ..................................................... 26 I~Ilcctrical Controls Panel ................................................................... 26 .......................................................................... Instullati(,il .. 26 ..................................... ......................... Materials Kequircd 26 ............................................ Ke~noval ............................... 26 ... ................................................ Support Equipment Kequired 53 Ihpmtor Pressure Kegulato ,. Valve ....................................................... 54 Installation .......................................................................... ....... ........... ......................................... 53 Materials Kcquircd ... 53 ............................. .... ................ Removal ....... .. 53 ...................................................... Support Equipment Koquiwd ....... 40 I~ iltcr I)rier ................................................................... 40 Installation .......................................................................... ... 40 .......................................................... ?vlaterialsKequired .... ...... 40 .................................. .. ..... K~moval ... ... 40 .............................................. SupportEquipmcntKequired ..... 63 I ront Wheel Assembly ............................................................ 70 Installation .......................................................................... 70 .._ ........................... .................................... Materialsl~cquired 70 Kemoval ................................................................... ......... 63 .. .............................. Support Equipment Required 54 ............................................ Ileud l rcssure Kugulator Valve ............. ., ., ., ., ., ... .. 54 Installatil)n ...................................................... .. 54 ............................................................. IMMaterials Kcquired . 54 ......................................................................... Kernoval 54 .. ........................................ .. Support Equipment Required .. ...... 55 ..... .. ......................................... ........ Ilol Gas Rypass Valve 55 Installation .......................................................................... .. 55 ................................... ..................... Materials Kequircd ... ... 55 ................................................................. Ikmxll ..... 55 ..................................... ............ Supporl Equipment Kcquired 26 .................. Inst~umentPancl......................................................, 27 Installation .......................................................................... 26 ..................... MaterialsKequired ............................................ .._ ... ............ 27 Removal ......................................................... 26 ............ ......... ... .. .. ..................... Support Equipment Required

AG-180AO-MMM-000

008 00
Page 3

Alphabetical Index(Continued) m Subiect 35 ....................................................................... ~lotor30HPBlower 36 Installation .......................................................................... 35 MaterialsRequired .................................................................. 35 Removal ............................................................................ ......................................................... SupportEquipmentRequired 35 . ........... ..................................... 23 Panel Assemblies and Duct Storage Rack ..... .. .... 7 .. ....... ......... ..... ......... Panel and Door Assemblies I recoolerModule...........................................................................3 8 38 Installation .......................................................................... 38 MaterialsRequired .................................................................. 38 Removal ............................................................................ 38 ........ ....... .............................. Support Equipment Required .. 22 ................................................................... PressureControlsPanel. 22 Installation .......................................................................... ...................... 22 MaterialsRequired ........................................... 22 Removal ............................................................................ ............ 22 ........................ ............ Support Equipment Required ...... 56 .......................................................................... QuenchValve ............. 56 lnstallation............................................................~ 56 MaterialsRequired .................................................................. 56 Removal ............................................................................ 56 ....................................... Support Equipment Required ................. ........................................ 71 I~earWheelAssemblies............................: 58 ....................................................................... ReceiverAssembly 61 Installation .......................................................................... 58 MaterialsRequired .................................................................. ..I ......... 58 Removal ................................................................ .............. SupportEquipmentRequired 58 .......................................... ...... ... 41 ........... ............. ................ Refrigeration Piping Assembly .... ... ...... ... ............ ........ ......... 70 Roadside and Curbside Rear Wheel Assemblies 70 Installation .......................................................................... 70 MaterialsRequired ............ ..I ................................................... 70 Removal ............................................................................ .. 70 ............................................... Support Equipment Required ... ...... ... 40 Solenoid Valves (Sl, 52, S3, S4, S5,, S6). ........................................ 53 lnslallalion .......................................................................... 40 MaterialsRequired .................................................................. ......... 40 Removal .................................................................. ........... 40 Support Equipment Kequired .. ......................................... ........ Thermostatic Expansion Valves(X1, X2, X3, X4). .................................. 57 57 Installation .......................................................................... .... 57 MaterialsRequired ............................................................ ...... 57 Removal ................................................................... 57 Support Equipment Rcquircd ........................................................ Record of Applicable Technical NWlC Directives

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 NO 1

PART NUMBER 1603ASlOO

DESCRIPTION AIRCONDITIONER,AIRCRAFT GROUNDCOOLING, A/M32C-21. . . . . . . . . . . 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, COMBATTYPEAIRCKAFT , LOWPKESSURE . . CLAMP,HOSE: TYPE F . . . . . . . . AIR . . DUCT, FLEXIBLE IIoSE/16632/AM~:2097/. . .

UNITS PERASSY

USABLE ON-CODE

SM&R CODE

PEOGD

NONUMBER

N/A

NONUMBER

S/A

NONUMBER

N/A

NONUMBER

S/A

NONUMBER

S/A N/A

NONUMBER NONUMBER

S/A

1603AS110

ADGGG AGGGG PACZZ PAGZZ I XBG%%

10 11 12 13

1603AS625 MS16051.I MS3584216 1603AS180

Figure 1. Air Conditioner,

Aircraft

Ground

Cooling,

A/M32C-21

(Sheet 21

AC-180AO-MMM-000

008 00
Page 6

INDEX X0 14 15 16 17

PART NUMBER 1603AS602 1603AS640 MS35842.15 NO NUMBER -. .

DESCRIPTION PACKING, PREFORMI 16632iDEA-003391 . . . . CONNECTOR ASSEMBLY/ 905981 . . . . . . . . . CLAMP, HOSE: LOW PRESSURE-TYPEF . . _ . PRECOOLER AND AFTERCOOLER MODULES/SEE FIGURE 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 . . . . . .

UNITS PERASSY

USABLE ONCODE

SM &R CODE

1 1 2 5

PAGZZ AGGGG PAGZZ

N/A

18

1603AS487

AGGGG

19

5SE01030.4

20 21 22

MS90556C 44152P MS3368.4.4D 5SEO1030.5

1 1 1

AGCGG PAGZZ PAGZZ

PAGZZ

23

CAB-A-1

24 25 26

M23053/ 2.109-c MS20659.113 1603AS274

. . _ .

1 4 1

PAGZZ XBGZZ PACZZ

. . .

. . . 1 PAGZZ

Figure 1. Air Conditioner,

Aircraft

Ground

Cooling,

A/M32C-21

(Sheet 3)

AG-180AO-MMM-000

008 00
Page 9

INDEX NO

PART NUMBER NO NUhlBER .

DESCRIPTION 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- CONDENSER FAN.. . . . . . /ATTACHING PARTS/ . . . SCREW,MACHINE *.. .

UNITS PERASSY

USABLE ON CODE

SM &R CODE

1603AS109

1 34 34 8 8

XBGGGH PAGZZ PAGZZ PAGZZ PAGZZ

2 3 4 5 6 7 8 9 10

MS27183.10 MS90725.5 MS27183-15 MS35206.295 1603AS179 1603AS371 1603AS666 M24243l l-F604 1603AS688

. . . . .

XBGCG
XBGGG XBGGG

. . . .

. . . . _ .

FAG%%

XHGZZ
XBGGG PAGZZ

11

1603AS361

. .

. .

1 10

12 13 14

MS35190.288 1603AS322.12 1603AS322.9

. . . .

. 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/ LOCK . . . . WASIIER, . SCREW,MACIIINE . .

XHGGG XBGGG
XBCGG I AGZZ PAGZZ

15

1603AS360

. .

1 . . IO 10

16 17

MS35333.40 MS35206280

. . . .

Figure

2. Panel and Door Assemblies

(Sheet 2)

AC-180AO-MMM-000

008 00
Page 10

INDEX NO 18

PART NUMBER 1603AS322.9 . .

DESCRIPTION . 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 TASSE,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 . . . . . .

UNITS PER ASSY

USABLE ON CODE

SM &R CODE

XBGZZ

19

1603AS322.10

XBGZZ

20

1603AS322.I

. . . . . . . . .

2 2 2 2 2 12 2 8 8

XBGZZ PAGZZ PAGZZ XBGZZ .MGGZZ PAGZZ PAGZZ PAGZZ PAGZZ

21

NAS1464.044. 04c IMIL-R-242431 lF402 1603AS675 1603AS678 .MS35206-280 MS51922.1 MS35191.272 MS21044S3 1603AS420

22 23 24 25 26 27 28 29

. . .

XBGGG PAGZZ PACZZ

30 31 32

MS35338.43 MS35207.263 1603AS687

. . . . . .

MGGGZ
XBGZZ

33

1603AS322-19

34

1603AS322.8

XBCZZ

Figure 2. Panel and Door Assemblies

(Sheet 3)

AC-180AO-MMM-000

008 00
Page 11

INDEX NO 35

PART SUMBER 1603AS323 . . .

DESCRIPTION LATCH /94222/43-1-16-O/ . . /ATTACHING PARTS/ RIVET,POP

UNITS PERASSY

USABLE ONCODE

SM &K CODE

. .

PAGZZ

36

M24243/6 A403H 1603AS509

. .

. .

37

38

MM2424316 A403H 1603AS741

. . . . . . -.*.. . PLATE, OPERATING INSTRUCTIONS . . . . /ATTACHING PARTS/ . RIVET,POP . . . . . . ..*..

12

PAGZZ

1 6

MGGZZ
PAGZZ

39

40 41 42 43 44

m35190-253 .MS27183-7 MS21044SO8 1603AS684 1603AS739

. .

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 . . .

XBGZZ PAGZZ PAGZZ PAGZZ

. .

MGGZZ
XAGZZ

45 46

1603AS718 1603AS740

. .

. .

PAGZZ

47 48 49

.MS51922-5 1603AS744 1603AS746

. . .

. . .

PAGZZ PAZZZ XAGZZ

. . . . .

XBGZZ
XBGZZ PAGZZ PAGZZ I AGZZ

50 51 52 53

1603AS742 .MS35190-253 MS27183.7 MS21044NOS

. . . .

. . . .

Figure 2. Panel and Door Assemblies

(Sheet 4)

AC-180AO-MMM-000

008 00
Page 12

I I
INDEX NO 54 55 56 57

PART NUMBER 1603AS684 1603AS677

I . . . . . .

DESCRIPTION BRACKET, SUPPORT 182851/107045/ . . . BAR, REMOVABLE, R.H./82851/107037/ . /ATTACHING PARTS/ BOLT, CARRIAGE /82851/156950/ . . . WASHER, FIBER, FRICTION 1828851/157040/. . . NUT, SELF-LOCKING *..

1 Pii-i%Y

1 ::i%i

1 sdMo:i

. .

. .

MGGZZ XAGZZ

1603AS718 1603AS740

. . . .

. .

PAGZZ

58 59 60

MS51922.5 1603AS743 1603AS745

. . . . . .

. .

PAGZZ PAZZZ XACZZ

61

1603AS421

. .

62 63 64 65 66 67 68 69 70 71 72 73

MS35338.43 MS35207.263 1603AS258 MS27183.12 MS35206.295 iMS90725-29 lMS9072532 MS24693.5273 LMS90725.5 MS27183.IO IMS51922-1 1603AS685

. . . . . . . . . . . . . . . . . . . . . .

STOP, SUPPORT, R.H. BAR ASSEMBLY, STATIONARY, R.H. /82851/107011/ . . . COVER, TOP, OUTERFUSEBOX. . . . . . /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 . *.. : BRACKET, HOLD-DOWS, PANEL . . . . . . . /ATTACHING PARTS/ WASHER.LOCK . . .

. .

. . . . . . . . . . . . . . . . . . . . .

1 I 10 10 1 34 11 11 12 10 10 20 10

XAGZZ MBGZZ PAGZZ PAGZZ MGGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ

. .

. .

. .

2 2

MGGZZ PAGZZ

74

MS35338.44

. .

Figure 2. Panel and Door Assemblies

(Sheet 5)

AC-180AO-MMM-000

008 00
Page 13

INDEX NO 75

PART NUMBER 1603AS688 .

DESCRIPTION SCREW, MACHINEI INTERCHANGEABLE MS35357, NOMINAL SIZE ,251. . . . . . .-*PANEGCURBSIDE . . IATTACHING PARTS/ . SCREW.CAP. _ . . . . WASHER.FLAT . . SCREW.CAP. _ _ . . *.. .

UNITS PERASSY

USABLE ON CODE

SM &R CODE

WITH . . . . 2 1 8 IO 2 XBGZZ MGGZZ PAGZZ PAGZZ PAGZZ

76 77 78 79 80

1603AS255 MS90725.32 MS27183.12 MS90725.29 1603AS629

. .

. . . _ _ . . . .

81 82 83 84

MS35207.264 MS27183.42 MS21044N3 1603AS630

. . . .

. . . .

85 86 87 88 89 90 91

1603AS626 1603AS628 1603AS566 MS35207.264 MS27183.8 MS21044N3 1603AS63 I

. . . . . . . . . . . . . .

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 . . . . . . . *.. . . .

_ . _ . . _ . . _ .

XBGGG PAGZZ PAGZZ PAGZZ MGGZZ

PAGZZ PAGZZ XBGZZ 1 2 1 PAGZZ PAGZZ PAGZZ

. . _ _ . . . . . .

92 93 94 95

MS90725.5 MS27183.10 1603AS627 1603AS455

BRACKET, DUCT COVER.STORAGE . /ATTACHING PARTS/ _ . . . . SCREW,CAP. . . WASHER,FLAT _ . *.. . . . .

. . . . . . PAGZZ PAGZZ

96

MS27183.I2

. .

RECEPTACLE, l/4 TURN/ 94222/85-47.101.15/ _ _ . _ PANEL, REAR, CURBSIDE-WELDMENT . _ /ATTACHING PARTSI WASHER,FI.AT . _ _ . .

PAGZZ XBGGG PAGZZ

Figure 2. Panel and Door Assemblies

(Sheet 6)

AG-180AO-MMM-000

008 00
Page 14

INDEX X0 97 98 99 100

PART NUMBER MS90725.32 1603AS666 M24243/1-F604 1603AS688 . . . . . . . .

DESCRIPTION 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 17U153148B7796l . . . RACK, CABLE STORAGE. /ATTACHING PARTS/ SCREW,CAP. . . . . WASHER,FLAT . . . * DOOR STOI , UPPERWELDMENT. . . . /ATTACHING PARTS/ SCREW,MACHINE . WASIIER, FLAT . NtiT,SELFLOCKING * . . . . . . . . . .

UNITS PERASSY

USABLE ON CODE

SM &R CODE

PAGZZ XBGZZ PAGZZ

. .

XBGZZ XBGGG PAGZZ

101

1603AS691

. .

. .

102 103

M24243/1-F604 1603AS688

. .

1
12 4 8 8

XBGZZ

104 105 106 107 108

1603AS182 1603AS601 MS90725.58 MS2-7183.I4 1603AS441

. .

LB . . . . . , .

PAGZZ XRGZZ PAGZZ PAGZZ

. . . . . .

. . . . . . .

MGCLZ PAGZZ PACT% FAG%%

109 110 III 112

MS35190.287 iMS27183.10 IMS51922-1 1603AS445

. . . . . . .

113 114 115

MS90725.5 MS27183.10 MS51922-I

. . .

DOOR, FILTER ACCESSWEI.DMES I . . . . . /ATTACHING PARTS/ _ . . . . SCREW,CAP. _ . _ . WAStIER, FIAT . . NUT, SELFLOCKING *

. . . . . . .

XBGGG
PAGZZ FAG%% PAGZZ

Figure 2. Panel and Door Assemblies

(Sheet 7)

AG-180AO-MMM-000

008 00
Page 15

PART NUMBER 116 1603AS171 . .

DESCRIPTION . PLATE, WIRING DIAGKAM _ . _ . . IATTACIIING PARTS/ . . RIVET, POP. . . . . *..

UNITS PERASSY

USABLE ON CODE

SM &R CODE

. . . .

1 10

XBGZZ PAGZZ

117

M24243l 6.A403F 1603AS322.17

118

. .

119

1603AS322.18

120

1603AS434

121 122 123 124 125

MS90725.32 MS27183.12 1603AS666 MS24243/1-F604 1603AS688

GASKET, PANEL, 28.06 L X .50 WIDE 186730/4tllNDB/. . . . . . . GASKET, PANEL, 28.80 L X .50 WIDE /86730/4111NDB/. . . . . . PANEL, REAR, ROADSIDEWELD.MENT. . . . . . /ATTACHING PARTS/ SCREW,CAP. . . . . . WASHER,FLAT . , . *.. DOOR,INSPECTION . . /ATTACtIINGPARTSI . RIVET. . . . . . . . . SCREW, MACHINE/ INTERCHANGEABLE WITH MS35357, NOMINAL SIZE .251. . . . . . . DOOR, STOP, LOWERWELDMENT. . . . . . WASIIER, FLAT . . . SCREW, CAP. . . . . . PANEL,ROADSIDE . . . /ATTACHING PARTS/ *.. WAStIER, FLAT SCREW,CAP. . SCREW,CAP. . . . . . . . . .

XBGZZ

. . .

2 1 10 10 1 1

XBGZZ XBGGG PAGZZ PAGZZ XBGGG PAGZZ

. .

. .

. . . . .

XBGZZ
MGGZZ I AGZZ PAGZZ MGGZZ

126 127 128 129

1603AS435 MS27183.12 MS90725.32 1603AS254

. . . .

130 131 132 133 134

MS27183.12 MS90725.32 MS90725.29 1603AS489 MS27183.IO

. . . . .

. . . . . .

PAGZZ PAGZZ PAGZZ XBGGG

DOOR, ACCESS. . . . IATTACIIING PARTS/ WASIIER.t I.A I . . .

PAGZZ

Figure 2. Panel and Door Assemblies

(Sheet 8)

AC-180AO-MMM-000

008 00
Page 16

INDEX NO

PART NUMBER

DESCRIPTION

UNlTS PERASSY

USABLE ONCODE

SM &R CODE

135 136

MS90725-3 1603AS322-13

. .

. .

137

1603AS322-14

138

1603AS266

. .

139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154

MS90725.5 MS27183.10 1603AS265 MS27183-10 MS90725.5 1603AS250 MS27183-12 MS90725-32 MS27183.14 MS90725.58 MS27183-10 MS90725-5 1603AS594 MS27183.12 MS90725.32 1603AS404

. . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . .

155 156 157

MS27183.10 MS90725-5 1603AS322.16

. . , .

158

1603125322.16

SCREW,CAP. . . . . . . GASKET, PANEL, 10.00 L X .50 WIDE /86730/4111NDBI . . . . , GASKET, PANEL, 12.00 I. X .50 WIDE /86730/4111NDBl . . . . -*-. GRILLE, CONDENSER COIL . . . . . . . . . . /ATTACHING PARTS/ SCREW, CAP. . . . . . WASHER.FLAT . . . . . ..*-. STOP,GRILLE . . . . . . /ATTACHING PARTS/ WASHER,FLAT . . . . . SCREW,CAP. . . . . . . PANEL,FRONT . . . . . IATTACHING PARTSI WASHER,FLAT . . . . SCREW,CAP. . . _ . . . WASHER,FLAT . . . . . SCREW,CAP. . . . . . . WASHER,FLAT . . . . . SCREW, CAP. . . . . . . ..*-. KEEPER,TOWBAR . . . . /ATTACHING PARTS/ WASHER,FLAT . . . . . SCREW . . . . . . . . . ..*.. 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/ . . . .

PAGZZ

XBGGG

2 40 40 2 16 16 1 8 8 17 17 9 9 I 2 2

XBGGG PAGZZ PAGZZ MGZZZ PAGZZ PAGZZ MBGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ MGZZZ PAGZZ PAGZZ

XBGGG PAGZZ PAGZZ

XBGZZ

XBGZZ

Figure 2. Panel and Door Assemblies

(Sheet 9)

AG-180AO-MMM-000

008 00
Page 17

INDEX NO

PART NUMBER

DESCRIPTION

UNITS PERASSY

USABLE ON CODE

SM &R CODE

159

1603AS688

160 161 162 163

MS35338.44 1603AS101 M24243/1-8404 1603AS623

. . . . . . . .

164 165 166

MS27183-10 MS90725-3 1603AS322.13

. . .

. . .

SCREW, MACHINE /INTERCHANGEABLE MS35357, NOMINAL SIZE .25/ . . . . WASHER,LOCK . . PLATE, DATA . . . /ATTACHING PARTSI RIVET . . . . . . .-*DOOR, ACCESS, DUCTSTORAGE . . /ATTACHING PARTS/ WASHER,FLAT . . SCREW,CAP. . . . * GASKET, PANEL, X .50 WIDE /86730/4111NDBI . GASKET, PANEL, X .50 WIDE /86730/4111NDBl * . . . .

WITH . . . . . . . . . . . . 2 2 1 4 XBGZZ PAGZZ MGGZZ PAGZZ

. . .

. . . . . .

XBGGG PAGZZ PAGZZ

12.00 L . . . . 10.00 L . . . . 2 XBGZZ

167

1603AS322-14

XBGZZ PAGZZ PAGZZ PAGZZ

168 169 170

NAS1298.3-3 MS21044N3 MS27183.9

. . .

. . .

SCREW, BRAZIER HEAD. NUT,SEI.F-LOCKING . . WAStIER,FLAT . . . .

Figure 2. Panel and Door Assemblies

(Sheet 10)

AG-180AO-MMM-000

008 00,
Page 18

1. CONDENSER Support Part Number

FAN. (4). Equipment Required Nomenclature Wrench, Torque O-50 ft-lhs Nomenclature Corrosion Preventive Compound, Solvent Cutback, Cold Application, Grade 1 Required None

d. Loosely

install

washers

(21, (3). and screws

e. Check fan-to-grille clearance hy rotating fan (17). Adjust condenser fan grille (1) so that fan (17) rotates freely. f. Tighten screws (4)

Soecification or Part Number MIL-C-16173D

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 figure 2). 4. CONDENSER Support Part Number condenser FAN fan panel MOTOR. Required
SOIW3lCl~lU!T

asremhly

(I,

Materials

2. REMOVAL. a. Shut down unit (WI 005 00).

Equipment

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. b. Remove condenser figure 2). fan panel assembly (1, ( 2)

1Konc 5. REMOVAL. a. Shut down unit IWP 005 00). IW*IININGQ To prevent injury to personnel or damage to equipment, unit shutdown and removal of power source must bc completed before removing condenser fan motor. h. Remove condenser fan (this WP, paragraph wiring. 1). c. Tag and disconnect

c. Remove screws (4, figure 3), and washers and (3) fromcondenser fan grille (1). d. Remove condenser fan grille e. Remove screws (20). f. Place screws (20) in two hushing(l8). g. Tighten h. Remove bushingtIE). push-off holes (1)

in

screws (20) until fan blade loosens condenser fan (171, key (19) and

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) 6. INSTALLATION. a. Position (30). h. Position shims fan motor (24). 126) and spacers 125) under motor (24, figure 3) on motor mount

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.

AG-l$OAQ-MMM-000

008 00
Page
19

NUSED HOLES IN FEET ARE UP. SHIM CONOENSERFAN MOTOR AS REOUIREOTO POSlTlON CENTER OF FAN HUB 34 INCHES FROM CENTERLINEOF CURBSIOE CONOENSER FAN PANEL ASSEMBLY BOLT HOLES AND 4.42 INCHES AFT OF FOURTH CONDENSERFAN 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 PREVENTIVECOMPOUNO GRI.

Figure 3. Condenser

fan and Motor

(Sheet I

of

3)

AC-180AO-MMM-000

008 00
Page 20

I I
INDEX NO 1

PART NUMBER I NO NUMBER 1603AS115

DESCRIPTION CONDENSER FAN AND MOTOR /SEE FIGURE 1 FOR NHA/ . . GRILLE, WELDMENTCONDENSERFAN . . . /ATTACHING PARTS/ . . . . . . WASHER,FLAT . WASHER, LOCK, SPRING. . . SCREW,CAP. . . . _ . *.. . .

. . . .

1 16 16 16

XBGZZ PAGZZ PAGZZ PAGZZ

.MS27183-10 MS35338.44 MS90725.8 1603AS117

iMS90725-8 MS27183-10 MS35338-44 1603AS116

. . . .

FRAME, CURBSIDECONDENSERFAN . . . . /ATTACHING PARTS/ . SCREW,CAP. . . . . . . . WASfIER,FLAT . . . . . . WASHER, LOCK, SPRING . t.. . FRAME, ROADSIDECONDENSERFAN . . . _ /ATTACHING PARTS/ SCREW,CAP. _ . . . WASHER,FI.AT . . . WASIIER, LOCK, SPRING . *.. . . . .

I 2 2 2

XBGZZ PAGZZ PAGZZ PAGZZ

XBGZZ PAGZZ PAGZZ PAGZZ

10 11 12 13

MS90725.8 MS27183.IO MS35338.44 1603AS118

. . . . . . . .

14 15 16 17

MS90725-58 MS27183-14 MS51922.9 1603AS120 -

. . . .

FRAME, REARCONDENSERFAN . . . /ATTACHING PARTS/ . SCREW, CAP. . . . . . . WASHER,FLAT . . . . . NUT, SELF-LOCKING . . *.. .

1 4 4 4

XBGZZ PAGZZ PAGZZ PAGZZ

1.3

1603AS750

19 20

KEOlAAOl 0838250 lMS90725-60

FAN, CONDENSER16398Pd 42.12.5ZLPPG-40AS . . . /ATTACHING PARTS/ . BUSHING,SPLIT, TAPERED, MALLEABLE /6A844/ PI . . . . . . . . . KEY318WX3116HX 2.88L. . SCREW,CAP. . . . . . .

XBGGG

XBGZZ XBGZZ PAGZZ

Figure 3. Condenser

Fan and Motor

(Sheet 2)

AG-180-AO-M

M M-000

008 00
Page 21

INDEX NO 21

PART NUMBER . . .

DESCRIPTION BLADE/63988/ 42.12-5ZL-PAGl. . . /ATTACHING PARTSI f BOLT,1/4X20XILC . HUB/63988/HZ12.03/ .06ASFORPI _ . . *

UNITS PERASSY

USABLE ON CODE

SM &R CODE

. . . . . .

12 12 1

XBGZZ XBGGG XBGZZ

22 23

. . . .

24

1603AS129

. .

25 26 27 28 29 30

1603AS748 1603AS751 MS90725-I 18 MS27183.18 MS51922.33 1603AS114

. . . . .

. . . . .

MOTOR, CONDENSER FAN, 7.5 HP1507061 5K254HL3169F2J . . . . IATTACHING PARTS/ SPACER, MOUNT, MOTOR SHIM, MOUNT, MOTOR . SCREW,CAP. _ . . . . WASHER,FLAT . . . . NUT,CAP . _ _ . . . . * . . . .

. . . . . .

1 2 AR 4 8 4

PBGDD MGGZZ MGGZZ PAGZZ PAGZZ PAGZZ

. .

31 32 33 34

MS90725.60 MS27 183-14 M&51922-9 1603AS644

. . . .

35 36

MS90725.6 MS2-7183.IO

. .

MOUNT, MOTORCONDENSERFAN . IATTACHING PARTSI . SCREW,CAP. . . . . WASHER,FLAT . . . NUT . . . . . . . -.*.. BRACKET, FRONTTUBING SUPPORT . . . . . . /ATTACHING PARTS/ SCREW,CAP. . . . . WASHER,FLAT . . .

. . . . . . . .

1 6 10 4

XBGZZ PAGZZ PAGZZ PAGZZ

. . . . . .

MGGZZ
PAGZZ PAGZZ

Figure 3. Condenser

Fan and Motor

(Sheet 3)

AG-180AO-MMM-000

008 00
Page 22

c. (27).

Install

washers

l28), nuts (291, and screws

11. REMOVAL. a. Pump down unit (WP 007 00) h. Shutdown unit (WI 005 00) figure 21

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 f. Install 7. DUCT condenser as tagged. fan (this WP, paragraph RACK. Equipment INone Materials Kequired Hequired Il.

c. Remove cabinet top(64,

STORAGE Support

To prevent iqjury to personnel or damage to equipment, unit pumpdown, shutdown and removill of power source must be completed hefore removing pressures control Pdd d Kemove stem caps from compressor discharge and coxnprcssor suction service valves. Close vnlvcs by turning stems clockwise. e. Open I KKSSL-RE COSTKOLS turning spring latchescounte~cl~)ckwise. panel by

8. REMOVAL. a. Remove licrure 2). condenser fan panel assembly (1, (341,

[WARNING

b. Remove nuts (35, figure screws (331 from bracket (29),

41, washers

c. Remove duct storage rack (32), 9. INSTALLATION. a. Position place. b. Install (35). c. Install ligure 2). 10. PRESSURE Support condenser fan panel assembly (I, duct storage washers rack (32, figure l33), 4) in

Refrigerant is toxic. To avoid in,jut-y to personnel, avoid breathing or CYposure to skin or eyes. Do not rxpost: refrigerant to open flame. f. I.oosen prcssurc bleed excess refrigerant g. Disconnect ~wP00900). switch capillary lines and pressure to atn~osphcrc. switch wirings capillary lines

pressure

(34). screws

and nuts

h. Tag and disconnect

i, Kemovc screws (2, figure 4) and washers (3). j. Kemove pressure controls panel (I 1.

CONTROLS Equipment None Materials

PANEL. Required

12. INSTALLATION. il. Position on front panel. b Apply scwws(2). c. Install pressure antiseize controls compound panel (I, figure to threads 41 of

Required SmcclatulY Antiseize Colnoound

Specification or Part Number

washers (31 and XI-EWS (2), as tagged. switch capillary lines (WI

d. Connect wiring c. Install 009 00) pressuw

AG-WOAO-MMM-000

00800
Page 23

GRIPLATCHES \

16

INSTRUMENTPANEL SUBASSEMCUYWPOlO00

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 NO

PART NUMBER NO NUMBER

DESCRIPTION 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 ELECTRICAL-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/. . .

UNITS PERASSY

USABLE ONCODE

SM &R CODE

1603ASllO

ADGGG PAGZZ PAGZZ

2 3 4

MS90725-5 x27183.to 1603AS112

1 6 6 I a 16 a

ADGGG PAGZZ PAGZZ MGGZZ PAGZZ PAGZZ PAGZZ

5 6 7

MS90725-32 hts27183.12 1603AS281

. . .

. . .

a 9 10 11 12 13

m27183.12 m27183.lo MS5 1849.96 1603AS322.1 1603AS322.2 1603AS288

. . . . . .

. . .

2 2

XBGZZ XBGZZ

. .

. . . . . . .

I I 10 10

MGGZZ MGGZZ PAGZZ PAGZZ

14

1603AS299

15 16 17 la

m27ta3.42 MS35207.263 1603AS322.6 1603AS322.5

. . . .

. . . .

. . . .

2 2

XBGZZ XBGZZ.

Figure 4. Panel Assemblies

and Duct Storage

Rack (Sheet 2)

AG-180AO-MMM-000

008 00
Page 25

INDEX NO
I

PART NUhtBEK,
I

DESCRIPTION
I

UNITS PER ASSY

I

USABLE ON CODE
I

S.M &R CODE

19

1603ASlll

20 21 22

lMs27ia3-10 MS90725.6 1603AS356

. . .

PASEL, INSTRUMENT /SEE WP 010 00 FOR BREAKDOWN/. . . . . . /ATTACHING PARTS/ WASHER,FLAT . . . . . . . . . . . . SCREW,CAP. * PANEL, . SUPPORT,TOP, INSTRUMENT. . . . /ATTACHING PARTS/ . . . . WASHER, FLAT . . . . . SCREW,CAP. * . . . . . .

---AGMxi PAGZZ PAGZZ

MGGZZ PAGZZ PAGZZ

23 24 25

MS27183.10 MS90725.6 1603AS358

. . .

26 27 28 29

x27183.to .Ms35338-44 MS90725-6 1603AS604

. . . .

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 a 4

MGGZZ PAGZZ PAGZZ PAGZZ

MGGZZ PAGZZ PAGZZ LIGGZZ PAGZZ PAGZZ PAGZZ

30 31 32 33 34 35 36

Ms27ta3.lo MS90725-3 1603AS103 MS90725.6 Ms27183.12 MS51922.1 1603AS622

. . . . . . .

. . . . . .

AGGGG PAGZZ PAGZZ PAGZZ

37 38 39

.MS35207-263 Ms35338.43 MS2104453

. . .

Figure 4. Panel Assemblies

and Duct Storage

Rack (Sheet 3)

AC-180AO-MMM-000

008 00
Page 26

f. Evacuate leaks.

unit

(WP 007 00) and check

for

d. Open ELECTRICAL e. Remove

CONTROLS

panel door.

screws (16, figure

4) and washers

g. Open compressor valves by turning valve Instnll stem caps.

suction and discharge stems counterclockwise.

(15). f. Remove controls panel top cover (14).

h. Operate air conditioning and evaluate performance. necessary (WP 007 00). i. Close PRESSURE j. Install stem caps.

unit (WP 005 00) Add refrigerant if

g. Disconnect

power cable from CBI. electrical connectors

h. Tag and disconnect Pl-P4. panel.

CONTROLS

i. Remove screws (5) and washers (6). j. Remove electrical k. Leak test connections I. Install cabinet top (64, figure 2). 15. INSTALLATION. il. Position electrical roadside fender. 13. ELECTRICALCONTKOLS Support Equipment None Materials Specification or Part Number Required PANEL. b. Apply antiseize Required c. Install screws (5) and washers (6), connectors PI-P4. compound to screws (5) controls panel (4) on controls panel (4),

d. Connect electrical e. Install

power cable to CBI controls panel top cover (14) on fuse

Nomenclature Antis&e Compound

f. Position box (13). g. Install

washers (15) and screws (16). CONTROLS

14. REMOVAL. a. Shut down unit (WP 005 00). h. Close and secure ELECTRICAL panel door. i. Install 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 roadside rear panel

assembly

(120,

cabinet top (64, figure 2). PANEL.

16. INSTRUMENT

Support

Equipment None

Required

c. Remove roadside ligure 2).

rear panel ussembly

(120,

Materials

Required 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)

k. Remove (wP01000).

delivered

air

temperature

gauge

I. Tag and disconnect Qa 2l (19, figWe 4).

wiring

in instrument

m. Remove screws (21), and washers (20). n. Remove instrument o. For disassembly WP 009 00. 18. INS I ALLATION. il. Position
SUQQWt (Z s?).

panel (19). instructions SC%!

or assembly

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 suction swvicu valves. Close villves by turning stems clockwise.

instrument

puncl (19, figure

4) on

Install washers (20) ilnd screws (21 I

compressor

Instill1 dclivcrcd -igerant is toxic. To avoid injury to personnel, avoid breathing 01cxposure to skin or eyes. l)o not CXQOSC refrigerant to OQE" flame. e. Open instrument punel suhassemhly 4) by turning grip lutchcs counterclockwise. (figure

air tcmpcroturc

gauge (WI

c. Connect delivered capillary line to delivered

airflow prcssure gauge airflow pressure gauge. pressure discharge

f. Connect compressor discharge gouge capillary line to compressor pressure gauge.

g. COn,W!Ct CO,llQ,SSO~ SUCtiOn QWSSE!

!$I@?

f. Loosen compressor suction pressure gauge capillary line (WP 009 000) and bleed refrigerant pressure to atmosphere. g. Loosen compressor discharge QESSR gauge capillary line (WP 009 000) and bleed refrigerant pressure to atmosphere. h. Disconnect compressor suction gauge capillary line from compressor QWSSW @I@. i. Disconnect compressor dischuge gauge capillary line from compressor QWSSW gauge. prcssurf suction prcssurc discharge

CaQilh y

line to compressor

suction

pressure gauge. subassembly by

h. Close instrument panel turning grip latches clockwise. i. Evacuate leaks. unit

(WP 007 00) and check

for

j. Open compressor suction and discharge service valves by turning valve stems counterclockwise. Instoll stem caps. k. 0Qcr;ite air conditioning und monitor performance. necessary (WP 007 00). unit (WP 005 00) Add refrigerant if

capillary

j. Disconnect delivered airflow Qrcssure gauge line from delivered airflow Qrcssure gauge.

I. Install cohinet top (63, figure 2).

AG-480AO-MMM-000
Page 28

19. BLOWER

ASSEMBLY. Equipment Required

f, Loosen setscrew (27) on coupling g. Slide motor (13). (9). i. Attach flange nuts (26) on blower (II), screws

flange (26). shaft towards

Support 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 Somenclature Corrosion Preventive Compound, SOlvent Cut-Back Cold Application, CR1 Automatic Transmission Fluid Sealing Compound

h. Remove

(10) and washers hoist.

sling to blower (8) and carefully

21. INSTALLATION. a. Using sling carefully (8, figure 5) into position. h. Install c. Position lower blower assembly

Specification or Part Number MIL-C-16173D Type Pl

washers (9), screws (lo), and nuts (11). key (24) on motor shaft,

d. Position coupling flanges (23 and 26) with an equal length of shaft extending into each flange. e. Position inches apart. coupling flanges (23 and 26) 2.563

T, Q 2 F or Dexron II

20. REMOVAL.

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. (GJA). g. Slide flange key (28). (26) far enough away to install

NOTE To prevent injury to personnel or damage to equipment, unit shutdown and removal of power source must be COmpleted hefore removing blower. b. Remove cabinet top (64, figure 2). c. Remove electrical paragraph 13). controls panel (this WP, Do not move the wire retaining to its final position. ring

h. Install neoprene sleeve (25) allowing it to hang loosely in the groove adjacent to the teeth. NOTE Setscrews (27) must be positioned degrees apart. 90

d. Remove clamps (78, figure 5) and flexible ducts 177) from blower adapters (12). c. Pry retaining (221. ring out of groove in coupling

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

SEE SHEET2 1. \

a=34-J

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 so

PART NUMRER NONUMHER .

I)ESCRIPTIoIU

CNITS PER ASSY

USA13LE ON COI)lc

541 &R CODE

1603AS488

I%I.OWKK AND MOTOR ASSE,MRLY, I l~lx00LEK AS0 AFTKK COOLER MoDCLE:S/SEE FIGLKE 1 FOR NHA/ . HLOWE:R ASI) MOTOR ASSE:MI%LY. . . . . . . . /ATTACHING PARTS/ * WASfIEK. FLAT. . . SCREW . . . . . . NCT,SEI.F-LOCKING WAStIEK, FLAT. . . SCREW . . . . * GIw~I>l1: r . . . . I1I.0WI:I~/60125/1~3230 c93owl~ !vll . . . /A l TACIIISG PARTS/ WASIIb:It, FI.AT . . SCRl:\V,CAl . SUT, SK1.F.LOCKISG. Al)All ~:I~, HI.OW~:R * . _ . . . . . . _ . . . . . . . . . . . . . . .

AGGGD

2 3 4 5 6 7 8

MS2 7183-14 MS90725.58 MS51922.9 MS27183.14 !MS90725-60 X435489-20 1603ASl23

. . . . _ . . . . .

. .

4 4 4 8 4 I I 6 4 2 2

PAGZZ PAGZZ
PAGZZ PACZZ I AGZZ I AGZZ I f-iGGD PAGZ% PAGZZ PAGZZ PAGZZ

9 IO II I2 I3

MS27183.21 MS90725.I64 .MS51922-49 1603AS671 1603AS128

. . . .

. . . .

. .

I4 I5 I6 17 I8

!v lS27183-I6 MS90725-90 .MSl6228-7C 1603ASl13 1603AS39.3

. . . . . . . . .

MOTOR, IsLoWEK. 30 IIf 150706 /5K256HLl339~F2/. . IATTACIIISG PARTS/ . WASHER, FLAT. . . . SCREW. . . . . . NUT,SEl.F-I.OCKISG. * l%ASE, I%I.OWE:R, i-:VAl ORATOR. . . FITTISG,I IPE, ISL-SlIISGi30327/ 110.13-08X02/ . . . FITTISG PIPE,
sriw~:~r

. . .

I 6 4 2

I RGGI)
PAGZZ PAGZZ [ AC%%

MGGZZ
PAGZZ

19

IfiOiASR97

i~:i.isowi
. . . . I I AGZZ

30327/l 16-fs-0%

Figure 5. Blower,

Blower

Motor,

Precooler

and Aftercooler

Modules

(Sheet 3)

AG-180AO-MMM-000

008 00
Page 32

ISDEX NO 20 21

PART NUMBER 1603AS396 1603AS395 . . . . .

DESCRffTfON VALVE, DRAIN COCK/30327/325EI . HOSE,DRAINI 11288/5A. . . . *..

UNITS PERASSY

USABLE ON CODE

SM &R CODE

. . .

. .

1 1

PAGZZ XBGZZ

. .

22

1603AS127

23

24 25

._ ._

. .

. .

26

-.

27 28 29

._ ._ 1603AS487

1 1

30 31 32 33

MS3533844 MS90725-5 1603AS480 1603AS105

: . .

: . .

34 35 36

MS27183.14 MS90725.60 iMIL-F-16552 CLASS 2 SIZE 14 AF

. . .

. . .

. COUPLING, BLOWERTO MOTOW79425l 7Sl-12/7Sl-58/7N/ . . . . . . 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 . . . . . . . . FLANGE, FINISHED BORE (WITH KEYSEAT ,375 WIDE X ,188 DEEP) /79425/7SXI-1121 . . . . . . SCREW,SET . . . . . KEY f.377 SQ X 2.50 LC). CONTROLLER, AIRFLOW . . . . . . . . /ATTACHING PARTS/ WASHER, LOCK. . SCREW . . . . . : : : : ..*.. COUPLING, FLEXIBLE/ 70901/58035/8X 9/16/ . . . . MODULE, PRECOOLER. . . (SEE WP 01100 FOR BREAKDOWN) /ATTACHING PARTS/ WASHER, FLAT. . . . . . SCREW . . . . . . _ . . ..*FILTER, AIR ENVIRONMENTAL CONTROLSYSTEM, CLEANABLE . . . . . . .

I 1

NIA N/A

N/A

N/A NIA N/A AGGGG PAGZZ PAGZZ

XBGZZ AGGGG

6 6

PAGZZ PAGZZ

PAGZZ

Figure 5. Blower,

Blower

Motor,

Precooler and Aftercooler

Modules(Sheet4)

AG-180AO-MMM-000

008 00
Page 33

INDEX NO 37 38 3Q 40

PART NUMBER 1603AS439 MS27183.IO MS90725.5 1603AS719 . . . . . . . .

DESCRIPTION ANGLE, SCPPOKT, WELDMENT . . . WASHER, FLAT. . SCREW, CAP . . . .-*.. VALVE:, BYPASS 04613/061-703-030. 100-0501 . . . . . /ATTACHING PARTS WASHER, FLAT. . SCREW,CAP . . NtJT,SELF-LOCKING. *

UNITS PERASSY

USABLE ONCODE

SM &R CODE

. . .

. . . . . .

. . .

1 12 12

MGGZZ
PAGZZ PAGZZ

. . .

. . . .

1 12 6 6

PAGZZ PAGZZ PAGZZ PAGZZ

41 42 43 44

MS27183.14 MS90725-44 MS51922.9 1603AS707

. . . .

. . . .

. . . . .

45 46 47 48 49 50

MS35338.44 MS27183.10 MS90725-5 1603AS471 1603AS708 1603AS154.1

. . . . . .

MOUNT, LOWER, WELDMENT . . . /ATTACHING PARTS/ . . WASIIER, LOCK. . . WASHER, FLAT. . SCREW, CAP . . . * GASKET, BYPASS :ilOUNT, UPPER, WELDMENT . . . . DCCT, FLEXIBLE/l6632/ FLXlOOl-00241 . . /ATTACHING PARTS/ . CLAMP, HOSE: LOW PRESSL!RE,TYPEF . . .

. . . .

. .

MGGZZ
PAGZZ PAGZZ PAGZZ PAGZZ XBGZZ 6 XBGZZ

. . . . . . . . .

VALVE. . . . . . . .

51

MS35842.14

. . . . . . , . . .

. . . .

PAGZZ MGGZZ FAG%! PAGZZ PAGZZ

52 53 54 55 56

1603AS655 MS90725.6 MS27183.10 MS51922.1 1603AS686

BAFFLE . . . . . . /ATTACHING PARTS/ . . . . . . SCREW,CAP . . . . . WAStIER,FLAT . . NUT,SELF-LOCKING * . . ANGLE, SUPPORT, CAPILLARYTUBES . IATTACttING PARTS/ . . . . SCKEW,CAI . WASHER, FI.AT . . . . NUT,SELF-LOCKING * .

. . . . , . . . I AGZZ FAG%! FAG%%

57 58 59

X390725-6 MS27183.10 MS51922.1

. . .

Figure 5. Blower,

Blower

Motor,

Precooler

and Aftercooler

Modules

(Sheet 5)

AG-180AO-MMM-000

008 00
Page 34

INDEX NO 60 61 62 63 64 65 66 67 68 69

PART NUMBER 1603AS645 MS90725.32 MS27183.12 .MS51922-9 MS90725.5 MS27183.10 1603AS65.4 MS90725.5 .MS27183-10 1603ASlO6 . . . . . . .

I~ESCRIII ION BAFFLE . . . /ATTACIlING PARTS/ SCREW, CAP . . WAStIER. FLAT. . SUT,SEI.F-LOCKING SCREW, CAP . . . WAStIER, FLAT. . *~. . . . . . . . . . . . . _ . . . . .

UNITS PICK ASSY 1 4 8 4 4 4 1 2 2

USABLE OS CODE

S.M &R CODE MGGZZ I AGZZ FAG%% I ACZZ FAG%% PAGZZ MGGZZ FAG%% PAGZZ

. . . .

. . . . . . .

. . .

. . . . .

BAFFLE . . . . . . IATTACIIING PARTS SCREW (KEY) . . . . . WASHER(REF) . . . *.. !.IODUl.E, AFTEKcooLEI~ (SEE WI 01 FOR BREAKDOWSI /,\TTACIIISG PARTS/ SCKI~:w . . . WASIIER, FLAT . . SUT, SE1.FLOCKISG *~. I 00 . . .

. . . . . .

. . . .

I 3 6 3

AGGGG
FAG%% FAG%% FAG%%

70 71 72 73

MS9072533 .MS27183-12 MS51922.9 1603AS558

. . . .

74

1603AS563

75

1603AS407

76 77

1603AS272 1603AS154.2

78

MS35842.15

BLOWER AIR Fl.OW DELTA PRESSURE CAPILLARY INFOR.MATIVE. (SEE WI 009 00 FOR BKEAKDOWN) . DELIVERED AIR FLOW DELTA AIR PRESSURE CAPILLARY INFORMATIVE. (SEE WP 009 00 FOR BREAKDOWN) . . ADAPTER, MALE PIPE TO HOSE BARB1930611 125HBL-4-61. . . . . . . . . . HOSE, DRAIN/lDS07/R-3603/ (CUTTO2l.50INLG). . _ . . . DUCT, FLEXIBLE /16632/FLXOOI-0018/ . . . . IATTACIIING PARTS/ . . CLAMP. IIOSB: LOW PRtiSSURE,TYPEF. . . . *.. . GKOMMET . . . . . . . .

XCGGG

XCGGG

I I 2

XBGZZ
XBGZZ XBGZZ

4 I

PAGZZ
FAG%%

79

Ms35489.345

Figure 5. Blower,

Blower

Motor,

Precooler

and Aftercooler

Modules(Sheet

6)

AG-180AO-MM

M-000

008 00
Page 35

j. Apply sealing compound to setscrew Torque setscrew(27) to 13 ft/lbs. (QAI. NOTE

(27).

22.30

HP BLOWER Support

MOTOR. Equipment Required

Part Number 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 0.020inches, realign the shafts. Shim blower base ss required. (See detail A, figure 5). (QA)

Nomenclature Wrench, Torque (O-25 ft/lbs) Straightedge Micrometer or Caliper, (0 3 inch) Sling Crane or Hoist (O-250 Ibs.) Materials Required Nomenclature Corrosion Preventive Compound, Cut-Back, Cold Application, CR1 Sealing Compound

Specification or Part Number MIL-C-16173H Type Pl

.Minimum and maximum angular offset between coupling flanges must not exceed 0.081 inches.

23. REMOVAL. a. Shut down unit (WP 005 001

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) m. Position retaining neoprene sleeve (25). ring into center groove of

To prevent injury to personnel or damage to equipment, unit shutdown and removal of power source must be completed before removing motor. b. Remove figure 2). c. Remove 1). d. Loosen setscrews flange (23). (27, figure 5) on coupling towards from blowol motor condenser fan panel assembly (1,

n. Treat exposed portion of shafts with 16173D corrosion preventive compound. o. Install p. Install flexibleducts clamps(78). (77).

MIL-C-

condenser

fan (this

WP, paragraph

q. If required, service blower (WI 007 quarts of automatic transmission fluid. r. Install electrical paragraph 13). s. Install controls panel

00) with 2

e. Slide coupling (22) on shaft (8). Remove key (24). f. Tag and asscmbly(l3). g. Remove (16). disconnect wiring

(this

WP,

screws (15), washers

(14) and nuts

cabinet top (64, figure 2).

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. h. Attach (13). 24. INSTALLATION. 3. Using sling, carefully 113, tigure 5) into position. h. Install (16). c. Install keys 124 and 281 an washers lower motor assembly sling and carefully remove motor

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 Torque setscrew (27) to 13 ft/lbs. (QA). 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 offset and maximum coupling angular flanges (27).

(14), screws

(151, and nuts

d. Position coupling flanges (23 and 2fi)with equal lengthofshaft cutending into each flange. e. Position coupling flanges approximately 2.563 inches apart. 1 (23 and

261 between

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 install sleeve (25). (2.3) far enough away to

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 neoprene sleeve (25). o. Install wiring ring into center groove of

NOTE Do not move the retaining final position. ring to its

h. Install neoprene sleeve (251, allowing it to hang loosely in the groove adjacent to the teeth. NOTE Setscrews (27) must he positioned degrees apart. 90

as tagged

to motor

assembly

(13). p. Install q. Install figure 2). condcnserfan condenser (this WI , paragraph fan panel assembly 1). (1,

i. Position setscrews 127) 90 degrees apart from opposite flange.

AG-180AO-MMM-000

008 00
Page 37

25. BLOWER

TO MOTOR Equipment

COUPLING Required

e. Apply sealing compound f. Install g. Position approximately

toscrews

(15)

Support Part Number

screws (15) washers (14) and nuts (16). coupling flanges 2.563 inches apart. (23 and 26)

Nomenclature Wrench,Torque (O-25 ft/lbs) Straightedge Micrometer or Caliper, (0 3 inch) Materials Required Nomenclature Sealing Compound

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 sleeve (25). (26) far enough NOTE Do not move retaining final position. ring to its away to install

Specification or Part Number

26. REMOVAL. a. Shut down unit (WP 005 00) b. Remove condenser figure 2). I c Pry retaining fan panel assembly (I,

j. Install neoprene sleeve (25), allowing it to hang loosely in the groove adjacent to the teeth. NOTE

ring out of sleeve (25, figure 5). flanges (23 Setscrews (27) must he positioned degrees apart. k. Position setscrews opposite flange. 90

d. Loosen setscrews (27) on coupling and 26). I e. Slide coupling (22) towards

motor (13).

(27) 90 degrees apart from

f. Remove keys (24 and 28) g. Remove (16). h. Slide motor (13) away from blower (8). i. Remove coupling 21. INSTALLATION. a. Slide flange (23) on motor shaft. b. Slide flange (26) on blower shaft c. Install d. Position keys (24 and 28) motor (13) so that shafts line up 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 (22). NOTE m.Apply sealing compound to setscrews Torque setscrews (27) to 13 ft/lbs. (QA) (27). screws (15), washers (14) and nuts I. Slide loose flange (23) on shaft until sleeve (25) is completely seated on teeth of each flange.

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 neoprene sleeve (25). q. Install figure 2). condenser ring into center groove of

Pumpdown, shutdown and removal of power source must be completed hefore removing compressor. Failure to comply could result in personal injury or death. c. Remove cabinet top(64, d. Remove paragraph 32). aftercooler figure 2). module (this W,P,

e. Remove precooler module refrigerant lines. (Refer to NAVSEA-0900.LP-001-7000 and Figure 6, this WP). f. Loosen clamps flexible duct (77). g. Remove paragraph 17). (78, figure 5) and remove

instrument

panel

(this

WP,

h. Remove screws (351 and washers lower flange of support angle weldmcnt.

(34) from

fan panel

assembly

(1,

i. Using slings and hoist, lift precooler (33) out of air conditioning unit. 30. INSTALLATION.

module

28. PHECOOLEH

MODULE.

a. Position prccoolcr conditioning unit. Required ~ omenclature Wrench,Torque (O-25 ft.lbs) Sling Crane or hoist (O-200 Ibs) h. Install washers conditioning unit.

module (33, figwe

5) in air air

Support Part Number

Equipment

(34) and SCI EWS (35) in

c. Install refrigerant lines (Refer to XAVSEA0900.LP-001~7000 and figure 6, this WP). d. Position module (33). e. Install f. Install g. Install 19). h. Evacuate system (WP 007 00). support angle (37) on precooler

washers (38) and ~crcws (39). flexible duct (77) and clamps (78). panel (this WP, paragraph

Materials

Required None

instrument

29. HEMOVAL. a. Pump down unit (WP 00 7 00). h. Shut down unit (WP 005 00). i. Leak test system (WP 007 00). Jo lnst.all cabinet top (64. cgure 2).

AG-180AO-MMM-000

008 00
Page 39

31. AFTERCOOLER Part No.

MODULE.

Support Equipment Required

Nomenclature Sling Crane or hoist (O-200 Ihs)

h. Remove aftercoole; refrigerant lines. (Refer to NAVSEA-OQOO-LP-001-7000 and figure 6, this WP). i. Remove clamps (51 and 78, figure flexible duct (50 and 77). j. Disconnect elbows (73 and 74) 5) and

Materials Required
None

k. Remove screws (39) and washers (38). 1. Remove szrew (67) and washers (68)

32. REMOVAL.
a. Pump down unit (WP 007 00). h. Shut down unit (WP 005 00). m.Remove (72). n. Using module (69). Pumpdown, shut down and removal of power source must be completed before removing compressor. Failure to comply could result in personal injury or death. c. Remove cabinet top (64, figure 2). d. Remove curbside panel (76). (95) hoist and sling, remove aftercooler screws (71). washers (70) and nuts

33. INSTALLATION.
a. Using hoist and sling, position aftercooler module (69, ligure 5) on curbside fender. b. Install c. Install d. Install washers (70). screws (71) and nuts (72) washers (68) and screws (67). washers (38) and screws (39). ducts (50 and 77) and install 0

e. Remove rear curbside panel weldment

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.

e. Position flexible clamps (51 and 78 ). f. Install

elbows (73 and 74).

g. Install refrigerant lines. (Refer to NAVSEA0900.LP-001-7000 and this WP, figure 6). h. Evacuate system (WP 007 00).

(W*RNING

i. Leak test system (WP 00700). 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 phere by depressing pneumatic inlet and outlet service valves. pressure to atmosvalves on receiver j. Install valve stem caps rear curbside panel weldment (95,

k. Install figure 2). I. Install m.Install

curbside

panel (76, figure 2).

cabinet top (64, figure 2).

AC-180AO-MMM-000

008 00
Page 40

34. FILTER

DRIER. Equipment None Materials Required Required (89).

h. i.. j. k.

Remove cap (79) and filter

element

(82).

Support

Remove screws (871, washers Remove straps (86).

(88) and nuts

Remove screws (84) and washers (85) Remove bracket (83). drier

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. a. Pump down unit (WP 007 00) h. Shut down unit (WP 005 00). c. Remove cabinet top (64, figure 2).

I.

m.Remove inlet and outlet lines from filter (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-OOl0700). b. c. d. e. f. (89). g. Position cap (79) in place and install (80) and nuts (81). screws Install Position Install Install Install filter element (82) in filter drier (78). (83) around filter drier.

bracket

washers (85) and screws (84). straps (86). screws (87) washers (88) and nuts

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.

h. i. j. k.

Leak test filter Evacuate

drier ( 78)

unit (WP 007 00). (WP 007 00)

Add refrigerant Install

cabinet top (64, figure 2) VALVES (Sl. S2. S3, S4.55. SW.

37. SOLENOID Support

Equipment Required NOW Materials Required NO@?

38. REMOVAL. a. Pump down unit (WP 007 00). b. Shut down unit (WP 005 00)

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 service valve pneumatic valve. g. from receiver inlet

Remove nuts (81, figure 6) and screws (80).

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

INDEX NO

PART NUMBER 1603ASl07 .

DESCRIPTION PIPING ASSEMBLYREFRIGERATION/ 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, REFRIGERATION, .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, LOOPALUMINUM, .62lD. . . . SCREW,MACHINE. . . . WASHER,FLAT . . _ . . NtiT. SELF-LOCKING _ . *..

UNITS PERASSY

USABLE ON CODE

SM &R CODE

AGGGG

1603AS650.2

PAGZZ

1603AS137

PAGZZ PAGZZ

3 4

1603AS683-4 1603AS652-1

PAGZZ

1603AS138.2

PAGZZ

A-1211

PAGZZ

7 8 9 10 11

1603AS589.4 1603AS590 1603AS648.48 1603AS606.I 1603AS662.1

1 5 1 4

XBGZZ XBGZZ XBGZZ PAGZZ

3 1

PAGZZ XBGZZ

12

1603AS769

13 14 15 16

MS21322.40 MS35207-264 MS27183.42 MS21044N3

. . . .

. . . .

1 1 1 1

PAGZZ PAGZZ PAGZZ PAGZZ

Figure 6. Refrigeration

Piping Assembly

(Sheet 2)

AC-18OAO-MMM-000

008 00
Page 44

DESCRIPTION 17 1603AS779 . . TUBE, REFRIGERANT, . . 1.125 OD X .050 WALL /ATTACHING PARTS/ CLAMP- LOOP, ALUMINUM, .62 ID . . . . . . . . . ANGLE, CLAMP SUPPORT. SCREW,MACHINE. . . . WASHER,FLAT _ . . . . NUTSELF-LOCKING. . . TEE, REDUCING1419471 W-40081. . . . . . . . . TUBE, REFRIGERANT, ,625 OD X .040 WALL . _ . IATTACfIINC PARTS/ CLAMP- LOOP, ALUMINUM, .62 ID . . . . . . . . . WASHER, FLAT . . . . . SCREW,MACHINE. _ . . *.. ELBOW, 90, SHORT RADIUS, 5/8 DIN419471W.20221 . . TUBE, COPPER, REFRIGERATION,l.62L. 0.625ODp040WALL _ _ _ GLASS. SIGHT178462l SA-15-S/ . . . . _ . . . TEE, REDUCING, 718 X 518 X 718 /419471w-40411 . . - . TUB&COPPER, REFRIGERATION, 5.001.,0.875OD . . . . . ELBOW, 90, SHORT RADIUS, FITTING X FITTING, 718 DIA 141947/w-2634/ _ . _ . . GLASS, SIGHT/78462 ISA-17-S . . . . . . . . ELBOW, 90, SIIORT RADIUS, FITTING X COUPLING, 718 DIN41947iW23341 . . ELBOW, 90, SHORT RADIUS, 718 DIN41947iW-20341 . . TUBE, REFRIGERANT, -875 OD X ,045 WALL . . /ATTACHING PARTSI CLAMP- LOOP, ALUMINUM, .881D . . . . . f . . .

PERASSY 1

USABLE ON CODE

SM &R CODE XBGZZ

18 19 20 21 22 23 24

MS21322.45 1603AS667 MS35207.264 MS27183.42 MS21044N3 1603AS649.1 1603AS768

. . . . . . . . . . . .

3 1 1 1 1 1 1

PAGZZ MGGZZ PAGZZ PAGZZ PAGZZ PAGZZ XBGZZ

25 26 27 28 29

MS2 1322.40 MS27183.42 MS35207.265 1603AS646.3 1603AS648.51

. . . . .

. . .

1 1 1

PAGZZ PACZZ PACZZ

PAGZZ

2 1 1 1

XBGZZ PAGZZ PAGZZ XBGZZ

30 31 32 33

1603ASl36.1 1603AS649-6 1603AS648.41 1603AS652.2

. . . .

. . . .

1 1

PAGZZ PAGZZ

34 35

1603AS136.2 1603AS650.3

. .

. .

6 2 1

PAGZZ PAZZZ XBGZZ

36 37

1603AS646.5 1603AS767

. .

. .

38

MS21322.43

PAGZZ

Figure 6. Refrigeration

Piping Assembly

(Sheet 3)

AG-180AO-MMM-000

008 00
Page 45

INDEX NO 39 40 41 42 43 44 45 46

PART NUMBER MS35207.265 MS27183-42 1603AS771 MS21322.43 MS35207.265 MS27183.42 1603AS783 1603AS650-4

DESkRH TION _ _ SCREW.MACHINE. - . WASHER,FLAT. t.. . . . . . . . . . _ _ _ . I 1 PACZZ PACZZ

TUBE. REFRIGERANT, .875 OD X .045 WALL. _ _ CLAMP- LOOP, ALUMINUM, .88 ID _ . . . . . . . . SCREW.MACIHNE. . . . WASHER,FLAT _ . . . t..

_ . . .

1 1 1 I I

XBGZZ PAGZZ PAGZZ PAGZZ XBGZZ

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

. . .

. 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 REGULATOR.EVAPORATOR /78462/0RIT-20.0175. 1-5/8ODF-120/50-60/ _ . IA lTACllING PARTS/ . . STRAP.VALVE . . . _ . . SCREW.CAP . _ _ . . _ . WASHER.FLAT _ . . .

PAZZZ

PAGZZ

XAGZZ

PAZZZ

PAZZZ

XAGZZ

PAZZZ

XAGZZ

1 2 4 4

XAGZZ MGGZZ PAGZZ PAGZZ

Figure 6. Refrigeration

Piping Assembly

(Sheet 4)

AC-180AO-MMM-000

008 00
Page 46

INDEX NO 58 59

PART NUMBER MS51922.1 1603AS653 . . . . . .

DESCRIPTION NUT, SELF-LOCKING * .

UNITS PER ASSY 4

USABLE ONCODE

SM &R CODE PAGZZ

60 61 62

MS90725-3 MS27183.IO 1603AS648.78

. . .

. . .

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, REFRIGERATION 3.75 L,2-118 DIA., ,070 WALL . . . . . . TEE, REDUCING 2-118 X . 2.118 X l/2/41947 m-40148/. . . . . . . . TUBE, COPPER, REFRIGERATION 5.50 L, 2.12 OD, ,070 WALL . . . . . . VIBRATION . ELIMINATOR, /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/ . . . . .

MGGZZ PAGZZ PAGZZ

XAGZZ PAZZZ

63 64

1603AS606.2 1603AS649.11

. .

. .

PAZZZ

65

1603AS648.77

XAGZZ

66

1603AS649.12

XAGZZ

67

1603AS648.76

XAGZZ XAGZZ XAGZZ

68 69 70

1603AS1 73.1 1603AS665 1603AS648.42

. . .

. . .

XAGZZ

71

1603AS646.8

PAZZZ

12

1603AS648.75

XAGZZ

73

1603AS650.6

PAGZZ PACZZ

74

1603AS659.2

Figure

6. Refrigeration

Piping

Assembly

(Sheet 5)

AC-1 86AQ-M M M-000

008 00
Page 47

DESCRIFTION 75 1603AS64519 . _ 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. _ . .

PER ASSY

USABLE ONCODE

SM &R CODE

XBGZZ

76

1603AS135

PAGZZ

77

1603AS652.3

2 1 1 8 8

PAGZZ PAGZZ N/A N/A N/A

78 79 80 81 82

1603AS134 NO NUMBER NO NUMBER NO NUMBER 1603AS172

. . . . . . _ .

PAGZZ MGGZZ PACZZ PAGZZ MGGZZ PAGZZ PAGZZ PAGZZ

83

1603AS126

ii 86 87 88 89 90

MS90725-3 MS27183-IO 1603AS611 MS90725-8 1MS27183-10 MS51922.1 1603AS648-7

91 92 93 94

1603AS763 1603AS766 1603AS649.2 1603AS764

. . STRAP, DRIER, FILTER. . IATTACHING PARTS/ . . SCREW,CAP. _ . . . . . . . WASHER,FLAT . _ _ . . . . NUT, SELF-LOCKISG . . ..*.. . . TUBE. COPPER, REFRIGERATION 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/

XAGZZ XBGZZ XBGZZ PAGZZ xmzz

Figure 6. Refrigeration

Piping Assembly

(Sheet 6)

AG-180AO-MM

M-000

008 00
Page 48

INDEX NO 95 96 97 98 99 100

PART NUMBER MS21322.42 MS35207.266 MS27183.42 MS21044N3 1603AS761 1603AS760 .

DESCRIPTION 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 . . . . . . . . *

U-NITS PER ASSY

USABLE ON CODE

SM &R CODE

PAGZZ PAGZZ PAGZZ PAGZZ

. . XBGZZ

101 102 103 104 105

MS21322.42 ~MS35207-266 MS27183.42 MS21044N3 1603AS758

. . . . .

. . . .

PAGZZ PAGZZ PAGZZ PAGZZ

XBGZZ

106

MS21322.43

PAGZZ XBGZZ PAZZZ

107 108 109

1603AS781 1603AS647 1603AS648.8

110 111

1603AS646.4 1603AS648.I5

112

1603AS649.3

113

1603AS762

114

MS21322.42

. . . 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 . . . . . . . . . * . .

3 4

XAGZZ PAGZZ

XBGZZ

PAGZZ XBGZZ

PAGZZ

Figure 6. Refrigeration

Piping Assembly

(Sheet 7)

008 00
Page 49

INDEX NO 115 116 117

PART NUMBER 1603AS759 1603AS752 1603AS133 . . . .

DESCRI~ION 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, REFRIGERATION 3.13L. 1.125 ODX.050WALL. . . . TUBE, COPPER, REFRIGERATION 3.69L, 1.125 ODX.050WALL. . . . TUBEREFRIGERANT . _ TUBE, COPPER, REFRIGERATION, 3.50 L, 1.125OD. .050WALL . . . VALVE, PRESSCRE REGULATOR. HEAD /78462/X 75.ORI-JO65/225/. . . . _ . . . . 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, REFRIGERATION 4.06 L.. 1.375 OD, .055 WALL _ . . . . .

UNITS PERASSY

USABLE ON CODE

SM &R CODE

I 1

XBGZZ XBGZZ

_ _

1 I 1 2 I 1 1 2 1 1 1 1

PAGZZ XBGZZ XBGZZ FAG%% XHGZZ XAGZZ XAGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ

118 119 120 121 122 123 124 125 126 127 126 129

1603AS755 1603AS753 1603AS132 1603AS780 1603AS649-7 1603AS648-25 1603AS6466 1603AS64823 1603AS64822 1603AS782 1603AS64818 1603AS131

. . .

. . .

. . . . . . . .

. . _ .

: : . .

1 I 1 1 1

PAGZZ XBGZZ XBGZZ XBGZZ XBGZZ

130 131 132 133

1603AS756 1603AS770 1603AS650-7 1603AS64611

. . . .

. . . .

Figure 6. Refrigeration

Piping Assembly

(Sheet 8)

AC-1 80AO-MMM-000

008 00
Page 50

INDEX NO 134 135 136 137

PART NUMBER 1603AS646-9 1603AS648-10 1603AS785 1603AS648-13 . . . .

DESCRIPTION ELBOW, 90 , SHORT * RADIUS/419 147/w-2064/ . _ TUBE. COP1 ?ER. ,REFRIGERATION 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, REFRIGERATION, 3 .OO L, 1.375 OD, ,055 WALL . . 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. . . * TUBE, COPPER, REFRIGERATION, 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. . .

UNITS PER ASSY

USABLE ONCODE

SM &R CODE

1 1 1

XBGZZ XBGZZ PAGZZ

. . * .

2 1 1 1 1 1 1 2 I 1

XBGZZ XBGZZ PAGZZ XBGZZ PAGZZ PAGZZ PAGZZ XBGZZ PAGZZ PAGZZ

138 139 140 141 142 143 144 145 146 147 148 149 150

1603AS757 1603AS173.2 1603AS648.12 1603AS649-8 1603AS649-9 1603AS140 1603AS648-47 1603AS141 A-121 1 1603AS648.57

. .

. .

. . . . . . . . . .

. . . . .

1 1 I

XBGZZ XBGZZ XBGZZ

1603AS775 1603AS776 1603AS138.1

. . .

. . .

2 1

PAGZZ PAGZZ

151

A-121 I

. .

Figure 6. Refrigeration

Piping Assembly

(Sheet 9)

008 00
Page 51

INDEX NO 152 153 154 155 156 157 158 159 160

PART NUMBER 1803AS64844 1603AS-772 1603AS778 1603AS142 1883AS848-68 1603AS649-4 1603AS649.5 1603AS773 1603AS774 . . . . . . . .

DESCRIPTION TUBE, COPPER, REFRIGERATION, 2.75 L. .875 OD. .045 WALL . . . . . . . TUBE. REFRIGERANT, .625ODX.O40WALL . . . TUBE. REFRIGERANT, .3750DX.O30WALL . . . VALVE, SOLENOID, QUENCH i78462/A3Sl-110

UNITS PERASSY

USABLE ON CODE

SM &R CODE

XBGZZ XBGZZ XBGZZ 1 PAG%%

(MKC-I COIL)/.

. . . . .

. . TUBE. COPPER, REYKIGEKATION, 1.94 I., .375 OD X.030

WALL . . . . . . . . .
718 X . . TEE, REDUCING, /41947AN-4033/ . . . . . TEE. REDUCING. 718 X /41947/w40431 . . . . . TUBE, RRFRIGERANT, .0625 OD X .040 WALL . . TUBE, REFRIGERANT. .0625 OD X .040 WALL /ATTACHING PARTS4 . . CLAMP, LOOPALCM1NU.M .62 ID. . . SCREW,MACHINE. : . . . . . WASHER.FLAT t . . . 718 X 518 . . 518 X 518 . . . . . .

XBGZZ PAG%% I AGXZ XBGZZ

XBGZZ

161 162 163 164 165

MS21322.40 MS35207-265 MS27183.42 1603AS143 A-1211

: .

: .

1 I
AR

PAGZZ PAGZZ PAGZZ

VALVE, QUENCH178462 /xv-I-L2/. . . . . . . . STRAP, TUBE, COPPER, PERFORATEDl41947l. . * .

. .

PAGZZ PAGZZ

166

1603AS650.I

167 168

1603AS777 1603AS662.2

. .

169

1603AS669

170

1603AS791

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/

PAGZZ XBGZZ

XBGZZ

XBGZZ

Figure 6. Refrigeration

Piping Assembly

(Sheet 10)

AG-180AO-MMM-000

008 00
Page 52

171 172 173 174 175 176 177 178 179 180

MS21322.34 MS35207.264 MS21044N3 MS21322.45 1603AS790 1603AS765 1603AS589.13 1603AS589.12 1603AS589-11 16ORAS589.IO

. . . .

. . . .

. . . . . . . , . . . .

CLAMP, LOOPALUMINU.M, .25 ID. SCREW, MACIIISE. NUT,SELF-LOCKING CLAMP, LOOPAI.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%%

Figure 6. Refrigeration

Piping Assembly

(Sheet 11)

AG-180AO-MMM-000

008 00
Page 53

c. Remove condenser Figure 2).

fan panel

assembly

(1,

g. Evacuate

unit (WP 007 00).

h. Service unit (WPOO7 00). i. Install figure 2). condenser fan panel assembly (1,

d. Remove cover from solenoid valve. e. Disconnect tag wires. wiring from solenoid valve and

f. Remove caps and close compressor suction and discharge service valves by turning stems fully clockwise. g. Open door. COMPRESSOR/RECEIVER access

j. Close nnd secure COMPRESSOR/RECEIVER accessdoor by turning grip latches. 40. EVAPORATOR VALVE. Support PRESSURE REGULATOR

Equipment None

Required

h. Remove valve stem caps on receiver outlet and inlet shutoff valves and close valves by turning valve stems fully clockwise. 41. REMOVAL.

Materials

Required NO 2

a. Pumpdown 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 refrigerant to atmosphere. excess

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 ligure 2). condenser fan panel assembly (1,

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 NAVSEA-0900.LP-001-7000). c. Connect d. Install e. Install wiring lines. (Refer to

Refrigerant is toxic. to personnel avoid exposure lo skin or expose refrigerant to

To avoid injury breathing or eyes. Do not open flame.

to solenoid valve as tagged.

d. Remove cop from EPR service port and bleed cxccss refrigerant to atmosphere. e. Remove lines from EPR valve (54, figure 6).

cover in place. capon pneumatic valve.

f. Leak test solenoid valve

f. Remove nuts (58) washers (56) from strap (55).

(57) and screws I

AG-18OAO-MMM-000

008 00
Page 54

g. Remove

strap

(55).

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. e. Remove service valves clockwise. caps from receiver inlet and outlet and close valves by turning stems

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 (54, figure 6) in place. pressure regulator valve

b. Install inlet and outlet NAVSEA-0900-LP-001-7000). I c. Position d. Install (58). e. Install strap washers

lines.

(Refer

to

(55) on valve (571, screws

(54). (561, and nuts

lines to EPR valve (54). to personnel avoid breathing or exposure to skin or eyes. Do not expose refrigerant to open flame. f. Remove cap from receiver pneumatic valve. g. Bleed refrigerant valve service. inlet service valve

f. Install cap on EPR service port, g. Perform h. Evacuate leak test (WP 007 00). unit (WP 007 00)

i. Service unit (WP 007 00) j. Install 21. 43. HEAD (v1). PRESSURE REGULATOR VALVE condenser fan panel assembly, figure

from receiver

inlet

service

Support

Equipment

Required

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 (Kefer to SAVSEA-0900.LP-001-0700). i. Remove HPR vnlve (129). 6).

Sane 44. REMOVAL. a.. Pumpdown h. Shutdown unit (WP 007 00 1 unit (WP 005 00). fan panel assembly (1,

45. INSTALLATION. il. Position head pressure figure 6) in place. b. Install 001-7000). lines. (Refer regulator valve (129,

c. Remove condenser figure 2).

to NAVSEA-0900.LP-

AG-180AO-MMM-000

008 00
Page 55

e. Install cap on receiver pneumatic valve.

inlet

service

valve

posure to skin or eyes. Do not expose refrigerant to open flame. g. Bleed refrigerant valve pneumatic valve. from receiver inlet service

d. Leak test unit (WP 007 00). e. Evacuate unit (WP 007 00). unit (WP 00 7 00).

f. Add refrigerant

g. If necessary, adjust valve (see WP 007 00) h. Install ligure 2). 46. HOTGAS condenser fan panel assembly (1, Do not allow kinks or hinds in capillary line. If this should occur, valve must be replaced.

RYPASS

VALVE. Required h. Disconnect capillary line (170, figure hot gas bypass valve (145). i. Remove screw, nut and strap (146). j. Carefully coil capillary line and sensor. 6) from I..

Support

Equipment NOlZ

Materials Specification or Part Number 107408 47. REMOVAL.

Required Nomenclature Heat Conductive Compound

a. Pump down unit (WP 007 00) b. Shut down unit (WP 007 00). I c. Remove condenser ligure 2). fan panel assembly (1,

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 NAVSEA-0900.LP-001-7000). outlet lines. (Refer to

d. Open COMPRESSOR/RECEIVER 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.

ACCESS

I. Remove hot gas bypass valve (145). 48. INSTALLATION.

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.

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 and install inlet and outlet lines. (Refer SAVSEA-0900.LP-001-7000). b. Apply heat conductive sensing bulb and tube (51). compound 6) to

Refrigerant is toxic. To avoid injury to personnel avoid breathing or eu-

between

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 (146), screw and nut. d. Install capillary sensing bulb with strap

Pumpdown, shutdown and removal of power source must be completed before removing quench valve. F ailure 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 regulator EPR (54, figure 6) pneumatic pressure valve,

lines (170)

e. Leak test unit (WP 007 00) f. Evacuate unit (WP 007 00) if required. (WP 007 00) ACCESS

g. Add refrigerant,

h. Close COMPRESSOKiRECElVER door. i. Install figure 2). 49. QUENCH condenser fan panel

assembly

(I,

Kefrigewnt is toxic. To avoid injury to personnel avoid breathing or exposure to skin or eyes. Do n ot expose refrigerant to open flame.

VALVE. Equipment NOW Required h. Bleed refrigerant from EPR pneumatic valve.

Support

Materials Specification or Part Number 107408

Required

Do not capillary capillary Compound

allow kinks or hinds in line. If this should occur, must be replaced.

Nomenclature Heat Conductive

i. Rcmovc screw, nut and strap (165) j. Carefully coil capillary line and sensor. lines. (Kcfer to

50. REMOVAL. a. Pumpdown b. Shutdown unit (WP 007 00) unit (WP 005 001 fan panel assembly (I, k. Remove inlet and outlet NAVSEA-0900.LP-001-7000). I. Kemove quench valve (164) 51. INSTALLATION. u. Position quench valve (164, figure and install inlet and outlet lines. NAVSEA-0900.LP-001-7000). b. Apply heat conductive sensor hulh and tube (70). compound 6) in pluce (Kefcr to

c. Remove condenser figure 2).

d. Open CO~PRF,SSOfliKEC~IV~:K door.

ACCESS

e. Kemove caps from receiver inlet and outlet service valves and close valves by turning vnlve stems fully clockwise.

between

AG-180AO-MMM-000

008 00
Page 57

d. Open COMPRESSOR door. Do not allow kinks or binds in capillary line. If this should occur. copillary must be replaced. c. Secure sensor bulb with and nut. strap (16%. screw

RECEIVER

ACCESS

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.

d. Open compressor suction and discharge service valves by turning valve stems fully clockwise. e. Install caps on compressor discharge service valve stems. f. Leak test quench valve ( 164). g. Evacuate unit (WPOO7 00). (WP 007 00). ACCESS assembly (1, h. Add refrigerant suction and

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

i. Close COMPRESSORIRECEIVER door. j. Install ligure 2). condenser fan panel

52. THERMOSTATIC (Xl. x2, x3, X4). Support

EXPANSION Required

VALVES

Equipment

Materials

Required

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, lines. (Refer to

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. a. Pump down unit (WP 007 00) b. Shut down unit (WP 005 00). c. Remove condenser figure 2). fan panel nsscmhly (I,

I. Remove inlet and outlet NAVSEA-0900.LP-001-7000). m. Remove thermostatic 150). 54. INSTALLATION.

expansion

valve (5 or

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).

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

[-I Do not allow kinks or binds in capillary line. If this should occur, capillary must be replaced. e. Apply heat conductive sensor bulb and tube. d. Install and nut. compound between 11.

b. Shut down unit (WP 005 00). c. Remove cabinet top (64, figure 2) d. Remove front panel (144, figure 2). e. Remove condenser fan (this WP, paragraph

sensor bulb(s) with strap (1511, screw

f. Remove graph 7).

duct

storage

rack

(this

WP, para-

e. Evacuate

unit (WP 007 OO), to unit (WP 007 001, To prevent injury to personnel or damage to equipment, unit pumpdown, shutdown and removal of power source must be completed before removing receiving assembly.

f. Add refrigerant

g. cb~e and secure COMPRESSOR/RECEIVER ACCESS door. h. Install ligure 2). condenser fan panel assembly (1,

55. RECEIVER Support Part Number

ASSEMBLY. Equipment Required Nomenclature Sling Hoist (O-200 Ibs) Materials Required Nomenclature Antiseize Compound R-22 Refrigerant is toxic. to personnel, avoid exposure to skin or expose refrigerant to To avoid injury breathing or eyes. Do not open flame. inlet service valve

g. Remove cap from receiver pneumatic valve.

Specification or Part Number

R-22

Refrigerant, (I30 Ibs) NOTE

h. Release refrigerant by opening pneumatic 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.
valve.

i. Remove refrigerant assembly (6, figure 7).

7000).

lines from top of receiver (NAVSEA-0900.LP-OOI-

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.

j.

Remove nuts (9), screws (7) and washers (8). sling and remove receiver assembly

k. Attach
(6).

AC-180AO-MMM-000

00800
Page 59 COMPRESSOR DISCHARGE PRESSURE ;p$fgR SUCT,ON pREssf%,;~ COMPRESSOR CAPILLARY INFORMATIVE h%%"E 'T] &

COMPRESSOR UNLOAOER SOLENOIO ,COMPRESSOR SUCTION SERVICE

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 NO NUMBER

DESCRIPTION . 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 KEFRICERANTR22 /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. . . * . . . . . . . . .

UNITS PERASSY

USABLE ON CODE

SM &R CODE

1603AS324

2 3 4 5 6

MS90725.68 MS90725-66 MS27183.15 1603AS616 1603AS125

. . . . .

1 2 2 4 4

ADGGD PAGZZ PAGZZ PAGZZ XBGZZ

. . . . . . . .

1 4 8 4

XBCZZ PAGZZ PAG%% PAGZZ

7 8 9 10

MS90725.60 MS2 7183.14 MS51922.9 1603AS121

. . . .

1 IO 15 15 5

PAGZZ PACZZ PAGZZ PAGZZ PAGZZ

11 12 13 14 15

MS90725.6 MS27183.10 MS51922.1 MS90725.5 1603AS144

_ . . .

. . . . . . . .

16 17 18 19 20

MS90725.6 MS27183.10 MS51922-1 MS90725.5 1603AS133

. . COIL, CONDENSING CURBSIDE . . . . /ATTACHING PARTS/ . .SCREW. . . . . . . . WASHER, FLAT . . NUT, SELF-LOCKING. : :SCREW,CAF. . . . *

. . . .

. .

1 IO 15 15 5

PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ

. _ . _ . . : : :

. .YALVE, RELIEF-ATMOSPHERIC /28193/5223.45OPSI/ . . . .

PAGZZ

Figure 7.

Compressor,

Receiver and Condenser

Coll Assemblles

(Sheet 2)

Page 61

57. Ii lSTALLATIBN. a. Using sling position figure 7) on chassis. receiver assembly (6.

59. KEMQVAL. a. Pump down unit (WP 007 00). b. Shutdown unit (WP 005 00)

b. Apply antiseize compound e. Install

to screws (7) c. Remove condenser fan panel assembly (this I, figure 21. d. Open COMPKESSOR/KlXEIVER door. ACCESS

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 h. Install front panel (144. figure 2) 1).

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.

i. Evacuate unit (WP 007 00). j. Leak test unit (WP 007 00) k. Charge unit with refrigerant (WPOO I 00)

c. Kemovo cap from receiver outlet service valve pneumatic valve. NOTE

I. Install cabinet top (64, figure 2) 58. ATMOSPHERIC Support RELIEF Equipment NOW2 Materials Specilication or Part Number R-22 Required Nomenclature Refrigerant, (130 Ibs) K-22 VALVE Required (VZ).

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 7) from receiver assembly. 60. INSTALLATION. a. Install atmospheric on receiver assembly.

relief

valve (20, figure

relief valve (20, figure

7)

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.

b. Install cap on receiver pneumatic valve.

valve

service

valve Compressor motor burnout toxic compounds. produces

c. Leak test unit (WP 007 00). d. Evacuate unit (WP 007 00) (WP 007 00)

b. If possible, pump down unit (WP 007 00) c. Shut down unit (WP 005 00).

e. Add refrigerant

f. Close and secure COMPRESSOR/RECEIVER ACCESS door. g. Install figure 2). condenser fan panel assembly (1, Removal of power source must be completed before removingcompresser. Failure to comply could result in personnel injury or death. d. Remove I). e. Remove graph 7). duct storage rack (this WP, paraACCESS condenser fan (this WP, paragraph

61. COMPRESSOR Support Part Number

ASSEMBLY. Equipment Required Nomenclature Sling Crane or Hoist (O-600 Ibs) Wrench, Torque (0.200 ft-lbs)

f. Open COMPRESSOR/RECEIVER door.

Materials

Required
NO@

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 valve cap. suction service valve pneumatic

62. REMOVAL. a. Identify and correct cause of compressor failure. Check for compressor motor burnout (WP 006 001, burned contactars, blown fuses, inoperative pressrecotrols, etc. NOTE If compressor failed and the cause of failure is not identified and corrected, the replacement compressor will fail.

j. Bleed refrigerant pressure in compressor to atmosphere by opening suction service valve pneumatic valve. k. Disconnect 1WP 009 00). capillary lines from compressor

AG-l$OAO-

008 00
Page 63

a. Position spacers (5, figure 7) on chassis. b. Using chassis. To prevent injury, removal of power source must be completed before solenoids are disconnected. I. Remove solenoids 7) and secure. from compressor (1. ligure sling position compound compressor (1) on

c. Apply antis&e

to screws (2 and 3). (2 and 3)

d. Install washers (4) and screws securing compressor (1) to unit. e. Connect wiring f. Position terminal install four screws. as tagged. jumper

NOTE Compressor suction and discharge valves remain connected to system piping. m.Dionnect from compressor compressor by removing suction service valve screws and washers. from

cover in place and on com-

g. Remove caps from lines and fittings pressor (1). h. Install capillary lines (WP 009 00).

n. Remove screws. washers and gasket eompressordisehargeservice valve. 0. Remove ~erews from compressor jumper cover and remove cover. p. Tag and disconnect electrical wiring.

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 I. Install solenoids on compressor (1).

terminal

duct storage rack (this WP, paragraph condenser fan (this WP. paragraph oil. Service 1).

q. Remove screws (2 and 3) washers spacers (5). from compressor ( I ). r. Cap refrigerant tittings on compressor

(41 and

71. m.Install

t 1I

n. Check compressor (WP 007 00). a. Replace filter p. Add refrigerant

if required

NOTE
To prevent condenser coils from damage, a cover may be fabricated from plywood or cardboard and placed between compressor and condenser coil.

drier core (82. iigure 6). (WP 007 00).

s. Attach remove.

sling

to compressor

(1) and carefully

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 64. FRONT cabinet top (64. figure 2). WHEELASSEMRLY. Equipment Required ?lomenelature Jack, O-5000 Ihs. Chock Wrench, Torque (O-200 ft.lbs.1

63. INSTALLATION.

Support Part Number

To prevent injury, be careful when positioning spacers (5. figure 7). washers (4). screws (2 and 3) and compressor t I).

AG-180AO-

00800
Page 64

APPLY ANTISEIZE COMPOUND TO THREADS PRIORTO ASSEMBLY.

54 52 (Sheet 1 of 6)

51

Figure 8. Chassis and Wheel Assemblies

AG-180AO-MMM-000

008 00
Page 65

I I
INDEX NO

PART NUMBER, NO IVUMRKR 1603AS104 1603AS233 MS171656 1603AS577 1603AS575 MS27183-23 MS171656 1603AS576 .

DKSCRIPTIOIV

UNITS PER ASSY

SIM& R CODE

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..

XI3GCG MCCZZ PA%%% XBC7.Z MGGZZ I AGZZ PAGZZ

I AG%% I AG%% I AG%%

9 10 II 12 13 14 15

MS35O i-263 MS27183.8 I603AS574 1603AS618 1603AS619 1603AS585 1603AS458

. _ . . . . _ . . . _. _ _ . _

16 17 18 19 24 21

MS90725.167 MS90725.165 MS27183.21 MS51922.49

_ _ _ .

_ _ . _

_ PIN. BALL LOCK /39428/983201\771/ . . _ - CABLE. NYLON COATED /99862lCI.-2-C-xX/. _ . _ . FERRULE. CABLE /99862/Cl.-4-k / _ _ _ . _ _ ARM, TOWHAR. . _ _ . WIIERLASSKMHLY. FRONT 101083/SH114S4016-44/ . _ . IAI-I ACIIING PARTSI SCREW. CAP. _ _ . _ _ _ SCRKW.CAP. . _ _ . . _ WASIIER, FLAT . _ . _ . 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/. _ . . .

XAGZZ

. _ . . .

. .

22

_ .

. _

23

. .

Figure 8. Chassis and Wheel Assemblies

(Sheet 2)

AC-180AO-MMM-000

008 00
Page 66

INDEX NO 24 25

PART NUMBER . . . . .

DESCRIPTION PIN, ROLL, 3116 X I-13/4/01083/1033/. . . CUP, GREASE, /01083/1360/ . . . . .

UNITS PER ASSY

USABLE ONCODE

SM &R CODE

. .

. .

1 1

XBGZZ XBGZZ

26

27

28 29 30 31 32 33

. . . . . .

. . . . . . . .

. .

34 35 36 37 38

. . . .

. . . .

. . .

. .

39 40 41 42 43

. . . . . . . .

. . . . .

. .

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/ . . .

XBGZZ

. . . . . .

1 1 1 I I 1

XBGZZ XAGZZ XBGZZ XBGZZ XBGZZ XBGZZ

. . . . . .

2 2 2 1 1 1

XBCZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ

. . . .

4 1 1 I 1

XBGZZ XBGZZ XBCZZ XBGZZ XBGZZ

Figure 8. Chassis and Wheel Assemblies

(Sheet 3)

AG-180AO-MM

M-000

008 00
Page 67

I I
INDEX NO 44 45 46 47

PART NUMBER I . . . .

DESCRIPTION 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/ . . . WASHERBEARING 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 . . *

1 P:?%Y

1 ,,cf%!

( %:E

XBGZZ

XBGZZ

XBGZZ

. . . . . . . .

2 10 IO 2 2 2 2 2 2 2 2 2 2 1 2 2 2

XBGZZ XBCZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ PAGZZ PAGZZ PAGZZ PAGZZ

48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 1603AS176 MS90725-67 MS27183.14 MS51922-9 1603AS427-100

. . . . . _

. . . . . .

. . . . . . . . . . . . f .

. . . . . . . .

. . . . . . .

65 66 67

MS20392-5C3t MS27183.14 MS24665.283

. CABLE ASSEMBLY, BRAKE . . . . . . . . /ATTACHING PAKTSI . . . . . . PIN.STRAlGtlT . . . . . . WAStlER,FLAT . _ . . . . . PIN,COTTER *

. . . .

1 I 1 1

AGGGG PAGZZ PACZZ PAGZZ

Figure 8. Chassis and Wheel Assemblies

(Sheet 4)

AC-180AO-MMM-000

008 00
Page 68

INDEX SO 68 69 70 71 72 73 74 75 76 77 78 79 c

PART NUMBER 1603AS426.1 1603AS449 MS35691.21 1603AS450 1603AS451 1603AS452 X390725-62 MS27183.14 MS51922.9 1603AS453 MS16562.71 1603ASJ27.IO1 . . . . . . . . . . . .

DESCRIPTION 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 . . . . . . . _ . . . . . . . . . . . . . . . . . . . . .

UNITS PERASSY 1 2

USABLE OSCODE

SM &R CODE

PAGZZ PAGZZ ~lGG%Z PAGZZ MGGZZ PAGZZ f AGZ% PAGZZ PAGZZ PAGZZ AGGGG

. . . . . . . . . . .

80 81 82 83 84 85 86 87 88 89 90

MS20392.5C31 MS27183.14 MS24665.283 1603AS449 MS3569 I-2 1 1603AS426.2 1603AS341 MS90725.32 MS27183.12 1603AS670 1603AS670

. . . . . . . . . . . . . . .

. . . . . . . . . . . : . . . . . . . . . . . . . .

I AGZZ I AGZZ PAGZZ PAGZZ PAGZZ XBGZZ MGGZZ PAGZZ PAGZZ

91 92 93

MS90725.6 MS27183.IO MS51922.I

. . .

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

. .

. . . .

MGGZZ MGGZZ
PAGZZ PAGZZ

_ . . . . . . ,

Figure 8. Chassis and Wheel Assemblies

(Sheet 5)

AC-180AO-MMM-000

008 00
Page 69

INDEX NO

PART NUMBER

DESCRIPTION

UNITS PERASSY

USABLE ON CODE

SM &R CODE

94 95 96 97

1603AS342 MS90725-32 MS27183-12 1603AS460

_ . . . _ . . .

98

1603AS459

_.

FENDER,CURBSIDE . . _ IAlTACHINC PARTS/ SCREW,CAP. _ . . . . . WASHER.FLAT . . . . . ..*WHEEL ASSEMBLY, . . . ClJRBSIDE/01083/B8000-44 RH /SEE FIGURE 9 FOR BREAKDOWN1 WHEEL ASSEMBLY, . . . ROADSIDE/01083/B800044 LH /SEE FIGURE 9 FOR BREAKDOWN . . _ . . . .

1 5 5 1

MGGZZ
PACZZ PAGZZ XBGCG

XBGGG

99 100 101 102 103

MS35489-79 MS35489-78 MS90726-185 MS35691.61 1603AS796

. . . . .

104 105 106

MS35207.263

MS3533843
1603ASl90

GROMMET . . . . . GROMMET . . . . . SCREW.CAP. . . . . NUT,PLAlN . . _ . _ WELDMENT. BRACKET, CHARGINGGAS . . . IATTACHISG PARTS/ . . SCREW,MACHINE . . . . WASHER,LOCK . . _ . . CHASSIS, WELDMENT *

. . . . .

2 : 2 2 1 1 1 1

PAGZZ PAGZZ PAGZZ PAGZZ MGCXZ PAGZZ PAGZZ MDGZZ

. . . . . . . .

Figure

8. Chassis

and

\;Vheel

Assemblies

(Sheet

6)

AG-180AO-MMM-000

008 00
Page 70

Materials Spccificution or Part Sumher

Hequired Nomenclature Antis&e Compound

Materials

Required NOW

68. REMOVAL. a. Chock rear wheels of unit. jack raise stands front wheels each off the front

65. REMOVAL. a. Remove cabinet top (64, figure 2). b. Chock rear wheels of unit. c. Usingjack raise front wheelsoffground.

b. Using ground. c. corner

Place jack of the unit. jack

under

d. Place jack stands under each front ccrner of the unit. e. Support front wheel assembly (15, figure 8). f. Remove scrc~s (19). g. Remow 119). screws ~171, washers (181 and nuts 116). washers (181 and nuts

d. Using ground.

raise

rear

wheels

off

the

e. Place jack corner of this unit. f. Remove cotter (81) and pin (80). g. 9). Support rear

stands

under

each

rear

pin (82, figure

81, washer

h. Lower front wheel assembly (1.5)~ 66. INSTALLATION. a. Support front wheel assembly in position under chassis. b. Apply 17). c. Install screws (161, washers (18) and nuts (19). Torque screws (16) to 180 ft-lbs (QA,. 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 CURBSIDE REAR antiseize compound (15, figure 81

wheel

assembly

(1, figure

h. Remove screws 8) and nuts (5 or 9). i. Lower front

(3 or 7), washers

(4 or

wheel

assembly

(15).

to screws (16 and

69. INSTALLATION. a. Support position. rear wheel assembly (1, figure 9) in

b. Install screws and nuts (5 or 9).

(3 or 71, washers

(4 or 8) I pattern

ROADSIDE AND 67. WHEEL ASSEMBLIES.

c. Torque screws (3 or 7) in a ctiss-cross to 95 ft.lbs. (QA) d. Position yoke lever (23, figure 9). end (83, figure 8). washer

8) on cam (81) and

Support Pal t. Sumher

Equipment

Required Nomenclatlm Jack, (O-5000 Ihs.) Chock Wrench. Torque (O-200 ft.lhs.)

e. Install pin (80, figure 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 SPRINGSEATS.P~ACE SPRINGCA (41) ON SPRINGS (39) WITH SCREW (43) FACING OUTEOARO. BACK OFF JAM NUT(42)ON CENTERSCREW(40)TO ALLOW BOLT 140) To BE THREAOEOINTO 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). TIGHTENSPRINGCAP SCREW143).

Figure 9. Rear Wheel Assemblies

(Sheet 1 of rl)

AG-180AO-MMM-000

008 00
Page 72

NO NCMBISIi I . . . WII~El.ASS~?tlMRI.Y, CUKI1SII)K /01083/K8000 44KHI . _ . Wlilclil,ASSIcMIHI,Y, KOAIXIDWO1083 /118000-K441.111 . . . . . IATTACIIING PAKTSI SCREW.CAP 112-20 x l-114 /01083/1658/ . . . . . . SCKEW, CAP 1/2-20x I12 20 X 1 /01083/1659/ . . . . . . WASIIl-ZR . . _ . . . . NCT _ _ . . . . . _ . * . IIlJls AND I)KLhl ASSImI1I.Y/O108:1 , I

XHC%% XHCU

. .

. .

XI%G%%

. .

.WS27183 19 MS51922 37

. . . . . .

. . .

2 4 .I

XBC%% IJAG%%
I AC%%

/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/ . . * . 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/ . . rTlSR . PIN Co l/8 DIA X l/01083/ 1125.. . . . . _ ,I)UST . . _ . CAI . . .

XHCU XBC%% XISGU XHG%%

4 4 4

. . . .

10 11 12 13 I4 15 I6 I7

. .

. . . . . . .

1 1 I 1 1 1 I

. . . . . . . . . . .

. . . . . . . .

. . .

. .

. .

. .

18

. .

. .

. .

1 1

Figure 9. Rear Wheel Assemblies

(Sheet 2)

AG-180AO-MMM-000

008 00
Page 73

I I
INDEX NO 19 20 21 22

PART NUMBER

I . . . .

DESCRIPTION . 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 /01083/1540/. . . . *..

. _ .

1 4 4

XBGZZ XBGZZ XBGZZ

. . . . . .

. . .

. . .

XBGZZ

23

XBGZZ

24

XBGZZ

XBGZZ

25

. .

. . 5/16 .

XBGZZ XBGZZ XBGZZ

26 21

. . . .

. .

28 29

. . . .

. .

. .

30 31 32

. . . . . .

. .

. .

. .

. BEARING /010083/1181/ . . . . . RETAINER ASSEMBLY/O1083/UCR-3/. /ATTACHING PARTS/ . PlN . . . . . . . . 506 . WASHER 101083/1428/. . . . . 3/32 DIA . PIN-ROLL X 5/8/01083/1019/. . . *.. . ROD ASSEMBLY, CONNECTING/O1083/USR-2/, IAITACHING PARTSI . SCREW,StiOUI,I~ER 101083/UCl.-11. . . . I

XBGZZ PAGZZ XBGZZ XBGZZ XBGZZ

33

PACZZ

34

. .

XBGZZ

Figure 9. Rear Wheel Assemblies

(Sheet 3)

AG-180AO-MMM-000

008 00
Page 74

ISDEX NO 35

PART NUMBER . . . .

DF:SCRIPTION

UNITS PERASSY

USABLE ONCODE

SM &R CODE I

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..

XBGZZ XBGZZ XBGZZ

XBGZZ

1 2

XBGZZ XBGZZ

XBGZZ XBGZZ XBGZZ XBGZZ

Figure 9. Rear Wheel Assemblies

(Sheet 4)

AC-1 80AO-MMM-000

008 00
Page 75/(76 Blank)

70. BRAKE

ASSEMBLY. Equipment Required Nomenclature Jack Chock Materials Required NOC

Support Part Number

g. Remove cotter pin, (17) castle nut (16), washer (15) and outer cone bearing (14) from axle. h. Pull spindle. i. j. wheel and drum (6 and 19) off

Remove

springs

and brake assembly

shoes.

Remove brake

(22).

72. INSTALLATION. 71. REMOVAL. a. Position brake shoes on backing plate. b. Install a. chock rear wheels of unit. b. Using ground. c. corner jack raise front wheels off the c. Position spindle. d. Install nut (16). wheel and drum (6 and 19) on springs

Place jack of the unit. jack

stands raise

under rear

each off

front the

bearing

(14) washer

(15), and castle

d. Using ground.

wheels

e. Install cotter pin (17). f. Install dustcover(l8).

e. Place jack corner of this unit. f. Remove

stands

under

each 9).

rear

g. Ad,just brakes (WP 007 00) h. Lower unit and remove chocks.

dust cap (18, figure

AC-180AO-MMM-000
15 way 1991

009 00
Page 1 of 22

ORGANIZATIONALAND PRESSURE SWITCHES AND

INTERMEDIATE AND CAPILLARY DISASSEMBLY

MAINTENANCE INFORMATIVES INSTRUCTIONS

ASSEMBLY

AIRCONDITIONER,AIRCRAFTGROUNDCOOLING AiMBZC-21 PART NUMBER 1603ASlOO-1 I

Heference Adjustment.............................................,......... Removal and Installation

Material IVPOO700 WI 008 00

Alphabetical Subiect

Index m 5 3 13 7 2 9 2 2 2 9 15 9 9 9 15 15 15 I5 15

Hlower Airflow Delta Pressure Capillary Informative .......................... ............ Rlower and Iklivered Airflow Differential Pressure Switches (PSI, PSZ, PS3). .................. Compressor Suction Pressure Capillary Informative. ......................................... Delivered Airflow Delta Pressure Capillary Informative ....................................... Differential Pressure Switch IPSl. 1 52, PS3). ................................................ lnstallution ......................................................................... Materialsfkquired ................................................................. Removal ............................................................................. Support Equipment Kequired .......................................................... Differential Pressure Switch, Close on Pressure Rise (PS4). ..................................... Installation .......................................................................... MaterialsKequired....~ .............................................................. [lemoval ............................................................................ ......................................................... SupportEquipmentRequired Differential Pressure Switch, Close on Pressure Rise (PS5). ..................................... Installation ... .................................................................... Materials Kequircd ................................................................... llcmoval ............................................................................ ......................................................... Suppol.tEquipmentl~equired

AG-180AO-MM

M-000

Alphabetical

Index

(Cont%li

DiNerentiaI Pressure Switch. Open on Pressure Rise(PS6) ...................................... Insl?IIation .......................................................................... ................................................................... ,~ateriaIsRequired Removal ............................................................................ ......................................................... SupportEquipmentRequired ........................................................................ FanCyclingSwitch ......................................................................... Insl.aIIation ................................................................. Mat&alsRequired ~moval ............................................................................. Support Equipment Required. ......................................................... ...................................................................... HighPressureSwilch ......................................................................... Installation ................................................................... MaleriaIsRequired ............................................................................. Removal Support Equipment Required. ......................................................... ....................................................................... LowPressureSwi~h ......................................................................... Inst.allntion MaterialsRequired ................................................................. Removal ............................................................................. Support Equipment Required. ......................................................... ....................................................................... OilPressureSwitch Installation ......................................................................... MaterialsRequired ................................................................. Removal ............................................................................. Support Equipment Required. ......................................................... PressureSwitehes .......................................................................... Record of Applicable TecRnical NOW Directives

I6 I6 16 I6 16 20 20 20 20 20 19 19 19 19 i9 18 18 18 18 18 17 I7 17 17 17 10

1. DIFFERENTIAL (Psi. PS2. PS2). Support

PRESSURE

SWITCH

Equipment NOIW

Required

Materials

Required N0ne

Shutdown and removal of newer source must be completed before removing differential pressure switches. Failure to comply could result in injury or death. b. Open door. BLOWER/FILTI~:R DRIER ACCESS

2. REMOVAL. a. Shut down unit (WP 005 00).

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

009 00
Page 4

NUMBER

DESCRIPTION DIFFERENTIAL PRESSURE SWITCHEStPSl, PS2, PS3) ISEE WP 008 00 FOR NHAI . SWITCH, PRESSURE DIFFERENTlAW /1823-2-MIW . . . . . . /ATTACHING PARTS/ SWITCH, PRESSURE DIFFERENTItW85274l /1627-I-MIIJ . . . . . . . NUT (SUPPLIED WITH SWITCH) . . . . . . . . WASHERKSUPPLIED WITH SWlTCH)/85274/1823-266/.

UNITS PERASSY

I
NO NUMBER 1 1603AS146

USABLE ON CODE

SM &R CODE

1
1 I

PAGZZ

1603As147

2 3

1603AS683-2

. . . .

2 3 6

PAGZZ NIA N/A

* *

. .

BUSHING, UNIVERSAL /28520/2089/ . . . .

. .

. .

NIA

Figure 4. Blower and Delivered Airflow Differential (Psi, PS2, PS3) (Sheet 2)

Pressure Switches

AC-180AO-MMM-000

009 00
Page 5 AFTERCOOLERMODULE
lG03AS106

., . . . . ..uLE AS625

PRESSUREDIFFERENTIAL SWITCH
iSOSAs147

/PSZI

&)3a
PRESSURE DIFFERENTIALSWITCH (~~31
1W3AS147 %3

I
DSECURE TUBING TO STRUCTUREWITH TIEOOWN STRAPS AS NECESSARY TO PREVENT BINOING.CHAFINGOR 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 1603AS558

DESCRIPTION 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/ . . . . . . .

UNITS PERASSY

USABLE ONCODE

SM &I? CODE

1603AS545.1 1603X5564-1

PACZZ

1603AS818.1 1603AS564.5

. .

2 2

XBGZZ PAGZZ

. _ .

XBGZZ PACZZ PAGZZ

1603AS545.2 1603AS818-2 1603AS564-9

XBCZZ

1603AS564.10

XBGZZ

Figure 2. Blower Airflow

Delta Pressure Capillary

Informative

(Sheet 2)

AG-180AO-M

M M-000

009 00
Page 7

AFTERCOOLERMODULE
COll. EVAPORATOR, AFTERCOOLEA 1603ASl45 1603AS106

AFTERCOOLER CABINET 1603AS416

"",,I "...JLI.IYLI, I LLAlYLL AIR HOSE 1603AS625

PRESSURE DIFFERENTIALSWITCH IPSII

1603ASl46

INSTRUMENT PANEL SUBASSEMBLY

1603AS333

OELIVEAEO AIR PRESSURE GAUGE 1603AS156

DSECURE TUBING TO STRUCTUREWITH TIEOOWN STRAPS AS NECESSARY TO PREVENT EINOING.CHAFINGOR KINKING. ~SERIAtNOS.51ANDSUESEOUENT

Figure 3. Delivered

Airflow

Delta Pressure Capillary (Sheet 1 of 2)

Informative

AG-180AO-MMM-000

009 00
Page 8

INDEX NO

PART NUMBER 1603AS563

DESCRIPTION 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 1.139OC, 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 . . . . . . *

UNITS PERASSY

USABLE ON CODE

SM &R CODE

1 2

1603AS545-1 1603AS564-1

PAGZZ

XBCZZ

1603AS564.2

2 . I

xlv.xz f AGZ%

4 5

1603AS567-1 1603AS564.3

. . .

XBCZZ
FAG%% PAGZZ PAGZZ PAGZZ

6 7 8 9 10

1603AS568.1 1603AS565 1603AS545-2 1603AS567-2 1603AS568-2

PAGZZ

11 . .~ 1603AS564.5

XBGZZ

12

1603AS564-6

XBGZZ

13

1603AS564-7

XBCZZ

Figure 3. Delivered

Airflow

Delta Pressure Capillary

informative

(Sheet 2)

AC-1 80AO-M

M M-000

009 00
Page 9

d. Remove switch (Il. e. Tag and remove capillary f. Remove elbows. Remove screw from cover. Remove cover. Tag and disconnect 3. INSTALLATION. a. Adjustswitch(l,figure b. Connect wiring 1). c. Position cover on switch (11 d. Install screw. e. Install f. Install fittings. elbows capillilry lines as tagged on elbow is toxic. To :tvoid in.jwy Kefrigcranl to personnel, avoid breathing or L Yposure 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). l)(WPOO700) (1, figure d. Remove caps from compressor discharge valve and compressor suction service valve. Close valves by turningstemsclockwise. wiring from switch (1) lines from elbows. 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 c. Remove condenser 008 00).

CONTKOLSdoor. fan panel assembly (WP

as tagged to switch

g. Position switch (1) in bracket. h. Install nut(Z).

i. Leak test lines. j. Close and secure RI.OWER/FlLTER ACCESS door. DRIER Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. f. Remove pressure (101. switch line from tee fitting

4. DIFFERENTIAL PRESSURE SWITCH, CLOSE ON PRESSURE RISE (PS4). Support Equipment None Materials Required None 5. KEMOVAL. a. Shut down unit (WPOO5 001 Kequired

g. Remove screw and COYCI from pressure switch (IO, ligurc 4). h. Tag and disconnect switch PS4(10). wiring from pressure

i. Kemovc SCI E\YS (14) ilnd wshers ,j. Kemove pressure bracket (13) by removing (3). switch screws

(151.

I S4 (IO) from (2) and washers

AG-180AO-MMM-000

009 00
Page 10

Figure 4. Pressure Switches (Sheet 1 of 3)

009 00
Page 11

PART NUMBER I 1603ASllO 1 1603AS163

DESCRIPTION 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 PORTWELDMENT . . IATTACIIINC P.AKT& . SCRISW, MACtIINE . . WASIIEK,FLAT . . *.. . . . . . . . . . . . . . .

PAGZZ

N/A N/A PAGZZ PAGZZ

.MS35207-261 .MS27163-42 1603AS617

MGGZZ
PACZZ PACZZ

7 8 9 10

%35207-261 MS27183.42 1603AS683.4 1603AS174

BUSHISG. UNIVERSAL/28520 /2119/. .~ . DIFFERENTIii Pi&S&ii SWITCH, CLOSE ON PRESSURE RISE, PS4/92578/P70GA-6/ . . /ATTACHING PARTS/

PAGZZ

PAGZZ

11 12 13

DELETED DELETED 1603AS402 . BRACKET, SUPPORT SMALL . _ . . . . /ATTACHING PARTS _ SCREW,MACHINE . . WASHER, FLAT . . ..*. SWITCH, PRESSURE, DIFFERENTIAL, OPEN PRESSURE RISE /92576/P70CA-11 . .

. . . . . .

. . . . . .

3 12 12

MGG
PAGZZ PAGZZ

14 15 16

MS35207.261 MS27183.42 1603AS175

ON . . . . 1 PAGZZ I

17 18

DELETED DELETED

Figure 4. Pressure Switches (Sheet 2)

AG-180AO-MMM-000

009 00
Page 12

INDEX NO 19 20 21 22

PART NUMBER 1603AS403 MS35207.261 Ms27183.42 1603ASl59

DESCRIPTION BRACKET, SUPPORT /ATTACtIINCPARTS/ . SCREWMACHINE . . WAStIER,FLAT . . . ..*.. SWITCH, LOW PRESSURE /80439/AF24-10831. . . /ATTACIIINCPARTS/ SCREW,MACHINE . . WAStIER, LOCK . . . *

UNITS PERASSY

USABLE ON CODE

SM &R CODE

. . . . . . . . .

1 4 4

MGCZZ
PAGZZ PAGZZ

. . .

. . .

. . .

PAGZZ
PAGZZ PAGZZ

23 24 25

MS35206.228 MS35333.37 1603AS160

26 27 28

MS35333-37 1603AS158

29 30

MS35333.37

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 . . . . *

. .

PAGZZ

. . .

2 2

NIA PAGZZ

PAGZZ

. .

2 2

NIA PAGZZ

Figure 4. Pressure Switches (Sheet 3)

AG-180AO-MMM-000

009 00
Page 13

PRESSURECONTROLSPANEL ,6031\~110

INSTRUMENT PANEL SUBASSEMBLY 1603AS333

C .

Figure 5. Compressor

Suction Pressure Capillary (Sheet 1 Of 2)

Informative

AG-180AO-MMM-000

009 00
Page 14

INDEX NO

PART NUMBER 1603AS597

DESCRIPTION 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). . . . . . .

UNITS PERASSY

USABLE ONCODE

SM &R CODE

XCGCG
PACZZ .MG%%% XDG%% XBCZZ XnC%% XHG%% XUC%% XBC%% XHGZZ xnwz xmzz

I
2 3 4 5 6 I 8 9 IO 11

1603AS821 1603AS796 1603As589.a 1603AS590 1603AS795 1603AS798 1603AS789 1603AS749 1603AS592 1603AS591 1603AS589-3 1603AS234

XCGCC xnczz XHGZZ xnczz XBGZZ XBGZZ XBGZZ

12 13 14 15 16 17

1603AS593 1603AS747 1603AS592 1603AS590 1603AS788 1603AS591 1603AS595 1603AS596

18 19

PAGZZ

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) to terminals on

must bc completed before removing pressure switch PS5. b. Open PRESSURE c. Remove condenser 008 00.) CONTROlSdoor, fan panel assembly (WP

c. Connect wiring as tagged pressure switch PS4(10).

d. Position cover on pressure switch screw.

(10) install

d. Remove stem caps from compressor discharge service valve and compressor suction service valve. Close valves by turning stems clockwise.

(WARNING\ Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. e. Install ligure 5) pressure switch line to tee filling (10. 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 phere by loosening connection (IO, ligwc4l tee(lO,ligure5). pressure to atmosat pressure switch

f. Evacuate unit (WP 007 00). g. Leak test connections

h. Adjust switch (10) (WP 007 00) Kneccssary i. Open compressor service valves by turning j. Install stem caps. condenser fan panel assembly (WI (IO). CONTROLS g. Remove screw and cover from pressure switch I S5 (10, ligure 4). h. Tag and disconnect switch PS5 (10). wiring from pressure suction and discharge stems counterclockwise.

k. Install 008 00).

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. f. Remove pressure swit,ch line from tee fitting

I. Close and secure PRESSURE door. 7.

DIFFERENTIAL PRESSURE SWITCH. CLOSE ON PRESSURE RISE (PS5). Support Equipment NOf! Materials Required NOC Required

i. Remove screws (14) and washers (15). j. Remove pressure bracket (13) by removing (3). 9. INSTALLATION. o. Install pressure switch I S5 (10, figure hwcket (131 with washers (3) and screws (2). h. lnstull scrc?ws (14). bracket (13) with washers 4) on switch screws PS5 (IO) from (2) and washers

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

(15) and

c. Connect wiring pressure switch (101.

ils tagged

to terminals

on

AC-180AO-MMM-000

009 00
Page 16

d. Position install screw.

cover on pressure

switch

(10) and

_~~~~~~~~~~~~~~~ Do not allow kinks or binds in capillary line, If this should occur, switch must be replaced. e. Install figure 5). pressure switch line to tee fitting (10,

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).

f. Leak test connections. g. Evacuate unit (WP 007 00). h. Adjust switch (10) (WP 007 00) if necessary. i. Open compressor service valves by turning j. Install stem caps. k. Install 008 00). condenser fan panel PRESSCRE assembly (WP suction and discharge stems counterclockwise. 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 (161. wiring from switch PS6

1. Close and secure door.

CONTROLS

i. Remove screws (14) and washers (15) j. Remove pressure bracket (13) by removing (3). 12. INSTALLATION. a. Install pressure switch PS6 (16, figure 4) on bracket (13) with washers (15) and screws (14). h. Install screws (14). bracket (13) with as tugged washers (15) and on switch screws PS6 (16) from (2) and washers

10. DIFFERENTIAL PRESSURE SWITCH, OPEN ON PRESSURE RISE (PSI3 Support Equipment Required None Materials Required None

1 I. REMOVAL. a. Shut down unit (WP 005 00).

c. Connect wiring switch PS6 (16). 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 c. Kemove condenser 008 00). CONTROLS door. (WI d. Position screw.

to terminals

cover on switch

PS6 (16) and install

fan panel assembly

d. Remove stem caps from compressor discharge service valve and compressor suction service wlvc. Close valves hy turning stems clockwise.

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. e. lnstull pressure switch switch tee fitting(l0, figure 5). line to pressure

AG-180AO-M

M M-000

009 00
Page 17

f. Leak test connections. g. Evacuate unit (WP 007 00). I h. Adjust switch(lG)(WP 007 00) if necessary discharge

e. Bleed excess refrigerant pressure to atmosphere by loosening oil pressure switch connections at compressor (I 8 and 19, figure 51.

i. Open compressor suction and valves by turning stems counterclockwise. j. Install k. Install 008 00). stem caps. condenser fan panel PRESSCRE

assembly

(WP

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. f. Tag and disconnect oil capillary lines from compressor. pressure switch

I, Close and secure door. 13. OIL PRESSURE Support

COSTROLS

SWITCH. Required

Equipment None

g. Remove screw nnd cover from switch 11, ligure 4). h. Tag and disconnect wiring

oil pressure

Materials

Required None

from switch (1)

i. Remove screws (7) and washers (8) j. Remove bracket (6).

14. REMOVAL. a. Shutdown unit (WP 005 00).

k. Remove oil pressure switch (1) from bracket by removing screws (2 and 4) and washers (3 and 5). 15. INSTALLATION. 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 c. Remove condenser 008 00). CONTROLS door. (WP

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. a. Route lines thru pressure control pncl 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 5cI c w5 17). bracket 16) with washers (8) and

fan panel assembly

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.

d. Connect wiring pressure switch (I I. e. Position insttill screw.

as tagged to terminals switch

on oil (1) and

cover 01 oil pressuw

BAG-1

0-MMM-000

009 00
Page 18

P d

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. f. Install oil pressure switch compressor (18 and 19, figure 5). g. Leak test connections. h. Evacuate unit (WP 007 001. capillary lines on

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).

i. Adjust switch (WP 007 00) if necessary. j. Open compressor suction and valves by turning stems counterclockwise. k. Install I. Install 008 00). stem caps condenser fan panel assembly (WP discharge

m.. Close and secure PRESSURE door. 16. LQW PRESSURE SWITCH.

CONTROLS

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. f. Remove from tee(10). low pressure switch capillary line

Support

Equipment None

Required

g. Tag and disconnect switch (22, figure 4).

wiring

from low pressure

Materials

Required None

h. Remove screws (20) and washers bracket (19). i. Remove screws (23) and washers low pressure switch (221. j. Remove low pressure 18. INSTALLATION. switch (22).

(21) from

(24) from

17. EWiOVAL. a. Shut down unit (WP 005 00).

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 c. Remove condenser 008 00). CONTROLS door. (WP

a. Position bracket (19). b. Install

low pressure switch

(22, figure 41 on

screws (23) and washers (24). support bracket (19) in pressure

c. Position ctrols panel.

d. lnslall support bracket washers (21) and screws (20). e. Connect wiring as tagged

(19) by installing

fan panel assembly

AG-180AO-M

M M-000

009 00
Page 19

d. Remove stem caps from compressor discharge valve and compressor suction valve. Close valves by turning stems clockwise. Do not allow kinks or binds in capillary line. If this should occw, switch must be replaced. f. Connect low pressure switch capillary tee (10, figure 5). g. Leak testconnection, h. Evacuate compressor (WP 00 7 00) i. Open compressor discharge and valves by turning stems counterclockwise. j. Install stem caps on compressor and suction valves. k, Close ilnd S~CUI V I KlX3URE door. I. Install 008 00). 19. HIGH condenwr fan panel suction line to 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).

discharge

COSTROLS Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. f. f<cmove high pressure from tee (17). switch capillary line

assembly

(WP

PRESSURE Support

SWITCH. Required

Equipment

g. Tag and disconnect wiring pressure switch (25, ligure 4). Materials
SOe

from

high

Required h. Remove screws (20) and washers support bracket (191. (21) from 1

20. REMOVAL. i. Remove screws 1261 and washers (27) a. Shut down unit (WP 005 00). j. Remove high pressure switch (251,

21. INSTALLATION. a. Position high pressure switch (25, figure 4) on support bracket (19). h. Install c. f osition cotrols panel. (WI washers (27) and screws (26). support bracket (19) in pressure

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 c. Remove condenser 008 00). CONTROLSdoor, fan panel asselnhly

d. Install support bracket washers (21) and screws (20).

(19) by installing

AG-180AO-MMM-000

009 00
Page 20

e. Connect wiring

as tagged.

c. Remove condenser 008 00).

fan panel assembly

(WP

[=] Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. f. Install high pressure switch capillary tee (17, figure 5). g. Leak test connection h. Evacuate system (WP 007 00). i. Open compressor discharge valves by turningstemscounterclockwise. j. Install stem caps to compressor suction service valves. k. Install 008 00). condenser fan panel and suction line on

d. Remove valve stem caps from compressor discharge service valve and compressor suction service 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 phere by loosening fan cycling switch connection at tee (17, figure 5). to atmoscapillary

discharge

and

assembly

(WP Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. f. Remove fan cycling tee (17, ligure 5). switch capillary line from

I. Close and secure PRESSURE door. 22. FAN CYCLING Support SWITCH. Equipment None Materials Required None 23. REMOVAL. a. Shutdown unit (WP 005 00).

CONTROLS

Required

g. Tag and disconnect switch (28, ligure 4).

wiring

from fan cycling

h. Remove screws (20) and washers support bracket (19).

(21) from

i. Remove screws 129) and washers (30). j. Remove fancyclingswitch 24. INSTALLATION. a. Position fan cycling support bracket (19). switch (28, ligure 4) on I (28). I

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

h. Install c. Position controls panel.

washers (30) and screws (29) support bracket (19) in pressure 1

d. lnslall support 121) and sc~ ews (20).

bracket

by installing

washers

AG-180AO-MMM-000

009 00
Page 21/(22 Blank)

e. Connect wiringas

tag@

h. Leak test connection i. Open compressor discharge and suction servicing valves by turningstemscounterclockwise. j. install stem caps to compressor suction service valves. k. Close and secure door. I. Install 008 00). condenser PRESStiRE discharge and

Do not allow kinks or binds in capillary line. If this should occur, switch must be replaced. f. Install fan cycling (17, figure 5). switch cupillary line lo tee

COYTROLS

fan panel

nssembly

(WP

g. Evacuate compressor

(WP 007 00).

AG-180AO-MMM-000
15 May 1991

mb3 00
Page 1 of 34

ORGANIZATIONAL ELECTRICAL CONTROLS ASSEMBLY PANEL, AND

AND

INTERMEDIATE

MAINTENANCE PANEL, AND WIRING

FUSE BOX, INSTRUMENT DISASSEMBLY

INSTRUCTIONS

AIRCONDITIONER.AlRCRAFTGROUNDCOOLINC AIM32C-21 PART NUMBER Reference 1603ASlOO-1 Material

NOIll? Alphabetical Sub&t 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 NolIe 1. ELECTRBCALCONTROLS Support Equipment NOW Materials Required NOW3 PANEL. Required To prevent injury or death, make sure electrical power source is OFF and power cable is disconnected before working inside electrical controls panel. 2. DISASSEMBLY. Directives Index

AG-180AO-M

M M-000

010 00
Page 2

8. Open controls panel access cover by turning grip latches (15, figure I). 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). light (22)

u. Remove screws (29) and washers main service circuit breaker (28). v. Remove main service circuit breaker

(30) from

(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 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 breaker (28). as tagged on main service circuit 1

d Remove lens (25) from indicator c Rcmo\~ bulb (261 f. Tag and disconnect 122) g I~rmove indicator wiring

from indicator

light

light (221, plate (17). (201 from

h. Remove rivets (181 and instruction i. Remove screws (211 and washers operating handle (19) j. Remove operating handle (19)

d. Position voltage control transformer (64) in place and install four washers (66) and screws (65). e, Install (64). f. Install wiring on control voltage transformer

ivxess cover (67) and screw (68).

k. Remove screws (9) washers ctrls panel wxx!ss cover (7).

(8) and remove 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 K2 (50) and K3 (61). assemblies Kl (41),

I. Tag and disconnect wiring from assemblies Kl (41), K2 (50) and K3 (61).

starter

m.Kemove screws (42,51,62) washers (43,52.63) from starter assemblies, Kl 1411, K2 (50) and K3 (61), n. Remove starter and K3 (61). assemblies Kl (411, K2 (50)

i. Position grip latches (151 on controls xcess cover (7) and install rivets (16). j. Install k. Install I. Install starter indicator wiring reset buttons (27) light (22).

panel

o. Remove screw (68) from access cover (67). p. Remove nccess cover (67) q. Tag and disconnect control transformer (64). wiring from voltage

as tagged on indicator

light (22).

m.lnstall

bulb 126) and lens (25). plate (17) in place and

r. Remove screws (65) and washers voltage control transformer (64). s. Remove voltage control transformer t. Tag and disconnect circuit breaker. wiring

(66) from

n. Position instruction in&all rivcts(l8).

(64).

o Position operuting handle washers (20) and screws (21).

(19)

and

install

from main service

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

,A

__

I ,,: A. \

DAPPLY LACOUEATHINNERTO GASKETSTO ACTIVATEAOHESIVE. ~;%lC&CUlT BREAKERTO INDEX 2% BY ROTATING ADJUSTMENT DSET

EtEcmxt POWER PHASE toss RELAY TO MINIMUM RY ROTATING AOJUSTMENTSCREWCOUNTERCLOCKWISE

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 1 2

PART NU.MBER 1603ASl12 1603AS298

i)ESCRIPTION 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 . . . . . . . . . . .

UNITS PER ASSY

USABLE ON CODE

SM &R CODE

1 1 14 14

ADGGG MCCZZ PACZ PAGZZ

3 4 5 6 7

MS35207.263 MS27183.42 1603AS322.3 1603AS322.4 1603AS295

XBGZZ XRGZZ A DGGC 5 5 I PAGZZ PAGZZ MGGZZ MGCZZ PAGZZ PAGZZ PAGZZ

8 9 10 II

MS27183.42 MS35207.264 1603AS297 1603AS296

_ . .

. . . . .

1 6 12 6

12 13 14 15

MS35207-264 MS27183.42 MS21044N3 1603AS323

. .

PAGZZ PAGZZ

16

M242431 6-A403H 1603AS316

10

17

I8

M24243/ 6.A403H

PLATE, lNSTRUCTlON, WARNING . . . . . . . IATTACIIING PARTS/ . RIVET, POP . . . . . . .

1 2

MGGZZ PAGZZ

Figure

1. Electrical

Controls

Panel

(Sheet

3)

AG-180AO-MMM-000

010 00
Page 6

INDEX NO I 19

PART SUMBER I 1603AS317 .

DESCRIPTION I HANDLE, OPERATING MECtlANISkt/28432/ 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.-STSTARTERRESET. . . . 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 . . . * . . . . .

UNITS PERASSY I

USABLE ON CODE I

SM &R CODE

PAGZZ PAGZZ PAGZZ

20 21 22

MS35338-43 x35207-259 1603AS325.1

PAGZZ

23 24

NIA N/A

25 26 27 28 1603AS326 1603AS313 1603ASl50

N/A PAGZZ PAGZZ

. ,

PACZZ

29 30 31 32 MS35333-38 1603ASl61 1603AS162

. . . .

. .

. .

3 4

N/A PAGZZ

. . . . .

. . . . .

PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ

33 34 35

MS27183.6 MS35333.37 MS51849.34

. . .

Figure 1. Electrical Controls

Panel (Sheet 4)

AC-180AO-MMM-000

01000
Page 7

INDEX NO 36

PART NUMBER 1603AS274

DESCRIPTION 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 ASSEMBLYBLOWERMOTOR. _ . /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 ,ASSEMBLYCOMPRESSORMOTOR /ATTACHING PARTS/ SCREW,MACHINE . WASHER, FLAT . . *.. .

UNITS PERASSY

USABLE ON CODE

S.M &R CODE

. .

PAGZZ

31

1603AS213

. _

PAGZZ

38

1603AS716

. . .

. . . . . _

AGGGG PAGZZ PAGZZ

39 40 41

MS35206.217 MS21044N4 1603AS280

. . .

. _ . . . .

PAGGG PAGZZ PAGZZ

42 43 4-1 45 46 47

MS51849-64 MS27183.42 1603AS710 MS35206.217 MS21044N4 1603AS712

. . . _ . . . . .

1 4 4

AGGGG PAGZZ PAGZZ

. .

AGGGG PAGZZ PAGZZ

48 49 50

MS35206-217 MS21044N4 1603AS278

: :

: :

. . . . .

. . . . . .

1 3 3

PAGGG PAGZ% PAGZZ

51 52 53

MS51849.64 MS27183.42 1603AS188

SOCKET, RELAY151 IO ?/ RD.08/ . . . . . . . . . .

PAGZZ

Figure 1. Electrical Controls

Panel (Sheet 5)

AG-18OAO-MMM-000

@ IQ
Page 8

-~.--__ INDEX NO PART NUMBER DESCRIPTION /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~LYCONDESSEK 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) . . . . * 1603AS683-I BUStlING,UNIVERSAL .

-UNITS PER ASSY USABLE OS CODE SM &R CODE

54 55 56 57

MS51849.54 MS35333-38 MS27183-41 1603AS167

. . .

. . .

2 2 2

PAGZZ PAGZZ PAGZZ

. . _ . . . . .

PAGZZ AGGGG t AG%% PAG%%

58 59 60 61

1603AS714 MS35206.217 MS21044N4 1603AS279

. . _ . . .

I AGGG I AC%% I AG%%

62 63 64

MS51849.64 MS27183.42 1603AS149

. . .

. . .

PAGZZ PAGZZ PAGZZ

65 66 67

MS51849.95 MS27183.IO

. .

NIA

68

. . . .

N/A PAGZZ

69

Figure 1. Electrical Controls

Panel (Sheet 6)

AG-180AO-MMM-000

010 00
Page 9

4. FUSE BOX Support Equipment Required

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). Materials Required p Tag and disconnect (17). wiring from fuse holder

5. DISASSEMBLY. a. Remove ~erews (3, figure 2) and washers from controls panel top cover (2). b. Remove controls hox (I). (4)

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 (20). wiring from fuse holder

panel top cover (2) from fuse

u. Remove screws (21) and washers (22) from fuse holder (20). v. Remove fuse holder (20) from fuse hox (1). To prevent injury or sure electrical power and power cable is before working inside death, make source is OFF disconnected fuse hox. 6. ASSEMBLY. a. Position fuse holder (20, figure washers (22) and screws (21). b. Install d. Tag and disconnect (6). wiring from fuse holder c. Install d. Position (18). e. Install g. Remove fuse (8) from fuse holder (9) f. Install h. Tag and disconnect (9). wiring from fuse holder g. Position fuse holder (15)andscrews(l4). h. Position fuse holder (Il)andscrcws(lO). i. lns~all wiring k. Removcfu~es(l2)from I. Tag and disconnect (13). fuse holder (131 j. Install wiring from fuse holder k. Position fuse holder (6) and install screws ( 7). fuse (8) in fuse holder (9). (13) and install washers fuses (16) in fuse holder(l7). fuses (19) in fuse holder (20). fuse holder (17) and install screws wiring 1) and install

c. Remove fuses (5) from fuse holder (6) as tagged on fuse holder (20).

e. Remove screws (7) from fuse holder (6) f. Remove fuse holder (6) from fuse box (1).

wiringon

fuse holder(l7).

i. Remove screws (IO) and washers ( I1 1 from fus;c holder (9).

(9) and install

washers

j. Remove fuse holder (9). as lagged on fuse holder (9)

AC-18OAO-MMM-000

010 00
Page 10

APPLY LACUUERTHINNER TO GASKETSTO ACTIVATE

Figure 2. Fuse Box (Sheet 1 of 3)

AG-18OAO-MMM-000

010 00
Page 11

I I
INDEX NO 1 2 3 4 5 6

PART NUMBER 1603AS288 1603AS299

DESCRIPTION I BOX, FUSE-WELDMENT /SEE FIGURE I FOR NHAI . . COVER, TOP, PANEL, CONTROLS . . . . . /ATTACHING PARTSI . . SCREW,MACHINE . . . . WASHER,FLAT . . . * . . . . . 1 1 10 10 MGGZZ MGGZZ PAGZZ PAGZZ

. . . _ . .

MS35207.263 MS27183.42 1603AS320.2 1603ASl64-2

7 8 9

MSl6997.58 1603AS321.2 1603AS319

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 /71400/2807/ . . . . /ATTACHING PARTS/ . . SCREW,MACEIINE . WASHER,LOCK . . * . . . . POLE . . . . . . . . . . . . .

3 1 3 1 1

PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PACZZ PAGZZ PACZZ PAGZZ m :

10 11 12 13

MS35206.230 MS35333.37 1603AS321-1 1603ASl66 . .

14 15 16 17

MS35206.230 MS35333.37 1603AS320.I 1603ASl64.1

. . . .

FCSEI71400/FSQ-11 . . HOLDER, FUSE, THREE POLE/71400/2809/. . . /ATTACHING PARTS/ . . . SCREW,MACHINE . WASHER,LOCK . . . * FL-SE, TIMI? DELAY, 600 /71400/JHC-601 . . . . . HOLDER, F USEIll873 lJ60060.30 . . . . . /ATTACHING PARTS/ . SCREW,CAP. . . . . * .

. . . . VOLT . . . . .

3 1 3

PAGZZ PAGZZ PACZi!

18 19

MSl6997.58 1603AS165

. .

FCSE,TIME DELAY/71.t00/ JIIC-so/ . . . . . . . . .

PACZZ

Figure

2. Fuse Box

(Sheet

2)

AC-1 80AO-MMM-000

010 00
Page 12

I I
INDEX NO 20 21 22 23 24

PART NUMBER 1603AS318 . .

,DESCRIPTION HOLDER, FUSE, CLASS J /11873/J60100-30 . . . . IATTCHING PARTS/ . . . . . SCREW,MACHINE . WASHER,LOCK . . . . . * . PANEL186730 . . . . . PAIUEL186730 . . . _ . . . . .

I 2 2

PAGZZ PAGZZ PAGZZ

MS35207-263 MS35333.39 1603AS322.6 1603AS322.5

. . .

GASKET, /4lllNDB/. . . GASKET, /4lllNDB/.

2 2

XBGZZ XBGZZ

Figure

2. Fuse Box (Sheet

3)

AG-180AO-MM

M-000
Page 13

1. lnstz~ll wiring m.lnstall

as tagged on fuse holder (6).

g. Capcompressordischarge h. Remove two screws (40) i. Remove compressor (39).

pressuregauge

line.

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 Support PANEL Equipment Non-2 Materials Required None 8. DISASSEMBLY. n. Open instrument latches (53, figure 3). panel door by turning grip Required

discharge

pressure

gauge

j. Crack fitting at compressor suction pressure gauge (41) and allow refrigerant to bleed to atmosphere. k. Remove line from compressor suction pressure gauge (41). Cap compressor suction pressure gauge line. I. Remove two screws (42). m.Remove (41). n. Remove meter (43). compressor suction pressure gauge

b. Remove rivets (54) securing grip latches (53) to instrument punel door (8) and remc~ve grip latches(53). c. Remove condenser 008 00). fan panel assembly (WP

and tag wiring

from

elapsed

time

o. Remove screws (44). p. Remove elapsed time meter (43) q. Remove air temperature sensing bulb from spring clips (48) and remove from aftercooler module. r.Remove two nuts removG air temperature (47) and clamp gauge (45). (48) and I

d. Remove caps from compressor discharge service valves and close discharge service valves by turning clockwise.

suction and suction and valve stems

s. Remove line from air pressure gauge (51) t. Remove screws (52) and remwe 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. e. Crack fitting gauge (39) and atmosphere. at compressor discharge pressure allow refrigerant to bleed to u. Remove cap and bulb panel lights (37). v. Remove and tag wiring remove nut (38). w. Remove instrument (17) from air pressure

instrument

from

light

(37) and

panel lights (37).

x. Remove lens (23) and bulbs (17) from indicator lights (22). y. Remove and tag wiring lights (22). and remove indicatot

f. Remove line from pressure gauge (39).

compressor

discharge

AC-18OAO-MMM-000
Page 14

ELAPSEDTIME METER WIRING

CAPILLARY INFORMATIVE wP00900

PRESSURE CAPILLARY INFORMATIVE COMPRESSORSUCTIO PRESSURECAPILLAR INFORMATIVE

56 57 56

..

1:
/ 7 . Figure

.E ADHESIVE. 1. APPLY LACOUERTHINNERTO GASKETSTO ACTIVAl

-1

2. COIL EXCESSSENSINGLINE.SECtlREAN0 STOW ON TOP OF PRECOOLER MODULE.

3. Instrument

Panel

(Sheet

1 of 5)

AG-l80AO-MMM-000

010 00
Page 15

INDEX NO 1 2 3 4

PART NUMBER 1603ASlll 1603AS327 MS35489-20 1603AS333

DESCRIPTION PANEL, INSTRUMENT /SEE WP00800FORNHAI . PANEL, INSTRUMENT WELDMENT. . . . . GROMMET,RUBBER . PANEL, INSTRUMENT, SUBASSEMBLY . . /ATTACHING PARTS/ . NUT,SELF-LOCKING . WASHER, FLAT . . *.. . .

UNITS PERASSY

USABLE ONCODE

SM &R CODE

. . . . . . . . . . .

AGGGG MGGZZ PAGZZ XBCGG PAGZZ PAGZZ

. . . . _ . . . . .

5 6 7

MS51922-9 MS27183.12 1603AS350

1603AS348

9 10 11 12

MS90725.6 MS27183.10 MS21044N4 1603AS347

. . . .

13 14 15

MS35333-39 MS35207.264 1603AS325-1

. .

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 *..

. . . .

_ . . . .

1 1 5 10 5

MGGZZ XBGZZ PAGZZ PAGZZ PAGZZ

PAGZZ PAGZZ PAGZZ

. _ _ .

. .

16

. .

17 18

1603AS326 1603AS343

. . . .

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

PAGZZ

S/A

6 I

PAGZZ f AG%Z

Figure

3. Instrument

Panel

(Sheet

2)

AG-180AO-M

M M-000

010 00
Page 16

INDEX NO 19

PAKT NUMBER . .

DESCRIPTION FLANGE RING (SUPPLIED WITHSWITCII). . . . . *

CNITS PER ASSY

USAK1.E OS CODE:

SM &K CODl?

20

1603AS344

21 22 l603AS325-2

23

SWITClI, PUSHBUTTOS, STOt 102288lI 133ESRZ . . IATTACIIISG PAKTSI I I.I~I~ . . FLANGE RISG(SUI 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).

I AGZZ

I 3

N/A PAGZZ

/A

24

1603,\Sl68

t AG%%

25

N/A

26

27 28

1603AS512

29

..

KSOK, OV/\l., I~ I.USII /82121/01040-11. . . /ATTACll ISG I AKTS/ SCREW/82121/02016-91. . SWITCtl ASS1:Ml~I.Y. DlM4lEK . . . . /ATTACtllSG I AKTSi SLT (SCPPI.IKD WlTtI SWITCII) . . . . . * . . .

t AG%% t AG%% AGCGG

. OS-Ob l . . . .

N/A

30 31 32

MILR~94-KV4 N,\YSD-352A 1603AS346 1603ASL75

. .

33

$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 . . . . *

SRG%% . I AG%% I AGZZ

S/A

Figure

3. Instrument

Panel

(Sheet

3)

01000
Page 17

DESCRIPTION 34 MS24523.27 . . SWITCIi.TOGGLE.ONE POLE. . . . . . . . . . /ATTACHING PARTS/ . LOCKWASHER(SUPPLIED WITHSWITCH). _ _ . . . . NUTfSUPPLIKD WITH SWITCH) . _ . . . . . _ -.*.. . I.RXlT. PANEL, INSTRUMKNT l71744/900-006l _ . . - - . . NUT (SUPPLIED WITH LBCIIT) . . _ _ _ . . . . * .

UNITS PER ASSY

USAHLE ON CODE

SNI &R CODE

PACZZ

35 36

__ __

. .

I I

NIA NIlI

31 38

1603AS169 __

. .

2 1

PAGZZ NIA

39

I603ASI53

40

._

41

1603AS152

42

-.

GAUGE. DISCIIARCE PRESSURE-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. . . . .

I AGZZ

N/A

PAGZZ

N/A

43

1603ASI51

I AC%%

44

-.

NIA

45

1603ASl57

I ACZZ

Figure

3. Instrument

Panel

(Sheet

4)

AG-180AO-M

MM-000

010 00
Page 18

INDEX NO

PART NUMBER

DESCRIPTION /ATTACtIlNC PARTS/ . . CLAMPfSUPPLIED WITH GAUGE). _ . . NUT (SUPPLIED WITHCACCE) . . . ..*.. . . CLIP, SPRING TENSION . . . . . /ATTACHING PARTS/ . . RIVET,BLIND . . . t.. . . .

UNITS PER ASSY

USABLE ON CODE

SM &R CODE

46 47

. .

_ . . .

I 2

N/A N/A

48

NAS1464.044 -04c M2424311-A403 X335489-345 1603AS156

. .

. .

. .

PACZZ PACZZ PACZZ

49 50 51

52

GROMMET . . . . . . . CAL-GE, DELIVERED AIR PRESSURE 157098iW24DSB51 . . . . IATTACIIISC PARTS/ SCREW (SUPPLIED WITH CACCE) . . . . . . *.. . . .

PACZZ

N/A

53

1603AS323

54

MM24231 l-B402 1603AS322.7 1603AS322.8 1603AS177.1 1603AS177.2

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/

5 10

PACZZ PACZZ

55 56 57 58

. . . .

. . .

. . .

XBCZZ XBCZZ XBCZZ PACZZ

. .

. .

Figure

3. Instrument

Panel

(Sheet

5)

AG-180AO-M

M M-000

010 00
Page 19

z. Disconnect and tag wiring start switch (18). aa. Remove flange ring pushbutton start switch (181. ah. Disconnect stopswitch (20). and tog wiring

from

pushbutton

9. ASSEMBLY. a. Position instrument panel subassembly weldment (7, figure 3) in instrument panel weldment (2) and install washers 16), and nuts (5). b. Position instrument panel door (8) on instrument panel subassembly (7) and install washers (IO), screws (9) and nuts (II). c. Position terminal block washers (13) and screws (14). d. Connect (121. wiring (12) and install

(19)

and

remove

from pushbutton

ac. Remove flange ring pushbutton stop switch (20).

(21)

and

remove

ad. Remove screw (27) from knob (26) se. Disconnect switch (24). and tag wiring from MODE

as tagged on terminal

block

e. Position air flow toggle switch washer (35) nnd nut (36). MODE f. Connect (34). and wiring to AIR FLOW

(34) and install

of. Remove four screws (25) and remove switch (24). ag. Remove screw remove knob (32). (33) from knob

toggle

switch

(32)

g. Position OYIOFF (281 in place and install

dimmer nut 129).

switch

assembly

ah. Disconnect and tag wiring dimmer switch assembly (28). ai. Remove nut (29) and ON/OFF assembly (28). aj. Disconnect and tag wiring control toggle switch (34).

from

ON/OFF

h. Connect wiring as tagged to dimmer switch assembly 128). i. Position knob (32) on ON/OFF dimmer assembly (28) and install screw 1331. j. Position (25). k. Connect (24). MODE switch 124) and install

OK/OFF

dimmer

switch

switch

to AIR

FLOW

screws

ok. Remove nut (36) and washer (35) remove AIR FLOW control toggle switch (34). al. Tag wiring. and disconnect terminal block (12)

wiring

as tagged

to MODE

switch

I. Position knob (26) on MODE install screw (27).

switch

(24) and

am. Remove screws (14) and washers (13) on. Remove terminal block (12).

m.Position pushbutton STOP switch and install flange ring(21). n. Connect (201. wiring to pushbutton

(201 in place

STOP

switch

ao. Remove screws (9), ten washers (I 0) und live nuts(ll1. op. Remove instrument aq. Remove nuts(5) sr. Remove weldment 17). panel door (8).

o. Position pushbutton START place and instoll llange ring ( 19). p, Connect wiring START switch 1181. as tagged

switch

(181 in

to pushbutton

and washers( panel subassembly

instrument

q. Position indicator (171 and lenscs(23).

lights

(221 and install

bulbs

AG-180AO-MMM-000

010 00
Page 20

r. Connect WI.

wiring

as tagged

to indicator

lights

ah. Evacuate system (WP 007 00) ai. install 008 001. IO. WIRING This section contains information required 11. for replacement of wiring. Repair of wiring should be accomplished in accordance with SAVAIR-Oll A-505. Information in this work package is arranged 12. in nine-column format. Columns are described in paragraphs below. 13. WIRE RUN NO. condenser fan panel assembly (WP

s. Position instrument and install nut (38). t. Connect wiring light (37). u. Install light.

panel

light

(37) in place

as tagged to instrument

pnnel

bulb (17) and cap on instrument

panel

v. Position air pressure install screws (521. w. Install

gauge (51) in place and

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. y, Position AIR TEMPERATURE gauge 1451 in place and install clamp(48) and nuts (47). z. Position ELASPED install three screws (44). aa. Connect wiring meter (43). TIME meter (43) and

This column lists the number used os o wire 14. 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. to the index

as tagged to ELASPED

TIME

The INDEX NO. corresponds 16. number listed in the Parts List. 17. STRIP INSULATION

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 PRESSURE gauge (39) and install DISCHARGE screws (40).

The STRIP ISSULATIOS 18. length of insulation to be installation. 19. FROM

column removed

lists the before

20. The FROM column lists that ZI specific wire begins at. 21. TO.

the component(s)

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). ag. Secure instrument grip latches (54). panel door (8) hy turning

22. The TO column lists specific wire connects with. 23. WIRE LG LG column

the component

that

il

24. The WIRE rcquircd

lists the length of wire

AG-18OAO-MMM-000

010 00
Page 21

TABLE
I
WIRE RUN NO INDEX NO. STRIP INSUL IINCHESI FROM

1. WIKING

LIS I
STRIP INSUL TO IINCHESI INDEX NO. WIKE .o.oo LG

+ 2.00

AG-180AO-MMM-000

010 00
Page 22

TABLE 11

1. W IRIN

; LIST (Continued) ,,
F9-L K3-LI K%LZ K3-L3 JZA .J3-B 63-C H3-T2 H%T, RX-T3 FlO-1. F1 1-L F12-I. K5-3 3, .3, .3, .I8 62 .31 31 31 5 5 5 18 18 IX 9 9 9 5 5 5 6

IO.00
12.00 30.00 30.00

TRI-HZ TKl-HI Fl3-L

I .I72 I

10

I .62 I
I .I8 I

LO
6

I
1 KlX4.NO 1 .18 28

I
1 1

20
6 7

3
35.50

18.00

AG-180AO-MMM-000

QIOD 00 Page 23
1. W IRING LIST(Continued)

TABLE

AG-!

Cl-MMM-000

01000
Page 24

TABLE

1. W IRING

LIST(Continued)

I 98
99

3.6

.I" .I8

sw3.:1-12 sw3.u

sw3-I.& "S4

28 .1x

7 6

I4.00 4.00

AG-18OAO-MMM-000

010 00
Page 25

TABI,E

1. W IRING

I,IST(Continued)

AC-1 80AO-M

M M-000

010 00
Page 26

TABLE T
.
131 132 133 134 135 136 137 138 139 3.6 3.6 3.6 3.6 3.6 .18 .18 .18 .I8 .I8 .lS .18 .62 .62

1. W IRIk;

; LIST (Continued)

PS4-Ml PS5-M2 PSS-MI TBL-5 TBL-4 PSG-Ml PSG-ML S6 53

[-:

396
3.6 3.10 3. LO

I i.l:,

143 144 145

3. IO 3.6 3.6

.62 .I8 .18

til TBI-7 TBI-8

149 150

3,6 3.7

.I8 .28

K.5. I KIXS-COM

ios-2
sw4-11141 PS4.I. 155 PS5.L

.I8 31

6 ISOLUERI

2.00 4.00

.I8 .I8

6 6

2.00 2.00

AC-18OAO-MMM-000

010 00
Page 27

LEGEND D

FOR TABLE

IDENTIFY IN ACCORDANCE WITH MIL-W-5088 USING MACHINE HOT STAMPED MARKING PRIOR TOASSEMBLY. USE INDEX NO. 9 (3 EACH) TO CONNECT MOTOR WIRES: B3-T4 & T7, B3-T5 & TS, AND B3-T6 & T9 TOGETHER, RESPECTIVELY. SOLDER PER MIL-STD.454, Cl C2 REQ 5

!D

D CD &I

SOLDER AT,CAPACITOR SOLDER AT CAPACITOR

AC-180AO-MMM-000

010 00
Page 28

I I
INDEX SO 1 2 3 4 5 6 I 8 9 IO I1 12 13 14

PART NUMBER I NO NUMBER MILW-5086/2 MIL-W-5086/2 MIL-W-508612 MS25036.118 MS25036.I 12

DESCRIPTIOS 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, ELECTRICALPl (SEE FIGURE 4 FOR BREAKDOWN) . CONNECTOR ASSEMBLY, ELECTRICAL - Jl (SEE FIGURE 4 FOR BREAKDOWN). . CONNECTOR ASSEMBLY ELECTRICAL -J2 (SEE FIGURE 4 FOR BREAKDOWN) . CABLE ASSEMBLY-WIRE ELECTRICAL 1 2 (SEE FIGURE 4 FOR BREAKDOWN) . CONNECTOR ASSEMBLY ELECTRICAL - 53 (SEE FICURE 4 FOR BREAKDOWN) . CABLE ASSEMBLY, -WIRE ELECTRICAL - P3 (SEE FICURE4 FOR BREAKDOWNI .

1 Pk%Y

1 &%:LoE

1 ,,:E

. . . . . . . . . . . . .

AS LISTED AS LISTED AS LISTED 3 6 102 31 3 3 29 5 3 31

PAGZZ PACZZ PACZZ PACZZ PAGZZ PAGZZ XBGZZ XBGZZ XBGZZ XIX%% PAGZZ I AGZZ PACZZ

MS25036-153 1603AS271 1603AS155.3 1603AS155.2 1603AS155.I MS25036.108 1603AS717 MS25036106 1603AS709

XBCZZ

15

I603AS710

AGCGC

I6

1603AS712

AGCGG

17

I603AS711

XBCZZ

18

1603AS714

ACGCC

19

1603AS713

XRGZZ

AG-180AO-MMM-000
Page 29

I I
INDEX NO
20

PART NUMBER 1603AS716 .

DESCRIPTION CONNECTORASSEMBLY, ELECTRICAL-J4(SEE FIGURE4FORBREAKDOWNl . CABLEASSEMBLY-WIRE, ELECTRICAL-P4(SEEFIGURE4FORBREAKDOWN) . TtiRMINAL,LUC,CRIMP STYLE . . . . . . . .

AGGGG

21

1603AS715

1 3

ACGGG PAGZZ

22

,MS25036-109

AG-180AO-MMM-000

010 00
Page 30

37

40.

39 \

26

27

28

Flgure

4.

Cable

and

Connector

Assemblies

(Sheet

1 of 3)

AG-180AO-MMM-000

010 00
Page 31

1 INDEX NO

PART NUMBER NONUMBER 1603AS709 MS3106R20.19P (8771 1603AS692.7

I DESCRIPTION . . . CABLE AND CONNECTOR ASSEMBLIES/SEE WP 008 00 FOR NHAI CABLE ASSEMBLYWIRE,ELECTRICAL-PI . . . . CONNECTOR . . . . . . U, . . . . . . U, . .

UNITS PERASSY

I USABLE ON CODE

)SM&R CODE
.I

1 1

XBGZZ PAZZZ

4 5 6 7 8 9 10 11

MIL-W-508612 1603AS710 MS3102A20-19s TYPEFP301,.38 MII..W-508612 i603~s711 MS3106R20-19PW (877) 1603AS692.6

. . TUBE, .75 ID X 68.00 LG/ IMIL-I-631,TYPE F, FORM GRADE C, CLASS I, CATEGORY 1 . . . _ . . . . WIRE, #8 WHITE, 8O.OOL . . CONNECTOR ASSEMBLY, ELECTRICAL-J1 . . . . . . . CONNECTOR . . . . . . TtiBING, HEAT SHRINK/ /2401 l/ . . . . . . . . WIRE #8, WHITE, 6.OOL . 1 CABLE ASSEMBLY-WIRE, ELECTRICALP . . . . . . . CONNECTOR . . . . . . . TUBE, .75 ID X 88.00 LGI MIL-I-631,TYPE F, F0R.M GRADE C, CLASS I, CATEGORY 11 . . . . . . WIRE. #8. WHITE. 100.001, , . . . . . CONNECTOR ASSEMBiy, ELECTRICAL-.J2 . . . . CONNECTOR . . : : TUBING, HEATSHRINK, 1.00 L/24011/. WIRE #8,WlIITF,,6.dOI: CABLE ASSEMBLY-WIRE, . ELECTRICAI..P3 . . . . . . COSNECTOR . . . . . .

1 3 1 1 3 3 1 1

XAGZZ PAZZZ AGGGG PAGZZ XBGZZ PAGZZ XBGZZ XACZZ

1 3

XAGZZ PAZZZ AGGGG PAGZZ XBGZZ PAGZZ XBGZZ PACZZ

12 13 14 15 16 17 18 19

MIL-W-5086/2 1603AS712 MS3102A20 -19sw TYPE FP301 .38 MIL-W-508612 1603AS713 MS3106R20.3P (877) 1603AS692.8

: : . . . . . . . . 1 1 3 3 1 1

20 21 22

MIL-W-5086/2 1603AS714 MS3102A20.3S

TUBE, .38 ID X 48 LG/ MILI-631, TYPE F, FORM 4, GRADE C, CLASS I, CATEGORY II. . . . . . , . . . . WIRE, #12, WHITE, 66.OOL . . . . . . . . CONNECTOR ASSEMBLY, ELECTRICALJ3 ...... .. CONNECTOR ......

1 3 1 1

XAGZZ PAZZZ AGCGG PAGZZ

Figure

4.

Cable

and

Connector

Assemblles

(Sheet

2)

AG-180AO-M

M M-000

010 00
Page 32

lSl)KX so
23 z-1 25 26 27 28 29 :111

I AI?I SUMHIcK ~~1 1: 1 1 301,.13 .Vll.-\V-5086/Z l603AS715 ~lS3106K22-l9P (8771 MS3367.5 I6lmwi92I .\IIl.-\V-SO86/:! llw3As692-2 . .

I)[ISCKI1I I0N TUHISC, II~:ATSIIKISK. 1.00 I.I L401 Ii . . . . . , . \VIKF:, #I& WIII I lc 6.00 I. . ASS~:~lI~l.Y-WIKI:. . c/we [iLI~C I I~ICAI.-I 4 . . . . . . . C0NNI:C I 0K . . . . . . STKAP, I IF:I)oWs . . TUItE:, .38 II) X 17.OOl.1 . . . \VIKI:. #16,W~i1 1 ~:.22.001. 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 . . . . . \VIKE, #l6, WII1 1 ~,60.001. . I CISK, .38 II) X lU7.001. . /~lIl.-l-6:~l. l YI ~: lJ, ~OKM u, GKADk: C, CLASS I. CAT1:COKY Ii . . . . . WIRI:, #Ifi,WIIIT~. 112.001.. TUl%E, .38 X 145,00/ Mll..I-631,TYl l: [:, k OK!vl U, GRADE C, CLASS I, CATEGORY II . . . . . . \VlRF., #l6, WIIITIS. 148.001. . . . . . . . TCRE, 1.00 X 3.001 \III.-I-631,TYI I: I:, FOKM U, GKAD11 C, Cl.ASS I, CA I k:COKY Ii . . COSS~CTOI~ASS~:~l~I.Y, I~:I.I:c I I~Ic/\I.-.~1 . . . . COSNKCTOR . . . . . . TL IHSG, tIEA l SllKlNK, 1.00L/2101 I/ . . . . . . WIRE, #lG, WIIITE, 23.00 I. . . WIRE, #l6, WlllTE, 17.001, . WIRE:, #lG, WIIITE, 14.001. . . . . . . . . . . WIRE, #I6 WIIITE, G.OOL . . . WIRE, #IF, WllITE, 14.001. . WIRE, #l6,WlIITl~,9.00L _ WIRE, #16, WIIITE, 12.001, . . WIRE, #I6, WIIITE, 16.001, . . WIKE, #I6, WIIIT~,26.001~ .

CSITS WK ASSY

USAI~LE OS COD1s

S!vl &K COI)K

3 3 I I I I 2

XRCZZ f AG%% ACCGG I AGZZ I AGZZ XHGZZ PACZZ

. .

. .

31 32

~III..W-508G12 l603AS692-3

. .

I -I

XBGZZ PAGZZ

33

34

MII.-W-508612 1603AS692.4

. .

XBGZZ PAGZZ

I 2

3.5 36

.\lll.-W508612 lGO3AS692.5

. .

I I I IO I I I I 2 I I I I

SI<G%% AGGCG PAGZZ XBCZZ PAGZZ I ACZZ I ACZZ PACZZ PAGZZ PAGZZ PAC%Z PAGZZ I AGZZ

37 38 39 -IO 41 42 43 44 45 46 47 48

l603AS716 MS3102A22-19s TYI I< FP301,.12 !vIII>-w-s086/2 Mll.-W.508612 Mll..W-5086/:! ~III..W-s086/2 !vllI,-W-5086/2 !vlll.-W-5086/2 MII.-W-5086/L MIL-W-5086/2 !dll.-W-508612

. . . . . . . . . . . .

Flgure

4.

Cable

and

Connector

Assemblies

(Sheet

3)

AG-180AO-M
15 May 1991

M M-000

01100
Page 1 of 18

ORGANIZATIONAL AIRFLOW CONTROLLER

AND INTERMEDIATE MOTOR, AFTE RCOOLER WATER DRAIN AND DISASSEMBLY AIRCRAFT A/M32C-21 PART NUMBER

MAINTENANCE MODULE, PUMP

INSTRUCTIONS MODULE, AND

PRECOOLER

ASSEMBLY

INSTRUCTIONS GROUND COOLING

AIR CONDITIONER,

1603ASlOO

Reference

Material

Alphabetical 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 ...... Record ................... ................... ...................

Index ...... ........ ........

................... ................... ................... ...................

...... ...... ...... ......

........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........

...... ......

................... ................... ................... ................... ................... .................... .................... .................... of Applicable Technical None

...... ...... ...... ......

........ ........ ........ ........ ........

Directives

AC-180AO-MMM-000

01100
Page 2

1. AFTERCOOLER Support Equipment

MODULE. Required

3. ASSEMBLY. a. Position air outlet panel weldment 1) in place and install screws (6). (5, figure

Materials Specification or Part Number 520

Required Nomenclature Adhesive, Insulation

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 aftercooler evaporator cabinet (I). e. Install f. install plate (22) in

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). 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 4. h. Remove by pass orifice plate (22) Support i. Remove insulation (4). Part Number _._ Materials k. Remove aftercooler evaporator coil (26) Specification or Part Number Nomenclature Nomenclature Torque Wrench O-100 inch-pounds Required Equipment Required elbows (17). MODULE.

washers (24 and 25) and screws (23).

Position aftercooler panel (12) in place and washers (14 and 15) and screws (13).

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).

PRECOOLER

j. Remove screws (27) and washers (28 and 29) from aftercooler evaporator coil (26).

I. Remove screws (31) and washers (32 and 33) from delivered orifice plate (30). I m. Remove delivered n. Remove insu!ation o. Remove screws weldment (5). orifice plate (30). (8). (6) from air outlet panel

520 613 5. DISASSEMBLY.

Sealing Compound Adhesive, Insulation Compound, Gasket Forming

p. Remove air outlet panel weldment

(5)

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

APPLYINSULATION AOHESlVElP/N 520 AOHES,"E.FSCM03938, TO INSULATION AND MATING SURFACE.WHEN AOHES,"E,S DRY TO TOUCH,INSTALLINSULATION. D CUT ,750 OIA. HOLEIN INSULATION. BAPPLY CONTINUOUSSEA0 OF GASKET FORMING COMPOUNO (P/N 6B. FSCM 623771 AAOUNO MATING SURFACESAND HOLES,ASSEMBLEPARTSAN0 TIGHTENHAROWA"E. ~CUT.5OHOLESINlNSULATlON mSERIALNOS.51 ANOSUBSE[1UENT.

Flgure

1.

Aftercooler

Module

(Sheet

1 of 3)

AG-180AO-MMM-000

631a OxI
Page 4

INDEX NO

PART NUMBER 1603AS106 1603AS372 1603AS428 1603AS430.4 1603AS430.3 1603AS412

DESCRIPTION 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,AFTERCOOLER . . . . . . . . /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. . . . . .

UNITS PERASSY

USABLE ONCODE

SM &R

. . . . . . 1 1 1 22

MGZZZ XBGZZ XBCZZ XBGZZ MGZZZ PAGZZ

6 I 8 9 10 11 12

MS90 725.5 1603AS627 1603AS431 1603AS430.2 MS35489.345 1603AS430.1 1603AS461

. . . . . . . _ .

PAGZZ XBCZZ XBGZZ PAGZZ

1 1 18 18 18

XBGZZ MGGZZ PAGZZ PAGZZ PAGZZ

13 14 15 16 17 18

MS907255 MS35333.40 MS27183.10 1603AS429 1603AS545.1 1603AS416

_ .

1 4 1

XBGZZ PAGZZ XBGZZ PAGZZ PAGZZ PAGZZ MGGZZ PAGZZ

19 20 21 22 23

X390725-6 x35333-40 MS27183.10 1603AS410 MS90725.5

. . .

20 20 20 1 16

. . . .

Figure

1. Aftercooler

Module

(Sheet

2)

AG-180AO-M

M M-000

01100
Page 5

INDEX NO 24 25 26

PART NUMBER MS35333-40 MS27183.10 1603AS145 . .

DESCRIPTION WASHER, WASHER, LOCK FLAT . . . . *.. . . . . . . . .

UNITS PERASSY 16 16

USABLE ON CODE

SM &R CODE PAGZZ PAGZZ

27 28 29 30

x390725-5 .ws35333-40 MS27183.10 1603AS409

31 32 33 34

MS90725-5 MS35333.40 MS27183.10 NAS1464. 044.04c M24243/1A403 1603AS545-2

. 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 . RIVET, BLIND .

. . . .

. . . . . . . .

1 20 20 20

PAGZZ PAGZZ PAGZZ PAGZZ

. .

1 20 20 20 2

MGGZZ PAGZZ PAGZZ PAGZZ PAGZZ

. . . . . . . . . . .

35 36

PARTS/ . . . . .

. .

PAGZZ

ELBOW, MALE /30327/269-P-04X02

*..

. .

PAGZZ

Figure

1. Aftercooler

Module

(Sheet

3)

AG-180AO-MMM-000
Page 6

@-D

27 *j

yj/ip22a

APPLYlNSlJLATloN AllHESIVE(P/N 520 AOHESIVE.FSCM 039381 TO INSULATION AN0 MATING SURFACE.WHEN ADHESIVEIS ORY TO TOUCH.INSTAtLl NSUtATION. FA" "F COMPO"NO,P,N mASSEMoLE ~hi~li-iLlN~fNOUS EL... -. GASKET -. .~~~ FORMlNG ~~~~ MOTOR TO MOUNTING BRACKETWITH ELECTRICAL LEAOSOOWN. 68. FSCM 62377) AROUNO MATING SURFACE AN0 HiLES. >APPtYSEALlNG COMPOUNOTOTHREAOS ASSEMBLE PARTSANOTIGHTEN HAROWARE. DAFTER A~~EMSLY.TREATEXPOSEO PORTIONOF SHAFT PER MIL. PRIOR10 ASSEMBLY. P-116H TYPE p., USING MIL.C.161730 CORROSION PREVENTIVE m INSTA LLAFTERPRECOOLERMOOULEISINSTALLEOIN AIR CONOITIONING UNIT. COMPOUNG.SOLVENT CUT.EACK.COtOAPPLICATION. GRI.

cs

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 NO

PART NUMBER 1603AS105

DESCRIPTION MODULE, PRECOOLERSEE WP 008 00 FOR NHAJ SIDE/039381 . INSULATION, MIL-P-15288/. . . . . . . BOTTOM . INSULATION, /03938/MIL-P-152801. . . . . INSULATION, TOP /03938/MlL-P-152801. . . . . INSULATION, TOP CENTER /03938/MIL-P-152801. . . . . INSULATION, TOP FLANGE /03938/MIL-P-15280/. . . . NOZZLE SIDE . INSULATION, /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 . . . . . . .

UNITS PERASSY

USABLE ONCODE

SM &R CODE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

1603AS737 1603AS657 1603AS658 1603AS661 1603AS736 1603AS733 1603AS735 1603AS734 1603AS430-11 1603AS430.12 1603AS556 1603AS519 x390725-3 MS35333-40 MS27183-10 1603AS430.5 1603AS518 MS90725.6 MS35333.40 MS27183.10 1603AS430-13 1603AS430.15

. . . . . . . . . . . . . . . 8 8 8

XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ MGGZZ PAGZZ PAGZZ PAGZZ

. . . . . . .

1 1 10 10 10 I 1

XBGZZ MGGZZ PAGZZ PAGZZ PAGZZ

PAGZZ

Figure

2. Precooler

Module

(Sheet

3)

AC-1 80AO-MMM-000
Page 9

INDEX NO 23 24 25 26 27 28 29 30 31

PART NUMBER 1603AS430-14 1603AS430.6 1603AS517 MS90725.3 MS35333-40 MS27183-10 1603AS430.10 1603AS430-8 1603ASBOO . . . . . . . :

DESCRIPTION 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 BREAKDOWN) .......... /ATTACHING PARTS SCREW, CAP. ....... WASHER, LOCK ...... WASHER,FLAT ...... * PLENUM, OUTLETPRECOOLER. ....... /ATTACHING PARTS/ SCREW.CAP. ....... WASHER, LOCK ...... WASHER,FLAT ...... -* . . MIST ELIMINATOR, MODIFIED ........ /ATTACHING PARTS/ SCREW.CAP. ....... WASHER, LOCK ...... WASHER, FLAT ...... *

UNITS PERASSY

USABLE ON CODE

SM &R CODE

1 1 1 14 14 14 4 1

PAGZZ XBGZZ MGGZZ PAGZZ PAGZZ PAGZZ XBGZZ XBGZZ

1 18 18 18

MGGZZ PAGZZ PAGZZ PAGZZ

32 33 34 35

MS90725.8 MS35333:40 MS27183-10 1603AS699

. . . .

1 18 18 18

XBGZZ PAGZZ PAGZZ PAGZZ

36 37 38 39

MS90725.3 MS35333-40 MS27183.10 1603AS392

. . . .

40 41 42 43

MS90725.3 MS35333-40 MS27183.10 1603AS122

. . .

PAGZZ PAGZZ PAGZZ

44 45 46

MS90725-3 MS35333.40 MS27183-10

. COIL, EVAPORATOR, PRECOOLER. ....... /ATTACHING PARTS/ . SCREW.CAP. ....... . WASHER, LOCK ...... . WASHER, FLAT ...... *

1 20 20 20

PAGZZ PAGZZ PAGZZ PAGZZ

Figure

2. Precooler

Module

(Sheet

4)

AC-1 80AO-MMM-000

01100
Page 10

INDEX NO 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65

PART NUMBER 1603AS102 MS90725-3 MS35333.40 MS27183-10 1603AS720 1603AS721 MS90725-5 MS27183.IO MS35338.44 MS51967 2 1603AS555 MS35206.228 MS355338.41 X35649-262 1603AS148

DESCRIPTION DAMPER ASSEMBLY . IATTACIIING PARTS/ SCREW,CAP. . . . . WASHER,LOCK . . WASIIER,FLAT . . . * . DAMPER, WELDMENT . BRACKET, MOUNTISG IATTACHING PARTS SCREW,CAP. . . . WASkIER. FLAT . . WASIIER, LOCK . . SCT. PLAIN . . . . * . . . . . . . . . . .

UNITS / PERASSY 1 16 16 16 I

USABL .E / ONCODE

ISM&RI 1 CODE AGGGG PAGZZ PAGZZ PAGZZ MGCZZ

. . . .

. . . . . .

FAG%% PAGZZ PAGZZ FAG%% FAG%% FAG%% PAGZZ PAGZZ

CAPACITOR/77228/CH70/ . /ATTACfIING PARTS/ SCKEW,MACHINE . . . WASHER,LOCK . NUT, PLAIN . . . . . . . * 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 * . . . . 1 4 4 4 4

PAGZZ NIA N/A NIA N/A

66 67 68 69 70

1603AS554 1603AS727 MS18066.20 1603AS672 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. . . *

PAGZZ MGGGZ PAGZZ FAG%% PAGZ%

Figure

2. Precooler

Module

(Sheet

5)

OA0-MMM-000

01100
Page 11

INDEX NO 71 72 73 74

PART NUMBER 1603AS722 NAS1298.3-3 MS27183.10 1603AS170 . . . . . . . .

DESCRIPTION BRACKET, WELDMENT /ATTACHING PARTS/ SCREW,BRAZIER . . WASHER.FLAT . . . * . . . . . . . . . .

UNITS PER ASSY 1 6 6

USABLE ON CODE

SM &R CODE MGGZ% I AGZZ PAGZZ

75 76 77 78 79 80

MS35206.234 MS35338-41 MS35649.262 1603AS683.1 1603AS674 1603AS525

SWITCH, LIMIT/91929 IBZ-2RW855-A2-SI. . /ATTACHING PARTS/ . SCREW,MACHINE . . . WASHER,LOCK . . . NUT,PLAIN . . . . * . BUSHING, UNIVERSAL /28520/2077 . . . . . . PLUG, BUTTON/83058/ /SS48143K1611/ . . . . CABINET, EVAPORATOR, PRECOOLER. . . .

. . . . . . .

2 4 4 4

PAGZZ PAGZZ PAGZZ PAGZZ

. .

. . . . .

1 8 I

PAGZZ PAGZZ XBGGG

Figure

2. Precooler

Module

(Sheet

6)

AG-180AO-MMM-000
~APPLYlNSULATlONAOHESIVE(P/N 520AOHESIVE.FSCM 03938) TO INSULATIONANO MATING SURFACE.WHENADHESIVEIS DRY TO TOUCH. INSTALLINSULATION DASSEMBLiTUiE AND FASTENEA[SI:OOUBLE FLARETUBINGPER1L MS33583

01100
Page 12

\b

mASSEMEtE WITH FLOW ARROW POINTINGAWAY FROM PUMP mAPpLY A SMALL AMOUNT OF SILASTICADHESIVE(P/N 732RTV FSCM 719841 AROUND ORAIN TUBE. POWER CORD ANO GROMMETSON OUTSIDEOF DRAIN PAN AFTER ASSEMBLY.

DCUT 625 i 19 DIA HOLE IN INSULATIONFOR DRAIN BEFORE INSTALLINGINSULATION. DCUT 250 + 20 OIA HOLE IN INSULATIONBEFOREINSTALLING INSULATION BAPPLYLACOUER THINNERTO GASKETSTO ACTIVATEAOHESIVE

Flgure

3.

Draln

Pan

Assembly

(Sheet

1 of

2)

01100
Page 13

INDEX NO

PART NUMBER 1603ASSOO .

DESCRIPTION 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 _ . . . . . . PLUG, PIPE, ,125 NPTI 30327/121-B-02/. . . . . . PUMP,DRAIN, WATER. . . /ATTACHING PARTS/ . CLAMP,HOSE . . . . . . . SCREW,SELF-TAPPING . . *..

UNITS PERASSY

USABLE ONCODE

SM &R CODE

I 2 3 4 5 6 7 8 9 10 11

1603AS801 1603AS430.16 1603AS430.17 MS35489.39 1603AS430-18 1603AS807 1603AS793 MS35842-15 MS24630.36 1603AS806 1603AS590

MGZZZ PACZZ PAGZZ PAGZZ XBGZZ XBGZZ XBGZZ PAGZZ PAGZZ

: . . . . . . . .

12 13 14 15 16 17 18 19 20 21

1603AS589.9 1603AS794 1603AS804 MS35489.36 MS21919.WDE4 MS35207266 MS21044-C3 MS25036.153 1603AS812 1603AS811

. TUBE, DRAIN, .25 OD X ,030 WALL. . . . . . . . . . NUT, SHORT .25 ODTUBE SIZE, 45FLARE/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.. . . TERMINAL, LUG . . . . . GASKET,PAN . . . . . GASKET, PAS . , . . . . . . .

XBGZZ

3 1 1 1 1 1 1 1 3 2 2

XEGZZ 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 evaporator cabinet.

(16 and 24) from precooler (68).

b.

Apply thread locking compound to setscrews

c. Remove screws (26) and washers (2 7 and 28) from access cover (25). d. Remove access cover (25). e. Remove screws (13) and washers (14 and 15) fromcoil accesscover(l2). f. Remove coil access cover (12). g. Remove screws (44) and washers (45 and 46) from precooler evaporator coil (43). h. Remove precooler evaporator i. Tag and disconnect terminal blockTB-1. damper coil (431, motor wiring at

c. Align motor shaft and tube (67) and install setscrews (68). Torque setscrews (68) to N-inch pounds (QA). d. Treat exposed portion of motor shaft per MILP-116H, type P-l using MILG16173D Corrosion Preventive Compound. Solvent Cut-Back Cold Application, GRl. e. Position mounting bracket (52) on damper weldment (51) and install screws (53), washers (54and 55) and nuts (56). f. install Position damper (47) in cabinet (79) and 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.

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 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). 163) and (64)

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 Equipment MOTOR. Required (O-50

j. Position protective kover (1) on mounting plate (19) and install washers (3) and screws (2). IO. WATER DRAIN PUMP Required

Support Part :Vumher

Equipment

Support Part Number -

Nomenclature Wrench, Torque inch-pounds) Materials Required Nomenclature Compound, Sealing

Nomenclature Jack, 0 5000 Ibs. Chock Materials Required Nomenclature Adhesive

Specification or Part Number 8. DISASSEMBLY.

Specification or Part Number 732 I I. DISASSEMBLY. a. Lock front rear wheels. b. (3) c. wheel

assembly

parallel

with

a. Remove screws (2, figure 4) and washers (3). b. Remove protective e. Remove setscrews actuator weldment (13). cover (1) (14) and washers

Chock front wheel assembly of unit Usingjack raise rear wheels off ground.

d. Remove screws (9), washers (10 and 11) and nuts (12). e. Remove gear motor (ZZ), decimal (21), gearhead (20) and weldment (8). 9. ASSEMBLY. a. Position motor (22). b. Position (21). c. (20). d. Install weldment (19). e. Install nuts (12). f. (20). g. Apply sealing compound setscrews to setscrews (14). h. Install pounds (QA). (14) and torque to 33 inchInstall motor (22) in mounting plate Position decimal gearhead gearhead (21, figure 4) on gearhead

d. Place jack stands under each rear corner of the unit. e. Tag and disconnect water drain wiring (19, figure 3) at terminal block TB-1. f. Remove screws (32, tigure (33 and 34). g. h. pump

2) and washers

Remove drain pan assembly (31) Remove hose clamp (8, figure 3). Remove screws (9). Remove elbows (14) from pump. Remove pump.

(20) on decimal

gearhead

i. .i. k.

panel weldment

(8) on gearhead

12. ASSEMBLY. a. Position (14, figure 3). b. c. Install Install pump in place screws (9). hose clamp (8). and install elbow

screws (9), washers actuator weldment

(10 and 11) and (13) on gearhead

d. Position drain pan assembly (31, figure 2) in place and install screws (32) and washers (33 and 34). e. Reconnect drain to terminal block E-l. f. g. pump wiring (19, figure 3)

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).

Apply adhesive around power cord. Lower unit and remove chocks

AG-180AO-MMM-000

01100
Page 17/(18 Blank)

I I
INDEX NO

PART NUMBER, 1603AS487 1603AS482 MS35207.261 MS35338-43 16093AS.555 MS35206.228 MS35338.41 MS35649.262 1603AS475

I~ESCRIPT10N CONTROLLER, AIR FLOW /SEE WP 008 00 FOR NHA/ COVERPROTECTIVE . . IATT,\CI1ISC PARTS/ SCREW,MACHINE . . . WASIIER, I.OCK . . . . *.. CAPACITOW77228/CH70. IATTACIIINC PARTS/ SCREW,MACHINE . . . WASHER, LOCK . . . . NUT,PLAIN . . . . . .

1 P&i%&

1 f%??Ifi:

1 :i?;

~IGCZZ I ACZZ PAGZZ PAGZZ

. . _ . . 2 2 2 I

. . . . . .

I AGZZ I AGZZ I ACZZ

10 11 12

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) . . *.. ACTUATOR, WELDMENT . . /ATTACILING PARTS/ SETSCREW _ . . . . . . *.. 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 . .

S/A S/A N/A S/A

13 14 15

1603AS477 MS18063.13 1603AS170

JlGC%% PACZZ

PAGZZ . . . PAGZZ PAGZZ PACZZ

16 17 18 19 20 21 22

MS35206.234 MS35338.41 MS355649.262 1603AS486 1603AS-554 1603AS553 1603AS148

. . . ,

MGGZZ PAGZZ XBGZZ PAGZZ

Figure

4.

Airflow

Controller

Motor

(Sheet

2)

AG-18OAO-MMM-000
15 May 1991

012 00
Page 1 of 6

ORGANIZATIONAL REFRIGERATION COMPRESSOR CYLINDEK

AND

1NTEKMEI)IATE

MAINTENANCE ASSEMBLY ANI) (CTCOI

COMPKESSOR

HEADTEMPERATUKE

CUTOUT

AIKCONI)ITIONEK.AIKCRAFTCROUNI)C001.INC; A/M32C-21 PART NUMBER Keference Operating Instructions. Servicing, Lubrication, Adjustment Cleanup After Compressor 1lotor Rurnout.. Assembly and Disassembly Instructions. Aircraft Electrical and Electronic Wiring Practices 1603ASlOO-1 Material ........ ....... WI 005 00 Wl 007 00 WI 00800 NAVAIKOI-IA-505

............... ...............

Alphabetical Subiect Compressor Cylinder Head Temperature cutout (CTCO). Installation Materials Required Removal. Support Equipment Required. KefrigfrutionCompressor Assembly. Refrigeration Compressor Assembly. Installation YvIMaterialsRequired Prcparationfor Installation.. Support Equipment Required. Record of Applicable

Index

..... ..... ...... ...... ...... ...... ...... ...... .... ..... .... Technical NOIll2 Directives

2 2 2 2 2 4 1 I 1 I 1

REFKIGERATION I. ASSEMRLY. Support I art No. Equipment Nomenclature Wrench,Torque Materials

COMPRESSOR

2. PKEPARATION B. Remove packaging.

FOR INSTALLATION and discard shipping plugs and

Kequired

(O-150 ft-lbs)

b. Kemovc und discard cover plates.

suction

and discharge

Kequired NON!

c. Install gasket (5, figure 1) and suction service wlve (3). Torque suction service valve screws (4) 90. 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 screws and cover. Install jumper junction box by removing

a. Shut down compressor b. Pumpdown compressor

(WP 005 00). (WP 007 OO),

c. Remove condenser fan panel assembly (WP 008 00). d. Remove caps from compressor discharge service valves. suction and

bars

(10) and nuts connector

(11). (15) in

g. Install two-screw compressor junction box h. Install i. Install heads.

e. Close compressor suction and discharge service valves by turning valve stems clockwise.

bushings (14) on solenoids (2). solenoid coils (2) on side cylinder

(WARNING

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 pressure connection. Install in gas charging 1WPOO9 00). I. Install compressor (1) in air conditioning (WP 008 00). low port

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 g. Disconnect box 01.IA-505),

splices (NAVAIR cable

h. Remove armored

unit

m. Evacuate system (WP 007 00) and service oil (WP 007 00) if required. 3. COMPRESSOR CYLINDER TEMPERATURE CUTOUT (CTCO). Support Equipment NOW Materials Specilication Part No. or Nomenclature Tape, Teflon 4. REMOVAL. NOTE CTCO is generally removed with compressor assembly installed in air conditioning unit. Required 5. Required HEAD

Refrigerant is toxic. to personnel, avoid exposure to skin or expose refrigerant to i. Carefully nllow refrigerant

To avoid injury breathing or eyes. Do not open flame. and

loosen switch (12) slightly to bleed to atmosphere.

j. Remove switch (12, figure I). 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. g. To prevent injury to personnel or damage to equipment, electrical power must be disconnected when working inside compressor junction box. d. Splice wiring into wiring(SAVAIROl-IA-505). e. air conditioning unit

Evacuate system tWP 007 00). Leak test system t WP 007 00). and discharge valve stems

h. Open compressor suction service valves by turning counterclockwise. i. Install caps on compressor discharge service valves. j. Install 00800). condenser

suction

and

fan panel assembly

(WP

Close and secure compressorjunction

box.

AC-18OAO-MMM-000
Page 4

1.lNSURETHAT011SlGHTGLASSIS ONLEFTSIOE OF COMPRESSOR WHEN FACING BEARING HEAD AN0 PUMP ASSEMBLY. IF COM. PRESSOR 0ltLEVEAISLOW.AOO OIt(WP 007 00). 2. REMOVE PNEUMATICvAtvE FROM tow PRESSUREc0NNEcTl0~ AN0 INSTALLIN GAS CHARGINGPORT. REFERTO SUCTIONPRESSURE CAPILLARY INFORMATIVE IWP 009 00). 3. OISCARO REMOVED PLUGS. SUCTION AN0 OISCHARGECOVER PLATESAN0 MOUNTINGHARDWARE,

22 23 24 COMPRESSOR MOTOR82 ARMORED CA8lE

HIGH PRESSURE CONNECTION WPOO900)

1
\

COMPRESSOR JUNCTIONBOX

e@

GLASS

&oN \ Fy
/ \ '
~wpoogOO~ BEARINGHEAO ANOPUMP ASSEMBLY PLUG

Flgure

1.

Refrlgeratlon

Compressor

Assembly

(Sheet

1 of 2)

AG-180AO-MMM-000

012 00
Page 5/(6 Blank)

PART NUMBER

~~~
I

DESCRIPTION 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 PifitkiY

/ ::coDE

1 %:E

1603AS324

1603AS124

1 2

PBCGD PACZZ

PAGZZ

PAGZZ

XBGZZ

PACZZ

8 9

PAGZZ

1 3

PACZZ PAGZZ

10

I1

XBCZZ

12

1 1 2 1

PAGZZ PAGZZ PAGZZ PAGZZ

13 14 15

1603AB821 1603AS683-2 1603AS792

Figure

1.

Refrigeration

Compressor

Assembly

(Sheet

2)

*.s c~~LNlPRlNrwcoFFlcL:

1992.602.ill ,3m: