TM-5-4220-209-12P DMC-AA Air Compressor Modem 1C41-RDOW Part Number 83207 Manual

SECTION I. INTRODUCTION AND GENERAL INFORMATION - TM-5-4220-209-12P_13
Table 1-1. Table of leading Particulars - TM-5-4220-209-12P_14
Figure 1-1.   Air Compressor Unit
AIR COMPRESSOR GROUP
Table 1-2. Consumable Materials
Table 1-2. Consumable Materials (Continued)
SECTION II. SPECIAL TOOLS AND TEST EQUIPMENT - TM-5-4220-209-12P_19
Table 2-1.   Special Tools and Equipment List
Figure 2-1.   Engine Special Tool Kit
TOOLS, Z-108 DIESEL ENGINE
SECTION III. PREPARATION FOR USE AND SHIPMENT - TM-5-4220-209-12P_23
SECTION IV. OPERATION INSTRUCTION
Figure 4-1. Air Flow Diagram
AUTOMATIC CONTROL AND DRAIN SYSTEM
OPERATING CONTROLS AND INDICATORS
Figure 4-2. Operating Controls and Indicators
SERVICE HOSE BLEED VALVE
TM-5-4220-209-12P_30
STARTING UNDER COLD CONDITIONS
EMERGENCY   STOPPING   PROCEDURE
SECTION V. MAINTENANCE INSTRUCTIONS - TM-5-4220-209-12P_33
Figure 5-1. Pressure Switch Adjustment
Table 5-2. Inspection, Checks, and Services
Table 5-2. Inspection, Checks, and Services - Continued
Figure 5-2. Air Compressor Air Filter
Figure 5-4. Dehydrators
Figure 5-6. Mechanical Filter
Figure 5-7. Ten Micron Air Filter
Figure 5-8. First. Second, and Third Stage Traps
Line Strainers
Figure 5-10. Clutch Adjusting Yoke Adjustment
Figure 5-12. Air Compressor Crankcase Filter
Figure 5-13. Engine Crankcase Breather Sieve
Figure 5-16. Engine Compression Adjustment Tolerances
Figure 5-17. Fuel Injector Nozzle
Table 5-3. Lubrication Instructions
Figure 5-19. Compressor Oil Filter
TROUBLESHOOTING
Table 5-4. Troubleshooting
Table 5-4. Troubleshooting - Continued - TM-5-4220-209-12P_52
Table 5-4. Troubleshooting - Continued - TM-5-4220-209-12P_53
Table 5-4. Troubleshooting - Continued - TM-5-4220-209-12P_54
Table 5-4. Troubleshooting - Continued - TM-5-4220-209-12P_55
Table 5-4. Troubleshooting - Continued - TM-5-4220-209-12P_56
SECTION VI. REPAIR SECTION - TM-5-4220-209-12P_57
AIR   COMPRESSOR   UNIT
Figure 6-2. Presetting Tubing Sleeve - TM-5-4220-209-12P_59
DISASSEMBLY   OF   MAJOR   COMPONENTS
Figure 6-3. Priority Valve Test Setup
Repair    or    Replacement
Cleaning - TM-5-4220-209-12P_63
Priority Valve Assembly
Figure 6-4. Seating Priority Valve Connector.
Disassembly - TM-5-4220-209-12P_66
Assembly - TM-5-4220-209-12P_67
Instrument   Panel   Assembly
Repair or Replacement
Rupture Disc Assembly
Figure 6-5. Typical Safety Valve Test Setup
Repair or Replacement - TM-5-4220-209-12P_72
AIR COMPRESSOR GROUP
Air Compressor Assembly
Figure 6-6. Oil Seal, Crankshaft
Repair or Replacement - TM-5-4220-209-12P_76
Assembly - TM-5-4220-209-12P_77
Figure 6-7. Non Drive End Cover, Oil Pump and Oil Seal Installation
Assembly - cont
Air Cleaner Assembly
Figure 6-8. Lentoid Spring Assembly )Detail
Cleaning - TM-5-4220-209-12P_82
Cleaning - TM-5-4220-209-12P_83
Disassembly - TM-5-4220-209-12P_84
Clutch and Clutch Housing Group
Assembly - TM-5-4220-209-12P_86
First Stage Trap Assembly
Second Stage Trap Assembly
Disassembly - TM-5-4220-209-12P_89
Accumulator Assembly
Element damage
Figure 6-9. Bleed Valve Port Locations
Disassembly. - TM-5-4220-209-12P_93
Figure 6-10.   Pressure Switch Test Setup
Repair or Replacement. - TM-5-4220-209-12P_95
Condensate Receiver Group
Condensate Receiver Group - cont
Condensate Receiver Group - cont - TM-5-4220-209-12P_98
Condensate Receiver Group - cont - TM-5-4220-209-12P_99
Diesel Engine Assembly - cont - TM-5-4220-209-12P_100
Diesel Engine Assembly - cont - TM-5-4220-209-12P_101
Diesel Engine Assembly - cont - TM-5-4220-209-12P_102
Diesel Engine Assembly - cont - TM-5-4220-209-12P_103
Diesel Engine Assembly - cont - TM-5-4220-209-12P_104
Figure 6-11. Compression Adjustment
Diesel Engine Assembly - cont - TM-5-4220-209-12P_106
Diesel Engine Assembly - cont - TM-5-4220-209-12P_107
Diesel Engine Assembly - cont - TM-5-4220-209-12P_108
Figure 6-13. Removing Retainer from Snap Ring
Figure 6-15. Grounded Armature test Setup
Figure 6-16. Field Winding Test Setup
Figure 6-18. Snap Ring Expansion Tool
ALTERNATOR ASSEMBLY
Air Filter, Engine Oil Bath
Fuel Injector Assembly
Figure 6-21. Cleaning the Nozzle Tip
Figure 6-24. Cleaning Nozzle Valve
Figure 6-27. Fuel Injector Spray Pattern
Fuel   Filter   Assembly
TABLE OF LIMITS
Table 6-1. Table of Limits- Continued - TM-5-4220-209-12P_121
Table 6-1. Table of Limits- Continued - TM-5-4220-209-12P_122
Table 6-1. Table of Limits- Continued - TM-5-4220-209-12P_123
Table 6-1. Table of Limits- Continued - TM-5-4220-209-12P_124
Table 6-1. Table of Limits- Continued - TM-5-4220-209-12P_125
Table 6-1. Table of Limits- Continued - TM-5-4220-209-12P_126
Table 6-1. Table of Limits- Continued - TM-5-4220-209-12P_127
Table 6-2. Miscellaneous Table
Figure 6-28. Spring Plate to Camshaft Adjustment.
Figure 6-29. Continuous Bleed Valve Assembly
Figure 6-32. Non Drive End Cover
Figure 6-37. Flywheel and Drive Sheave
Figure 6-39. Compressor Crankshaft
Figure 6-42. Third Stage Cylinder, Piston and Pin Assy
Figure 6-44. Fourth Stage Piston and Pin Assay
SECTION VII. DIAGRAMS
Figure 7-1. Air Flow Diagram
Figure 7-2. Wiring Diagram
SECTION VIII. ILLUSTRATED PARTS BREAKDOWN
FEDERAL SUPPLY CODES FOR MANUFACTURERS
RELATED PUBLICATIONS
Figure 8-0. How to Use Illustrated Parts Breakdown, Example
Figure 8-1. Air Compressor Unit
DESCRIPTION - TM-5-4220-209-12P_144
Figure 8-2. Dehydrator and Air Purification Group
DESCRIPTION - TM-5-4220-209-12P_146
Figure 8-3. Mechanical Filter Assembly
Figure 8-4. Dehydrator Cylinder Assembly
Figure 8-5. Priority Valve Assembly
Figure 8-6. Ten-Micron Filter Assembly
Figure 8-7. Control Panel Assembly (Sheet 1 of 2)
Figure 8-7. Control Panel Assembly (Sheet 2 of 2)
DESCRIPTION - TM-5-4220-209-12P_153
Figure 8-8. Instrument Panel Assembly
DESCRIPTION - TM-5-4220-209-12P_155
Figure 8-9. Rupture Disc Assembly
Figure 8-10. Air cooler Group
DESCRIPTION - TM-5-4220-209-12P_158
Figure 8-11. Air Compressor Group
DESCRIPTION - TM-5-4220-209-12P_160
Figure 8-12. Air Compressor Assembly (Sheet 1 of 3)
DESCRIPTION - TM-5-4220-209-12P_162
Figure 8-12. Air Compressor Assembly (Sheet 2 of 3)
DESCRIPTION - TM-5-4220-209-12P_164
Figure 8-12. Air Compressor Assembly (Sheet 3 of 3)
DESCRIPTION - TM-5-4220-209-12P_166
Figure 8-13. Air Cleaner Assembly
DESCRIPTION - TM-5-4220-209-12P_168
Figure 8-14. First Stage Head, Cylnder, and Piston Group
Figure 8-15. Second Stage Head, Cylinder, and Piston Group
Figure 8-16. Third Stage Head, Cylinder, and Piston Group
Figure 8-17. Fourth Stage Head and Cylinder Group
Figure 8-18. Fourth Stage Piston Assembly
Figure 8-19. Clutch and Housing Group (Sheet 1 of 2)
DESCRIPTION - TM-5-4220-209-12P_175
Figure 8-19. Clutch and Housing Group (Sheet 2 of 2)
Figure 8-20. Trap and Accumulator Group
DESCRIPTION - TM-5-4220-209-12P_178
Figure 8-21. First Stage Trap Assembly
Figure 8-22. Second Stage Trap Assembly
Figure 8-23. Third Stage Trap Assembly
Figure 8-24. Accumulator Assembly
Figure 8-25. Bleed Valve Assembly
Figure 8-26. Bleed Valve Subassembly
Figure. 8-27. Drain Valve Assembly
DESCRIPTION - TM-5-4220-209-12P_186
Figure 8-28. Unloader Control Box Group
DESCRIPTION - TM-5-4220-209-12P_188
Figure 8-29. Condensate Receiver Group
DESCRIPTION - TM-5-4220-209-12P_190
Figure 8-30. Diesel Engine Assembly (Sheet 1 of 10)
DESCRIPTION - TM-5-4220-209-12P_192
DESCRIPTION - TM-5-4220-209-12P_193
DESCRIPTION - TM-5-4220-209-12P_194
Figure 8-30. Fuel System (Sheet 3 of 10)
DESCRIPTION - TM-5-4220-209-12P_196
DESCRIPTION - TM-5-4220-209-12P_197
Figure 8-30. Piston, Cylinder and Crank Group (Sheet 4 of 10)
DESCRIPTION - TM-5-4220-209-12P_199
DESCRIPTION - TM-5-4220-209-12P_200
Figure 8-30. Crankcase Assembly (Sheet 5 of 10)
DESCRIPTION - TM-5-4220-209-12P_202
Figure 8-30. Crankcase Assembly (Sheet 6 of 10)
DESCRIPTION - TM-5-4220-209-12P_204
Figure 8-30. Cam, Pushrod and Head Group (Sheet 7 of 10)
DESCRIPTION - TM-5-4220-209-12P_206
DESCRIPTION - TM-5-4220-209-12P_207
Figure 8-30. Blower Group (Sheet 8 of 10)
DESCRIPTION - TM-5-4220-209-12P_209
Figure 8-30. Blower Group (Sheet 9 of 10)
DESCRIPTION - TM-5-4220-209-12P_211
Figure 8-30. Engine Electrical Accessories (Sheet 10 of 10)
DESCRIPTION - TM-5-4220-209-12P_213
Figure 8-31. Starting Motor Subassembly
DESCRIPTION - TM-5-4220-209-12P_215
Figure 8-32. Alternator
DESCRIPTION - TM-5-4220-209-12P_217
Figure 8-33. Engine Air Filter
Figure 8-34. Fuel Feed Pump Assembly
Figure 8-35. Fuel Injection Pump Subassembly
Figure 8-36. Fuel Injector Subassembly
Figure 8-37. Fuel Filter Subassembly
Figure 8-38. Frame Group
DESCRIPTION - TM-5-4220-209-12P_224
Figure 8-39. Tubing Identification
DESCRIPTION - TM-5-4220-209-12P_226
CHAPTER II
WARNINGS
SECTION I. INTRODUCTION AND GENERAL INFORMATION - TM-5-4220-209-12P_230
Table 1-1. Table of Leading Particulars - TM-5-4220-209-12P_231
Figure 1-1. Servicing Unit, Type I and Type II
SECTION II. SPECIAL TOOLS AND TEST EQUIPMENT - TM-5-4220-209-12P_233
SECTION III. PREPARATION FOR USE AND SHIPMENT - TM-5-4220-209-12P_234
SECTION IV. OPERATING INSTRUCTIONS
Figure 4-1. Operating Controls and Indicators (Type I) (Air)
Air half of control panel
Figure 4-2. Operating Controls and Indicators (Type II) Air/Oxygen
OPERATION INSTRUCTIONS.
Figure 4-3. Component Layout, Type I (Air)
TYPE     II     (AIR/OXYGEN)-     CHARGING     THE TYPE II (AIR/OXYGEN) SERVICING UNIT
Figure 4-4. Component Layout, Type II (Air/Oxygen)
TO BLEED PRESSURE FROM TYPE I AND TYPE 11 SERVICING UNITS
Figure 4-5. Cylinder Locations, Bulkhead (Panel View)
SECTION V. MAINTENANCE INSTRUCTIONS - TM-5-4220-209-12P_245
Figure 5-1. Purification Cylinder
Table 5-2. Troubleshooting
SECTION VI. REPAIR SECTION - TM-5-4220-209-12P_248
Inspection - TM-5-4220-209-12P_249
Figure 6-2. Presetting Tubing Sleeve - TM-5-4220-209-12P_250
DISASSEMBLY OF M A J 0 R COMPONENTS
Repair or Replacement. - TM-5-4220-209-12P_252
CONTROL PANEL ASSEMBLY, TYPE I (AIR)
Figure 6-3. Typical Safety Valve Test Setup
Repair or Replacement
CONTROL PANEL ASSEMBLY, TYPE II (AIR/ OXYGEN)
CONTROL PANEL ASSEMBLY, TYPE II (AIR/ OXYGEN) - cont
Figure 6-4. Typical Safety Valve Test Setup (Oxygen)
CONTROL PANEL ASSEMBLY, TYPE II (AIR/ OXYGEN) - cont
AIR/OXYGEN PURIFICATION CYLINDER GROUPS-TYPE II (AIR/OXYGEN) SERVICING UNITS
TEST - TM-5-4220-209-12P_261
SECTION VII. ILLUSTRATED PARTS BREAKDOWN
USABLE    ON    CODES
Figure 7-0. How to Use Illustrated Parts Breakdown, Example.
Figure 7-1. Service Unit, Type I (Air) and Type II (Air/Oxygen).
DESCRIPTION - TM-5-4220-209-12P_266
DESCRIPTION - TM-5-4220-209-12P_267
Figure 7-2. Air Purification Cylinder Group, Type I
Figure 7-3. Oxygen Purification Cylinder Group, Type II.
Figure 7-4. Control Panel, Air, Type I (Sheet 1 of 2).
DESCRIPTION - TM-5-4220-209-12P_271
Figure 7-4. Control Panel Assembly, Air (Sheet 2 of 2).
DESCRIPTION - TM-5-4220-209-12P_273
Figure 7-5. Control Panel Assembly, Air/Oxygen, Type II (Sheet 1 of 2)
DESCRIPTION - TM-5-4220-209-12P_275
Figure 7-5. Control Panel Assembly, Air Oxygen, Type II (Sheet 2 of 2)
DESCRIPTION - TM-5-4220-209-12P_277
DESCRIPTION - TM-5-4220-209-12P_278
WARNING - TM-5-4220-209-12P_280
SECTION II. SPECIAL TOOLS AND TEST EQUIPMENT - TM-5-4220-209-12P_283
SECTION III. PREPARATION FOR USE AND SHIPMENT - TM-5-4220-209-12P_284
AFTER OPERATIONS
SECTION V. MAINTENANCE INSTRUCTIONS - TM-5-4220-209-12P_286
TABLE 5-1. TROUBLESHOOTING
SECTION VI. REPAIR SECTION - TM-5-4220-209-12P_288
PRELIMINARY   PROCEDURE
DISASSEMBLY OF MAJOR COMPONENTS
AIR OVER HYDRAULIC BRAKE SYSTEM
AIR   FILTER - TM-5-4220-209-12P_292
AIR   FILTER - TM-5-4220-209-12P_293
AUTOMATIC DRAIN VALVE
POWER CLUSTER (MASTER CYLINDER)
CABLE   ASSEMBLY   12   Volt.
WIRING   HARNESS,   TRAILER
ELECTRICAL BOX
ELECTRICAL BOX - cont
CONNECTION BETWEEN AIR COMPRESSOR
MARKER/CLEARANCE LIGHTS
MARKER/CLEARANCE LIGHTS - cont - TM-5-4220-209-12P_302
MARKER/CLEARANCE LIGHTS - cont - TM-5-4220-209-12P_303
PARKING BRAKE LEVER AND CROSS-SHAFT ASSEMBLY
BRAKE ASSEMBLY
SECTION VII
Figure 7-1. Trailer Assembly, Commercial
DESCRIPTION - TM-5-4220-209-12P_308
DESCRIPTION - TM-5-4220-209-12P_309
Figure 7-2. Hose and Tubing Assemblies
DESCRIPTION - TM-5-4220-209-12P_311
Figure 7-3. Electrical System
DESCRIPTION - TM-5-4220-209-12P_313
Figure 7-4. Cable Assembly,24 Volt
DESCRIPTION - TM-5-4220-209-12P_315
Figure 7-5. Cable Assembly,12 Volt
DESCRIPTION - TM-5-4220-209-12P_317
Figure 7-6. Trailer Chassis Wiring Harness
DESCRIPTION - TM-5-4220-209-12P_319
Figure 7-7. Electrical Box Assembly
DESCRIPTION - TM-5-4220-209-12P_321
Figure 7-8. Air Filter
Figure 7-9. Axle Assembly
DESCRIPTION - TM-5-4220-209-12P_324
Figure 7-10. Brake Assembly
DESCRIPTION - TM-5-4220-209-12P_326
Figure 7-11. Automatic Drain Valve.
DESCRIPTION - TM-5-4220-209-12P_328
Figure 7-12. Parking Brake Assembly
Figure 7-13. Wiring Diagram
DESCRIPTION - TM-5-4220-209-12P_331
SECTION VII. MANUFACTURERS DATA AIR-OVER-HYDRAULIC POWER CLUSTER
MAINTENANCE OF THE POWER CLUSTER
MAINTENANCE OF THE POWER CLUSTER - cont
PARTS DESCRIPTION POWER CLUSTER
Service Data
EMERGENCY APPLICATION
REMOVING AND INSTALLING
Exploded View Figure 4
SERVICE PARTS CATALOG
APPENDIX A MAINTENANCE ALLOCATION CHART
EXPLANATION OF COLUMNS IN SECTION II
EXPLANATION OF COLUMNS IN SECTION III
Section II. MAINTENANCE ALLOCATION CHART - TM-5-4220-209-12P_344
Section II. MAINTENANCE ALLOCATION CHART - TM-5-4220-209-12P_345
Section II. MAINTENANCE ALLOCATION CHART - TM-5-4220-209-12P_346
Section II. MAINTENANCE ALLOCATION CHART - TM-5-4220-209-12P_347
Section II. MAINTENANCE ALLOCATION CHART - TM-5-4220-209-12P_348
Section II. MAINTENANCE ALLOCATION CHART - TM-5-4220-209-12P_349
Section II. MAINTENANCE ALLOCATION CHART - TM-5-4220-209-12P_350
Section II. MAINTENANCE ALLOCATION CHART - TM-5-4220-209-12P_351
Section II. MAINTENANCE ALLOCATION CHART - TM-5-4220-209-12P_352
SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-5-4220-209-12P_353
SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-5-4220-209-12P_354
SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-5-4220-209-12P_355
SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-5-4220-209-12P_356
MAINTENANCE ALLOCATION CHART - TM-5-4220-209-12P_357
APPENDIX B REPLACEMENT PARTS
APPENDIX B REPLACEMENT PARTS - cont - TM-5-4220-209-12P_359
APPENDIX B REPLACEMENT PARTS - cont - TM-5-4220-209-12P_360

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