General Service Instructions

INTRODUCTION
- Before any component of the air conditioning system is removed, the system must be discharged. When the component is replaced, the system must be evacuated to remove all traces of old refrigerant and moisture. The system must then be recharged with new refrigerant.
- Any service operation that requires the loosening of a refrigerant line connection should be performed only by qualified service personnel. Refrigerant and/or oil will escape whenever a hose is disconnected.
- All work involving the handling of refrigerant requires special equipment, a knowledge of its proper use and attention to safety measures.

SERVICING EQUIPMENT
The following equipment is required for full servicing of the air conditioning system:
Recovery/Charging station
Leak detector
Safety goggles
Refrigerant charging line seals
Thermometer +20°C to -60°C (+68°F to -76°F)
Compressor dipstick

SERVICING MATERIALS
- Refrigerant 12, which includes Freon 12 or Arcton 12.
- Compressor oil Shell Clavus 68, BP Energol LPT68, or equivalent.




PRECAUTIONS IN HANDLING REFRIGERANT LINES
- Always wear safety goggles when opening refrigerant connections.
- When disconnecting any hose or flexible connection the system must be discharged of all pressure. Proceed cautiously, regardless of gauge readings. Open connections slowly, keeping hands and face well clear, so that no injury occurs if there is liquid in the line. If pressure is noticed, allow it to bleed off slowly.
- Lines, flexible end connections and components must be capped immediately they are opened to prevent the entrance of moisture and dirt.
- Any dirt or grease on fittings must be wiped off with a clean alcohol dampened cloth. Do not use chlorinated solvents such as trichloroethylene. If dirt, grease or moisture cannot be removed from inside the hoses, they must be replaced with new hoses.
- All replacement components and flexible end connections must be sealed, and only opened immediately prior to making the connection.
- Ensure the components are at room temperature before uncapping, to prevent condensation of moisture from the air that enters.
- Components must not remain uncapped for longer than fifteen minutes. In the event of delay, the caps must be fitted.
- Receiver/driers must never be left uncapped as they contain Silica Gel crystals which will absorb moisture from the atmosphere. A receiver/ drier left uncapped must not be used, fit a new unit.
- The compressor shaft must not be rotated until the system is entirely assembled and contains a charge of refrigerant.
- A new compressor contains an initial charge of 135 ml (4.6 fluid oz) of oil when received, part of which is distributed throughout the system when it has been run. The compressor contains a holding charge of gas when received which should be retained until the hoses are connected.
- The receiver/drier should be the last component connected to the system to ensure optimum dehydration and maximum moisture protection of the system.
- All precautions must be taken to prevent damage to fittings and connections. Slight damage could cause a leak with the high pressures used in the system.
- Always use two wrenches of the correct size, one on each fitting when releasing and tightening refrigeration unions.
- Joints and O-rings should be coated with refrigeration oil to aid correct seating. Fittings which are not lubricated with refrigerant oil are almost certain to leak.
- All lines must be free of kinks. The efficiency of the system is reduced by a single kink or restriction.
- Flexible hoses should not be bent to a radius less than ten times the diameter of the hoses.
- Flexible connections should not be within 5O mm (2 in) of the exhaust manifold.
- Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of lines and panels transmits noise and must be eliminated.