| Safety measures for working on vehicles with air conditioning system and for handling refrigerant R134a |
| Vehicles with high-voltage system (hybrid vehicles) |
WARNING | Safety hazard: the engine can start unexpectedly. |
| Before carrying out general work on a vehicle with high-voltage electrical system, switch off the ignition and remove the ignition key from the vehicle. |
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WARNING | Working on vehicles with high-voltage wiring: |
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| Do not support yourself or tools on high-voltage wiring or associated components --> this can damage the insulation. |
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| High-voltage wiring must not be excessively bent or kinked --> this can damage the insulation. |
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| The round high-voltage connectors are colour-coded with an external coloured ring and are provided with mechanical coding or guide lugs. It is important to observe this coding when joining up the round high-voltage connectors, otherwise the connectors can be damaged. |
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DANGER! | Risk of fatal injury if high-voltage components are damaged. |
| Observe the following when working in the vicinity of high-voltage components or wiring: |
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| It is not permitted to use cutting or forming tools, other sharp-edged tools or heat sources such as welding, brazing, soldering, hot air or thermal bonding equipment. |
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| Before starting work, visually inspect the high-voltage components in the areas involved. |
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| Before working in the engine compartment, visually inspect the power electronics -JX1-, electric drive motor -V141-, air conditioner compressor -V470- and high-voltage wiring. |
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| Before working on the vehicle underbody, visually inspect the high-voltage wiring and covers. |
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| Before working on the rear section of the vehicle, visually inspect the high-voltage wiring and the electro-box with the maintenance connector for high-voltage system - TW -. |
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| Visually inspect all potential equalisation lines. |
| Check the following when making the visual inspection: |
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| There must be no external damage on any component. |
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| The insulation of the high-voltage wiring and potential equalisation lines must not be damaged. |
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| There must be no unusual deformation of the high-voltage wiring. |
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| All high-voltage components must be identified by a red warning sticker. |
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| Vehicles with start/stop system |
WARNING | Injury risk due to automatic engine start (vehicles with start/stop system). |
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| On vehicles with an activated start/stop system (indicated by a message in the instrument cluster display), the engine may start automatically on demand. |
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| Therefore, please make sure that the start/stop system is deactivated when performing repair work on the vehicle (switch off the ignition, and switch it on again if required). |
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WARNING | Danger of asphyxiation, frostbite and poisoning from escaping refrigerant |
| Risk of injury from escaping refrigerant |
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| Danger of asphyxiation from displacement of ambient air |
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| Danger of frostbite (or risk of cryogenic burns caused by the evaporation of liquid refrigerant) |
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| Danger of poisoning from decomposition products |
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| Work may only be performed on the refrigerant circuit of an air conditioning system in well ventilated areas. |
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| Ensure good ventilation when handling refrigerant and working on the refrigerant circuit (exchange of air at least 1 once per hour in workshops and 3 times per hour in low-level areas (e.g. inspection pits). Workshop exhaust gas extraction systems are to be switched on. |
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| Vessels and devices containing refrigerant are only to be stored in well ventilated areas (e.g. not in cellars or in the vicinity of cellar entrances) |
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| Never inhale refrigerant vapours emerging |
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| Wear suitable protective gloves and safety goggles when handling refrigerant and working on the refrigerant circuit |
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| It is advisable to keep an eye bath to hand. |
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| Work may only be performed on the refrigerant circuit of an air conditioning system in well ventilated areas. Switch on workshop extraction systems, if available. |
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| Refrigerant must not be stored in low-level areas (e.g. cellars) and their exits or light wells. |
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| Following inhalation of highly concentrated refrigerant vapours, the person concerned is to be removed immediately from the hazard area and laid down in the open air. Keep the person concerned warm and calm. Perform artificial respiration in the event of breathing difficulties (administer oxygen if necessary). If the person affected is having great difficulty breathing or is not breathing at all, tilt back head and administer artificial respiration. Consult a doctor. |
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| Should liquid refrigerant come into contact with the eyes, rinse them thoroughly with water for about 15 minutes. Then administer eye drops and consult a doctor immediately even if no pain is felt. |
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| Never attempt to administer liquids through the mouth of an unconscious person. Consult a doctor if the symptoms persist and in cases of doubt |
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| The doctor must be informed that the frostbite was caused by refrigerant R 134a. Should refrigerant come into contact with other parts of the body despite compliance with the safety regulations, these must likewise be rinsed immediately for approximately 15 minutes with cold or luke warm water. |
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| Following accidental contact with eyes or mucous membranes, immediately rinse with copious amounts of running water and consult an eye specialist. |
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| In the event of skin contact, immediately remove wet clothing and rinse the areas of skin affected with a copious amount of cold or luke warm water (never use hot water). Consult a doctor in the event of frostbite. |
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| The refrigerant has a scarcely perceptible odour and is thus not noticeable. |
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| The refrigerant gas is heavier than air and accumulates in low-level areas such as inspection pits, cellars and hollows, where it displaces the ambient air and thus the oxygen. A lack of oxygen in the atmosphere is potentially fatal. |
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| Liquid refrigerant escaping from a leak for example evaporates at an ambient pressure of approx. 1 bar at around -29.4 °C. If the refrigerant evaporates on the skin, it will cause frostbite or cryogenic burns. Sensitive parts of the body such as the cornea of the eye are particularly at risk. Large-scale cryogenic burns are potentially fatal. |
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| The refrigerant decomponses on coming into contact with a flame or a hot surface. Danger of poisoning on inhaling toxic decomposition products. A pungent odour indicates that products of decomposition have already developed. Avoid inhaling these substances under all circumstances, as otherwise the airways, lungs and other organs could be damaged. |
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| The specific hazards associated with refrigerant and the substance data etc. can be found in the safety data sheets. |
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| Welding, brazing and soldering work must not be performed on components of air conditioning system when charged. This also applies to welding and soldering work on the vehicle if there is a danger of air conditioner components becoming hot. When performing paintwork repairs, the temperature in the drying booth or preheating zone must not exceed 80 °C. |
| Exposure to heat generates considerable pressure in the system, which could cause the high-pressure safety valve to open. |
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| Discharge refrigerant circuit using air conditioner service station. |
Note | Damaged or leaking components of the air conditioning system must not be repaired by welding or soldering. They must always be renewed. |
| Refrigerant vessels (e.g. charging cylinders of air conditioner service station) must never be subjected to excessive heat or exposed to direct sunlight. |
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| Vessels must never be completely filled with liquid refrigerant. Without sufficient room for expansion (gas cushion), vessels will rupture with explosive effect in the event of an increase in temperature → Chapter. |
| Refrigerant should never be poured into systems or vessels containing any air. |
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| Evacuate systems and containers before charging with refrigerant. |
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