General precautions remedial actions (page 2 of 2)

SERVICING PRECAUTIONS A new compressor is sealed and pressurised with Nitrogen gas. Slowly release the sealing cap, gas Care must be taken when handling refrigeration pressure should be heard to release as the seal is system components. Units must not be lifted by their broken. hoses, pipes or capillary lines. Hoses and lines must not be subjected to any twist or stress. Ensure that hoses are positioned in their correct run before fully tightening the couplings, and ensure that all clips and supports are used. Torque wrenches of the correct prior to fitting type must be used when tightening refrigerant connections to the stated value. An additional spanner Fitting a new compressor must be used to hold the union to prevent twisting of the pipe. A new compressor is supplied with an oil fill (X) of 180ml, 5.3 fl oz. Before connecting any hose or pipe ensure that refrigerant oil is applied to the seat of the new ’0’ ring A calculated quantity of oil must be drained from a but not to the threads. new compressor before fitting.

Check the oil trap for the amount of oil lost. To calculate the quantity of oil to be drained:

All protective plugs on components must be left in place until immediately prior to connection.

The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times.

CAUTION: Whenever the refrigerant system is opened, the receiver/drier must be renewed immediately before evacuating and recharging the system. X - (Y + 20ml, 0.7 fl oz) = Q

Use alcohol and a clean cloth to clean dirty Rapid refrigerant discharge connections. Ensure that all new parts fitted are marked for use with R134a. When the air conditioning system is involved in accident damage and the circuit is punctured, the Refrigerant oil refrigerant is discharged rapidly. The rapid discharge of refrigerant will also result in the loss of most of the Use the approved refrigerant lubricating oil - Nippon oil from the system. The compressor must be Denso ND-OIL 8. removed and all the remaining oil in the compressor drained and refilled as follows: CAUTION: Do not use any other type of refrigerant oil.

Refrigerant oil easily absorbs water and must not be stored for long periods. Do not pour unused oil back into the container.

When renewing system components, add the Servicing Equipment following quantities of refrigerant oil: The following equipment is required for full servicing

• NOTE: A new compressor should always
• have its sealing caps in place and these
• must not be removed until immediately

1. Remove sealing plugs from the OLD compressor.
2. Invert compressor and gravity drain oil into measuring cylinder. Rotating the compressor clutch plate will assist complete draining.
3. Note the quantity of oil drained (Y).
4. Calculate the quantity (Q) of oil to be drained from the NEW compressor using the following formula:
1. Gravity drain all the oil, assist by rotating the clutch plate (not the pulley).
2. Refill the compressor with 130ml, 4.6 fl oz of new refrigerant oil.
3. Plug the inlet and outlet ports.

- Leak detector - Thermometer +20°C to -60°C, 70°F to -70°F - Safety goggles and gloves