305

•

Compared with the early used mineral oil, the SW-100 type compressor oil is of comparatively high

moisture absorption performance. If you mix the moisture object with the SW-100 type compressor oil, it

will damage the Refrigeration system. Therefore, after treating the compressor oil or removing the

refrigeration system components, the lid shall be covered immediately to prevent the SW-100 type

compressor oil from absorbing the moisture.

Section 5 The Refrigeration System Operation Procedure

I. Refill Refrigerant

Notice:

• During the filling of refrigerant into the refrigeration system, be careful that it is required to

have the professionals operate under the specified standard and procedure, otherwise it will

reduce the A/C efficiency greatly and even damage the refrigeration system components.

Refill the HFC-134a refrigerant

Refill Preparation

1. Install the inflating equipment.

2. Connect the low pressure tube to the low pressure

refill valve.

3. Connect the high pressure tube to the high pressure

refill valve.

4. Connect the intermediate tube to the vacuum pump.

Vacuumization:

1. Open all valves.

Notice:

• Close all valves of the manifold gauge immediately after the vacuum pump stops operation. If

the valve is still open after the vacuum pump stops operation, then the vacuum pump oil will

return to refrigerant circulation loop and reduce the A/C efficiency.

2. Start the vacuum pump and run it for 15min.

3. Check if the readings at high and low sides of the manifold gauge fall within the range of -101 kPa{-760

mmHg }. Close the valves of the manifold gauge.

Check the air tightness:

1. Stop the vacuum pump and have it wait for 5min.

2. Check the high pressure side of the manifold gauge and the reading at the low pressure side.

•

Check for leakage if the reading changes and vacuumize it again.

•

Refill the new HRC-134a refrigerant if the reading doesn't change.

To low pressure fill valve

Low Pressure Gauge

High Pressure 

Gauge

Connect the high 

pressure refill valve

Low Pressure Tube

High Pressure Tube

Low Pressure 
Manual Valve

High Pressure 
Manual Valve

Vacuum Pump

Intermediate Tube

Refrigerant Steel Jar

306

3. Check for leakage if the reading changes and vacuumize it again.

4. Refill the new HFC-134a refrigerant if the reading doesn’t change.

Fill the new HFC-134a refrigerant

1. Connect the intermediate pipe to the refrigerant steel jar.

2. Open the refrigerant steel jar valve.

3. Weigh the refrigerant steel jar to charge the right refrigerant volume (refrigerant refill 630g¡À20g).

Warning:

• Check for air leakage or any other leakage when refilling large amount of refrigerant into the

Refrigeration system. The operator is recommended to fill small amount of refrigerant first to

prevent the refrigerant from leakage, which will result in ozonosphere damage.

• It is very dangerous to open the engine high pressure side valve if filling the refrigerant with

the service tank. The pressure in the service tank will rise during the operation, which will

result in the service tank explosion. The exploded mental fragment and the splashed refrigerant

will hurt the operator badly. Therefore, do close the high pressure side valve when the engine

is working.

4. Open the manifold gauge low pressure side valve.

5. Close the manifold gauge low pressure side valve when the manifold gauge low pressure side reading is

increased to 0.098Mpa{1.0kgf/cm

2

}.

6. Check cooling pipeline/hose for leakage with leak detector.

•

Proceed to step 8 if there is no leakage.

•

Tighten the union joint if there is leakage at the loosened union joint and go to next step.

7. Re-check the leaked points.

•

Go to next step if there is no leakage after tightening the union joint.

•

If there is still leakage at the same union joint, drain refrigerant and repair the union joint. Repeat

the filling procedure and vacuum it.

8. Open the valve at the low pressure side of the manifold gauge. Fill the refrigerant until the refrigerant

tank weight from the one mentioned in Step 3 drop to 250g.

9. Close the valve at the low pressure side of the manifold gauge.

10. Start the engine and switch on A/C.

11. Open the valve at the low pressure side of the manifold gauge. Fill the refrigerant until the refrigerant

tank weight from the one mentioned in Step 3 to specified value.

12. Close the valve at the low pressure side of the manifold gauge and the valve of the refrigerant steel jar.

13. Stop the engine and A/C compressor.

307

Check For Leakage:

1. Using leak detector, check refrigerant steel jar for leakage.

•

Go to Step 3 if there is no leakage.

•

Tighten the union joint if there is leakage at the loosened union joint and go to next step.

2. Re-check the leaked points.

•

Go to next step if there is no leakage after tightening the union joint.

•

If there is still leakage at the same union joint, drain refrigerant and vacuum the union joint.

3. Disconnect the high and low pressure pipe at the refill valve.

4. Install the filling valve cap.

Check Refrigerant Pressure:

1. Install the manifold gauge.

2. Warm up the engine and run it with constant 1800rpm.

3. Set the rpm of the cooling fan to the HIGHEST.

4. Turn on the A/C switch.

5. Set to internal circulation mode.

6. Set the temperature control mode to the COLDEST.

7. Set to be ventilation mode.

8. Close all door and windows.

9. Measure the environment temperature and the reading of the high pressure side and low pressure side

from the manifold gauge.

•

Shoot the Refrigeration system trouble as required if it is not as specified in the technical specification.

The Performance Inspection of the Refrigeration System:

1. Check refrigerant pressure.

•

Go to next step if the pressure value is correct.

•

Shoot the Refrigeration system trouble promptly if the pressure value is not as specified in the

technical specification.

2. Insert a thermometer into the middle vent port at the driver's side.

3. Warm up the engine and run it at the constant 1800rpm.

4. Set the rpm of the cooling fan to the HIGHEST.

5. Switch on A/C.

6. Set to internal circulation mode.

7. Set the temperature control mode to the COLDEST.

8. Set to Ventilation Mode.

9. Close all doors and windows.

10. Wait until A/C output temperature is constant. (When the environment temperature is 38°C, the temperature

at the middle ventilation port at the drivers side is 10°C~16°C. )

308

Section 6 Basic System

1.  Blower Removal / Installation

1. Disconnect the negative (--) terminal cable from the battery.

2. Remove instrument panel.

3. Remove motor connector.

4. Remove the resistor connector.

5. Remove the band.

6. Remove bolt. Remove blower.

7. The installation is in the reverse order of the removal.

2. Heater Removal / Installation

1. Remove water hose No. 1 and 2.

2. Remove instrument panel.

3. Remove the band.

4. Remove 2 wind door cables.

5. Remove heater.

6. The installation is in the reverse order of

the removal.

3. The Evaporator Removal / Installation

1. Remove evaporator inlet and outlet pipeline.

2. Remove instrument panel.

3. Remove thermistor connector.

4. Remove 2 bands.