Table of Contents 9
Chapter 16:
Refrigerant Recovery, Recycling, and
Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Refrigerant Service 252
Rules for Handling Refrigerants / Using a Refrigerant
Identifi er / Adding Refrigerant to a Partially Charged
System
Recovering Refrigerant 254
Recovering R-134a or R-12 / Recovering Blends and
Contaminated Refrigerant / Recycling Refrigerant
Evacuating Refrigeration Systems 257
Evacuation Procedure
Flushing Refrigeration Systems 258
Open Loop Flushing / Closed Loop Flushing
Checking and Adding Oil 259
Checking Compressor Oil Level / Adding Oil to
a Charged System / Adding Oil to Replacement
Components / Adding Oil to the Compressor
Vacuum and Pressure Testing Refrigeration
Systems 261
Vacuum Testing / Nitrogen Pressure Testing
Recharging Refrigeration Systems 262
Recharging with Refrigerant Service Center /
Charging with Gauge Manifold / Refrigeration
System Purging
Installing an Inline Filter 264
Maintaining Refrigerant Service Centers 264
Replacing the Filter-Drier / Calibrating the Service
Center’s Scale / Changing the Vacuum Pump Oil /
Checking for Leaks / Installing a New Tank / Adding
Refrigerant from a Disposable Tank / Removing Air
from Charging Cylinders
Chapter 17:
Hose, Line, Fitting, and O-ring Service . . . . 269
Servicing Fittings and O-rings 270
Compression Fittings / O-ring Replacement / Spring
Lock Couplings / Service Fittings
Servicing Hose Fittings 273
Crimped Fittings / Hose Clamps
Gasket Replacement 274
Hose Service 274
Hose Removal and Replacement
Making Hoses 274
Selecting Proper Hoses / Installing and Crimping
Hose Fittings
Line Service 276
Line Removal and Replacement / Making Lines
Chapter 18:
Compressor and Clutch Service . . . . . . . . . 279
Common Compressor and Clutch Problems 280
Noises / Compressor Clutch Not Engaging /
Excessive Pressure / Constant Low Pressure /
Occasional Low Pressure
Compressor Removal and Replacement 282
Compressor Removal / Adding Oil to Compressors /
Compressor Installation / Compressor Retrofi tting
Compressor Clutch and Electromagnet Service 284
Clutch Removal / Electromagnet and Clutch
Replacement
Compressor Overhaul 287
Shaft Seal Replacement / Rebuilding Compressors /
Overhauling Radial Piston Compressors /
Overhauling Axial Piston Compressors / Overhauling
Scroll Compressors / Capacity Control Valve
Removal and Replacement / Replacing Other
Compressor Components
Overhauling Older Compressors 294
Chapter 19:
Valve, Evaporator, Condenser, and Related
Parts Service . . . . . . . . . . . . . . . . . . . . . . . . 297
Common Problems 298
Expansion Valve Failures / Orifi ce Tubes / Evaporator
Pressure Control Valves / Compressor Cycling
Switches / Evaporator / Condenser / Accumulator /
Receiver-Drier
Component Service 301
Expansion Valves / Evaporator Pressure Control
Valves / Orifi ce Tubes / Compressor Cycling
Switches
Evaporators 303
Evaporator Cleaning / Evaporator Replacement /
Afterblow Module Installation
Condensers 307
Condenser Cleaning / Condenser Replacement
Accumulators 307
Replacement Guidelines / Accumulator Replacement
Receiver-Driers 309
Replacement Guidelines / Receiver-Drier
Replacement
Systems with Multiple Component Units 309
Chapter 20:
Heater and Engine Cooling System
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Safety Considerations 314
Cooling System Inspection 314
Cooling System Checks
Heating System Problems 320
Poor or No Heating / Too Much Heat / Coolant
Leaks / Heater Problems—Air-cooled Engine