ECO DATSUN PICK-UP 1977 Service Manual

REFRIGERAi
H
R
12

COMPRESSOR
OIL

MAINTENANCE

PERIODIC
MAINTENANCE
AND

SEASON
IN

INSPECTION

GENERAL
SERVICE
INSTRUCTION

SAFETY

PRECAUTIONS

EV

ACUA
TlNG
AND

CHARGING
SYSTEM

HANDLING

MANIFOLD
GAUGE

HANDLING
SERVICE
VALVE

HANDLING
CAN
TAP

DISCHARGING
SYSTEM

REFRIGERANT
R
12

The

refrigerant
used
in
the
air

conditioner
is

generally
called
Re

frigerant
12

R
12
No
other

refrig

erant
than
the

above

refrigerant
should

be
used

This

refrigerant
is

usually
available

in
a
small
can
or
a

cylinder
In

either

case
it

is

liquefied
under

high
pressure

in
the
container

Refrigerant

evaporates
easily
has
a

low

evaporation
point
and
moreover

since
the
latent

heat
of
the

refrigerant

is

large
it

can
abSorb

a

large
amount

of
heat

wh

err
e

vaporating
Extreme

care
must
be
exercised
when

handling

the

refrigerant

COMPRESSOR
OIL

The
SUNISO
5GS
or
SUNISO

351

should
be
used
as

refrigeration

lubricant

Mixing
of
the

two
is

allowable

The

refrigeration
lubricant
should

be
used
to
assure
the
successful
com

pressor
operation
Use
of
oils
other

than
recommended
or

mixing
of
the

oil

with
other
oils
would
cause

chemical
reaction

or
lead
to
lowered

viscosity
or
deficient
lubrication

The
oil

absorbs
moisture
as
it

con

tacts

the
air
This

points
out
the
need

for

care
not
to

expose
it

to
atmos

phere
for
an

extended

period
of
time
Air

Conditioning

GENERAL
SERVICE

CONTENTS

EVACUATING
SYSTEM

CHARGING
REFRIGERANT

CHECKING
FOR
LEAKS

HALIDE
LEAK

DETECTOR

ELECTRIC
LEAK

DETECTOR

REFRIGERANT
LEVEL
CHECK

SIGHT

GLASS

PERFORMANCE
TEST

COMPRESSOR
OIL
LEVEL
CHECK

PERFORMANCE
TEST

REFRIGERANT

LEAKS
AC
8

AC

8

AC
8

AC
8

AC
8

AC
9

AC
9

AC
9

AC10

AC

11

AC
12

MAINTENANCE

PERIODIC
MAINTENANCE

AND

SEASON
IN

INSPECTION

Both

periodic
maintenance
and

season
in

inspection
are

most
essential

to
enable
the
air

conditioner
to

give

full

performance

Perform
the

following
checks

Start

engine
and

check

refrigerant

level

through
sight
glass
on

receiver

dryer
For

details
refer
to

relative

topics
under

Refrigerant
Level

Check

2
Check
the
entire

sysiein
for

sign

of

refrigerant
leaks

Refer
to
relative

topics
under

Checking
for

Leaks

and

Refrigerant
Leaks

If

any
trace
of
oil
is

noted
at

and

around
connection

fittings
it
is
a

sure

indication

that

refrigerant
is

leaking

This
condition

can
be
corrected

easily

by
retightening
the

joints
If

any
joint

on
line

is

suspected
of
small
amount
of

leakage
use
a
leak

detector
to

locate

leaking
points

3
Check

compressor
drive
belts

for

proper
deflection

Season
off

Observe
the

following
maintenance

tips
to
allow

the
air

conditioner

to

operate

normally
in

the
next

season

I

Keep
the
entire

system
free
from

AC
8
AC12

AC

13

AC15

AC15

AC16

AC

16

AC16

AC
17

AC17

AC
17

AC18

refrigerant
leakage
by

periodically

checking
for

refrigerant
gas
leak

even

out
of
season

2

Turn
the

compressor
for
10

minutes

at
least
once
a
month

by

running
the

engine
at
1

500

rpm

c
ENERAL
SERVICE

INSTRUCTION

The

servicing
of
the
air
conditioner

should
be
carried
out

only
by
well

trained
servicemen
This

chapter
de

scribes
essential

points
of

servicing

Jf

a

Jarge
amount
of

dirt
and
sand

enter

the

system
they
will
be

carried
with

refrigerant
and

may

clog
the

system
or
scratch

rotating

parts
This

points
out
the
need
for

care
in

servicing
the

system
That

is

disconnecting

joints
should
be

carried
out

in
a
dean

place

Water
should
not
be
allowed
to

get

inside
the

system
The

refrigerant

does
not

readily
mix

with
water

However
the

presence
of
even
a

minute

amount
of

water
will
cause

a
chemical
reaction

at

high
tem

perature
which
will
in

turn

produce

hydrochloric
acid

HCl
Since

hydrochloric
acid
is

highly
corro

sive
to
metals
the
aluminum
and

copper
piping
etc
will
become

corroded
and
the

refrigeration

system
will
become

clogged

Water
in
the

system
will

ice
the

orifice
when
the

high
pressure
re

frigerant
is

changed
to
low

pressure

refrigerant
by

expansion
valve
etc

and
will
obstruct
the

refrigerant

flow

The

following
items

are

general

instructions
to
be

closely
observed
in

servicing
the

system

I
When
a

system
line
is

discon

nected

plug
the

opening
immediately

This
is

especially
necessary
to

prevent

moisture

condensation
from

forming

in
the
line
and
to

keep
out
dirt
and

dust
It
is
also

necessary
to

keep
the

line
at
and
above

surrounding
air

temperatures
at
all

times
When

con

necting
system
lines
do

not

attempt

to
remove
the

plug
from
the

opening

until

ready
for
immediate
use

2

Always
keep
the

working
place

clean
and

dry
and
free
from
dirt
and

dust

Wipe
water
off
with
a
clean

cloth

3
Have
all

necessary
tools
in

pre

paration
beforehand

and
have

tools

clean
and

dry

4
The

compressor
oil
will

easily

absorb
moisture
when

exposed
to
air

Immediateiy
close
the

opening
of
the

container
after
use
It
is
also

necessary

to
observe
the

following
notes

Notes

a
The
oil
should
not
be
transfused

from
a
container
into

another
as

the
failure

will

possibly
cause
mois

ture
to
mix

with
the
oil

b
The

used
oil
should
not
be

returned

into
a
container

c

The
oil

should
not

be
used
if
its

state
of

preservation
is

not
clear

enough

5
When

connecting
or

disconnect

ing
pipes
from
the

refrigeration
sys

tem
use
two

wrenches
One
wrench
is

used
for

holding
the

fixing
nut

in

place

while
the

other
for

turning
the

mating

flare

nut
Failure
to
do

so

may
result

in
a

twisted
tube
or

may
damage

connection

6
Also
use
care
not
to

give
scratches

to
the

seating
surface
at
connections

A

small
scratch
on

the

seating
surface
Air

Conditioning

may
be
the
cause
of

gas
leakage

Before

connecting
pipes
be
sure
to

give
coating
of

compressor
oil
to
the

sea

ting
surfaces

SAFETY

PRECAUTIONS

I

Since
direct

contact
of
the

liquid

refrigerant
with

your
skin
will
cause

frostbite

always
be
careful

when

handling
the

refrigerant
Wear

gloves

or

wrap
a

piece
of
cloth
around
service

valve

to

protect
your
fingers
against

frostbite

by

refrigerant
If

any
of
the

refrigerant
should

get
into

your
eyes

when

charging
the

refrigerant
splash

your
eyes
with

cool
water
to
raise

the

temperature
gradually
Apply
a

protec

tive

film
to

the

eye
to

avoid
infection

Do
not
rub

your
eyes
Consult
an

eye

specialist
Always
wear

goggles
or

glasses
to

protect
your
eyes
when

working
around
the

system
Should

refrigerant
strikes

your
body
splash

on
cool
water
and

apply
a

protective

film

2
The

refrigerant
service
container

has
a

safe

strength
However
if
han

dled

incorrectiy
it
wili

explode

Therefore

always
follow
the
instruc

tions
on
the

label
In

particular
never

stpre
it
in

a
hot

location
above

S20C

l250F
or

drop
it
from

a

high

height

3
The

refrigerant
gas
is

odorless
and

colorless
and

breathing
may
become

difficult

due
to
the

lack
of

oxygen

Since
the

refrigerant
gas
is

heavier
than

air
and

will

lay
close
to
the
floor
be

especially
careful
when

handling
it

in

small

confined

spaces

4

The

refrigerant
itself
is
nonflam

mable
However
a

toxic

gas

phosgene

gas
is

produced
when
it

contacts
fire

and

special
care
is
therefore

required

when

checking
for

leaks
in

the

system

with

a
halide
torch

5

Do
not
steam

clean
on
the

sys

tern

especially
condenser
since
exces

sively
high
pressure
will
build

up
in

the

system
resulting
in

explosion
of
the

system

The

above

precautions
are
essential

in

handling
of

Refrigerant
l
2
and

their
strict
observation

requires
suffi

AC
9
dent

training
Therefore
it
is

of
first

importance
that

any
other

personnel

than
a
well
trained
serviceman
should

not
be

allowed
to
handle
the

refrig

erant

EVACUATING

AND

CHARGING
SYSTEM

During

servicing
use
caution
to

keep
air

from

getting
into

refrigerant

When
air

enters
the

system
all

refriger

ant

must
be
evacuated
from

system

prior
to

charging
new
refrigerant
Air

in

refrigerant
has
the

following
delete

rious

effects

I

Since
the
condensation

tempera

ture

of
the
air
is

extremely
low
the
air

will

not
be

condensed
when

refrigerant

gas
is
condensed

in
the
condenser
and

the

air
will

thus
remain
in

gaseous

form

Consequently
the
effective

thermal

transmission
area

of
condenser

for

refrigerant
gas
will
be
red
uced
and

refrigerant
gas
to
be
condensed
will
be

red
ueed
The

pressure
rise
will
become

proportional
to

the
volume
of
the
air

in

system

2

When
air
and

refrigerant
are

mixed
in

system
a
chemical
reaction

will
be

produced
and

hydrochloric

acid
which
will

adversely
affect
the

aluminum

copper
iron
and
other

materials
in

system
may
be

generated

HANDLING
MANIFOLD

GAUGE

The

pressure
at
the

high
and
low

sides
of

system
should
be

measured

when

evacuating
and

charging
refrig

erant
and
when

diagnosing
trouble
in

the

system
The
manifold

gauge
is
used

for
these

purposes
A

manifold

gauge

has
two

pressure
gauges
a

low

pressure

gauge
and
a

high
pressure
gauge
These

gauges
are

connected
to

the

high
and

low

side
service

valves
of

system

through
flexible

charging
hoses

The

construction

of
manifold

gauge
is

shown
in

Figure
AC
13

When
valve
stem
is

fully
screwed

the
valve
is
front
seated
and
valve

path

and
the
center

path
are
blocked
When

valve
stem
is

backed
off
the

paths
are

opened

Air
Conditioning

Low

pressure
gauge

Compound
pres
lIrt

gaug
High
rHe
ure

g
Uge

c

7

I

Back
se
ted

Full
counter

J

clockwise

Ji

r

rnF
r

r1
gL

r

W
t

g

2

Connection
to
service
valve

I

Fully
close
both
valves
of
mani

fold

gauge
Connect
high
and
low

pressure
charging
hoses
to
manifold

gauge

2
Remove

caps
from
service
valves

Connect
high
and
low

pressure
charg

ing
hoses
to
service
valves
in

system

The

refrigerant
gas
wili
be

discharged

since
check
valve
is

open
when

pressing
charging
hose
onto

service

valve

3

Next
loosen
the

connection
fit

ting
of

charging
hose
at
manifold

gauge
side
for
2

to
3
seconds
to

purge

any
air

inside

charging
hose

by
the

pressurized
gas
in

system

Disconnedion
from

service
val
v

I

Fully
close
both
valves
of
mani

fold

gauge

2

Disconnect
two

charging
hoses

from
service
valves
At

this
time
the

gas
will
be

discharged
until
check
valve

is
closed
Therefore
disconnect
hose

quickly

Caution
Work
with

fingers
protected

with
cloth

against
frostbite

by
re

fri
l
fant
To
low
side
To
vacuum

pump
OI

To

high
ide

rvicc
valve

refrigerant
can

service
va
lve

HANDLING
SERVICE
VALVE

An
automatic
check
valve
is
built

into

service
valve
When
this
valve

presses
against
the
connection

fitting

that
is
when

charging
hose

is
con

nected
to
service
valve
the
valve
is

open
When

charging
hose
is
discon

nected
the
valve
is
closed
automatical

ly
Always
observe
the

following
usage

precautions

Always
install
valve

cap
after

using
service
valve

When

high
speed
opera
tion
is

per

formed
without
valve

cap
a

negative

pressure
will

gradually
build

up
at

the

low

pressure
side
of

system
and
air

may
be
sucked
in
In
addition
dirt
and

dust

will

easily
enter
the
valve
result

ing
in
foreign
matter

entering
the

system

L

5V

j

Close

AC
l0
Front
seated

Full
clockwise

AC243

Fig
AC
13

Manifold
gauge

2
Check
valve
will
be
half

opened

during
connection
and
disconnection

of

charging
hoses
and

refrigerant
will

be
forcefully

discharged
Therefore

connect
and
disconnect

charging
hoses

quickly
while

pressing
flare
nut

of

charging
hose

against
service

valve

Caution
Work
with

fingers
protected

with
cloth

against
frostbite

by
re

frigerant

3

Since
close
contact
between
the

thread
of
valve

eap
and

the
thread
of

service

valve
will

prevent
gas
leakage

keep
these
sections
clean
and
free
of

scratches
and
damage

4

Since

packing
of

charging
hose

will
be

lost

during
long
use

always

check

packing
prior
to

installing
charg

ing
hose

J

17

t

1
1

t

Cap

2

Service
valve

3

Charging
hose

AC733

Open

Fig
AC
14
Service
oolve

b

r
r

AC734

Fig
A
C

15
Service
value

docK
wise

n

r
Air

Conditioning

HANDLING
CAN
TAP

A

wide

variety
of
can

taps
are

available
The

following
procedures

apply
to

conventional

can

taps

For
the

correct

usage
refer
to

the

manufacturer
s

instructions

Caution
Use

can

tap
of

good
quality

I
Connect

charging
hose
to
the

center
fitting
of
manifold

gauge
At

this
time
confirm
that
both
stems
are

fully
turned
in

front
seated

2
Turn

can

tap
handle

fully
coun

Counterclockwise

s

r

@

A

rn

Purging
air

n

R
I2

AC
terclockwise

so
that
the

needle
is

pulled

up

3
Attach

can

tap
to

refrigerant
can

firmly

4

Turn

can

tap
handle

fully
clock

wise
to

make
a

hole
in

refrigerant

can

5

Turn
the
handle

fully
counter

clockwise
to
raise
the

needle

Refriger

ant

gas
will

flow

up
to
the
center

fitting
of

manifold

gauge

6
Loosen
the

connection
a
t

the

center

fitting
of
manifold

gauge
for
a

few
seconds
to

purge
air

inside

charg

ing
hose
See

Figure
AC
16

1
Can
tap
handle

2

Charging
hose

3
Needle

4

Refrigeran
t
can

AC246

AC247

Fig
AC
16
Can

tap
and

pw
ging
air

q

J

I

1
Air

Conditioning

J

lJ

R

J

g

j

ru

Fig
A
C
l8

Euacuating

system
First

step
AC736

Fig
AC

19

Euacuatingsystem
Second

step
AC737

CHARGING

REFRIGERANT

I
Install

manifold

gauge
to

system

Refer
to

Handling
Manifold

Gauge

Notes

a

Be
sure
to

purge
air
from
the

high

and
low

pressure
charging
hoses

b
If
air
is

mixed
with

refrigerant
gas

in

system
evacuation
of

system

should
be

performed
Refer
to

Evacuating
System

2

Attach
center

charging
hose
of

manifold

gauge
to

refrigerant
can

through
can

tap
Break
seal
of

refriger

ant
can
to

allow

refrigerant
to
enter

manifold

gauge
Loosen

charging
hose

at
the
center

fitting
of
manifold

gauge

and

purge
air

from
inside

charging

hose
Refer
to

Handling
Can

Tap

3

Open
high
and
low

pressure

valves
of
manifold

gauge
and

charge

refrigerant
into

system
See

Figure

AC
20

Notes

a

When

refrigerant
charging
speed
is
1

j

jJ

i

j

Fig
AC
20
Charging
refrigerant
AC738

slow
immerse

refrigerant
can
in

water
heated
to

a

temperature
of

about

400C

l040F
However

note
that
this
is

dangerous
when

water
is

hot
See

Figure
AC
21

Cautions

a

Under

any
circumstances
the

refrig

erant
can
must
not
be

warmed
in

water
heated
to
a

temperature
of

over
520C

l2S0F

b
A

blow
torch
or

stove
must
never

be
used
to
warm

up
the
can
R

121
Immerse
in
water

heated

to
about

400C

1040F

Note
that

hot

water
is

dangerous

AC252

Fit
AC

21
Heating

refrigerant

AC13

Air
Conditioning

b

When

charging
hquefied
refrigerant

into
the

system
lith
the
can
turned

upside
down
to
reduce

charging

time

charge
it

only
through
high

pressure
valve
but
not

through
low

pressure
3
h
e

After

completion
of

charging
the

compressor
should

always
be

turn

ed
Several
times

manually
See

Figure
AC
22

t

UL
Q

v1ifl
j

AC739

Fig
A
C
22

ClUJrging
refrigerant
First

step

4
If

refrigerant
charging

speed
slows

down

charge
it
while

Iunning
the

compressor
for
ease
of

charging
After

having
taken
the

steps
up
to

3
above

proceed
with

charging
in

the

following

order

I
Shut
off

high

pressure
valve
of

manifold

gauge
back
into

refrigerant
can
and
can

may
explode

2

Run
the

engine
at

idling
speeds

about
1
500

rpm

3
Set
the

temperature
control

lever
and
fan
switch

at
maximum

cool

and
maximum

speed
respectively

4

Charge
refrigerant
while
con

trolling
low

pressure
gauge
reading
at

2
8

kgfcm2
40

psi
or
less

by
turning

in
or

out
low

pressure
valve
of
mani

fold

gauge
See

Figure
AC
23
Caution
Never

charge
refrigerant

through
high

pressure
side
of

sys

tem
since
this
will
force

refrigerant

t

AC740

Fig
A
C
23

Charging

refrigerant
Second

step

AC
14
5
When

refrigerant
can
is

empty

fully
close

both
Ives
of
manifold

gauge
and

replace
refrigerant
can
with

a

new
one

Before

opening
manifold

gauge

valve
to

charge
refrigerant
from
new

can

be
sure
to

purge
air
from
inside

charging
hose

6

Charge
the

specified
amount

of

refrigerant
into

system
by
weighing

charged
refrigerant
with
scale

Over

charging
will

cause

discharge

pressure

to

rise

AC255

Measure
the

amount
of

charged

refrigerant
with
a
scale

Make
a

note
of
the

amount

charged

from

can

Fig
AC

24
Measuring
refrigerant

Refrigerant
capacity

Unit

kg
lb

Refrigerant
Minimum

Maximum

R
12

0

7
1
5
0
9
2

0

Note
The

presence
of
bubbles
in

sight
glass
of

receiver

dryer
is
an

unsuitable
method
of

checking
the

amount

of

refrigerant
charged
in

system
The
state
of
the
bubbles
in

sight
glass
should

only
be
used
for

checking
whether
the
amount
of

charged
refrigerant
is
small
or
not

The
amount
of

charged
refrigerant

can
be

correctly

judged
by
means

of

discharge
pressure
Refer
to
Re

frigerant
Level
Check

7
After
the

specified
amount
of

refrigerant
has

been

charged
into

sys

tem
close
manifold

gauge
valves
Then

detach

charging
hoses
from
service

valves
of

system
Be
sure
to
install

valve

cap
to

service
valve

8

Confirm
that
there
are

no
leaks
in

system
by

checking
with
a
leak
detec

tor

Refer
to

Checking
for
Leaks

Note

Conducting
a
performance
test

prior
to

removing
manifold

gauge
is

a

good
sen
ice

operation
Refer
to

Performance

Test

CHECKING
FOR

LEAKS

Conduct
a

leak
test
whenever
leak

age
of
refrigerant
is

suspected
and

when

conducting
service

operations

which
are

accompanied
by
disassembly

Dr

loosening
of

connection
fittings
Air

Conditioning

Refrigerant
is
a

colorless
odorless

gas
and

leakage
from

system
is
diffi

cult
to
detect

Accordingly
the
use

of

a

leak
detector
facilitates

check
for

leaks

Two
methods
of

checking
are

available
one

employs
a
halide

leak

detector
which
burns

propane
gas
or

butane

gas
and
the
other

is
an
electric

type
leak

detector

HALIDE
LEAK
DETECTOR

Since
the

propane
leak
detector
and

butane
leak
detector

are
the

same
in

respect
to
their

operation
this

section

describes
the

operation
of
the

propane

leak
detector

The

copper
screen
is
heated

by
the

burning
of

propane
Refrigerant
gas

decomposes
to

color
the
flame
when

it

contacts
the
heated
screen
The

gas
to

be
checked
is
drawn
into

the

sampling

tube

and
sent
out
to
the
burner
A

refrigerant
leak
can

clearly
be
detected

by
variations
in
the
color
of
the
flame

Propane
type

NO
LEAK

SMALL

LEAK

LARGE
LEAK
Greenish

blue

Yellow

Purple
AC010
1

Copper
reaction

plate

2

Flame

adjusting
lines

3

Burner

4

Sampling
tube

5

Strainer

6

Gas
bomb

7
Flame

adjuster

Fig
A
C
25

Checking
for
leak

Butane

type

Pale
blue

Bright
blue

Vivid

green

AC
15
I

Discharge

refrigerant
in

one
or

two
seconds
to
ascertain

that

system

has
a

sufficient

pressure
needed
for

leak
detection

Charge
with
04

kg
I

lb
of

refrigerant
if

necessary

2

Light
leak
detector

Adjust
the

height
of

the
ilame
between

flame

adjusting
lines
at
the

top
and
bottom

of
combustion

tube
A

reaction

plate

will

immediately
become
red

hot

3

Place
the
end

of

sampling
tube

near
the

point
of
the

suspected
leak

in

system

Notes

a
Since

refrigerant
gas
is
heavier
than

air

small
leaks
can
b

easily
detect

ed

by

placing
sampling
tube
direct

ly
below
the
check

point

b
Suitable
ventilation
is

required
If

refrigerant

gas
is

mixed
with
the

surrounding
air
leak
detector
will

always
indicate
a

response
and

detection
of
the
actual
leak
will
be

difficult

c

Never
bold
leak
detector
at
an

angle

Cautions

a
Never

inhale
the
fumes

produced

by
combustion
of

refrigerant
gas

since

they
are
toxic

b
Never
use
halide
torch
in
a

place

where
combustible
or

explosive

gas

is

present

4
The

ilame
will
be
almost

colorless

when
there
is

no

refrigerant
gas
being

burned
When
there
is

a
small

refriger

ant

gas
leak
the
ilame

will
be

green
or

yellowgreen
When

refrigerant

gas
leak

age
is

large
the
ilame
will
be
brilliant

blue
or

purple
Since
the
color
of
the

ilame
will
be

yellow
when
dust
is

being
burned
Or
there
is

aging
scale
on

copper
reaction

plate
always
keep
the

strainer
of

sampling
tube
and
reaction

plate
clean

5

Major
check

points

I
Compressor

Compressor
shaft
seal

rotate
the

compressor
by
hand

Oil
filler

plug

Flexible
hose
connections

Rear
cover
and
side
cover

gaskets

Service
valve

2
Condenser

Condenser

pipe
fitting

Condenser
inlet
and
outlet

pipe

connections

I

3

Piping

Flared
section
of

high
pressure
and

low

pressure
flexible

hose

Pipe
connections

rvice

valve

4

Evaporator
housing

Jnlet
and

outlet

pipe
connections

Expansionvalve

ELECTRIC
LEAK
DETECTOR

for
the

operational
procedures

refer
to

the
instructions
furnished
with

each
electric
leak
detector

Amount

of

refrigerant
Air

Conditioning

REFRIGERANT

LEVEL
CHECK

SIGHT
GLASS

Sight
glass
is

provided
at
the

top
of

receiver

dryer
One

guide
for
whether

there
is

enough
refrigerant
in

system
is

given
by
observing

refrigerant
flow

through
sight
glass
However
this

method

is
unsuitable
for

judging
the

amount
of

refrigerant
The
correct

refrigerant
level

can
be

judged
by

measuring
t
e

system
pressures
in
ac

cordance
with
the

procedures
de

scribed
Performance
Test

I

Start
the

engine
and
hold

engine

speed
at
1
500

rpm

Almost
no

reftigerant

Check
item

Temperature
of

high
pressure

and
low

pressure
pipes
Almost
no
difference

between

high

pressure

and
low

pressure
side

temperature

Bubbles
flow
continu

ousty
Bubbles
will

disappeu
a
nd
some

thing
like
mist

will

now
when

rerrigeran

is

nearly
gone
State
insightglass

A

I
I

AC256

Pressure
of

system
High
pressure
side

is

abnormally
loW

Repa
ir
Stop

compressor
and

conduct
an
overall

check
Insufficient

High
pressure
side
is

warOl
and

low

pressure

side

is

fairly
cold

The
bubbles
are
seen

at
intervals
of
1
2

seconds

A

r

I

AC257

Both

pressures
on

high

and
low

preS
ure
sides

are

slightly
low

Check
for

gas
leakage

repair
as

required
re

plenish
and

charge

system

AC

16
2

Set

temperature
control
lever
to

maximum

position

3

Set
blower
to
maximum

speed

4

Check

sight
gla
after
the

lapse

of
about
five

minutes
Judge
according

to
the

following
table

AC741

Fig
AC
26

Temperature
control
lever

Suitable
Too
much

refri
crant

High
pressure
side
is

hot
and
low

pressure

side
is
cold
High

pressure
side
is

abnormally
hot

Almost

transparent

Bubbles

may
appear

when

engine

speed
is

raised
and
lowered
No
bubbles
can
be

seen

No
clear
difference
exists
between
these
two

conditions

M

II
I

AC258

Both

pressures
on

high

and
low

pressure
sides

are
normal
Both

pressures
on

high

and
low

pressure
sides

are

abnormally
high

Discharge
reft

gerant

from

service
valve
of

10
11

pressure
side

Notes

a
The
bubbles
seen

through
the

sight

glass
are
influenced

by
the
ambient

temperature
Since
the
bubbles
are

hard
to
show

up
in

comparatively

low

temperatures
below
200C
6S0

F
it
is

possible
that

a

slightly

larger
amount
of

refrigerant
would

be
filled
if

supplied
according
to

the

sight
glass
Be

sure
to
recheck

the
amount
when
it

exceeds
200C

680F
In

higher
temperature
the

bubbles
are

easy
to

show

up

b

When
the

screen
in
the

receiver

dryer
is

clogged
the
bubbles
will

appear
even
if
the
amount
of

refrig

erant
is
normal
In
this
case
the

outlet
side

pipe
of
the
receiver

dryer
becomes

considerably
cold

PERFORMANCE
TEST

Check
for
the
amount
of

refrigerant

in
the

system
can
be

made

by
meas

uring

pressure
on

discharge
side

The

correct
amount
of

refrigerant
is

in
the

system
if

pressure
on
the

discharge
side
is
within

the

specified

range
For
details
refer
to

Perform

ance

Test
described
later

Overcharging
will
show

up
in

higher

pressure
on
discharge
side

COMPRESSOR
OIL

LEVEL

CHECK

The
oil

used
to
lubricate

compres

sor
circulates
into

system
from
the

oil

sump
while

c9mpressor
is

operating

The

efore
to

correctly
measure
com

pressor
oil
the

amount
of
oil

flowing

to

system
must
be

considered
If
a

considerable
amount
of

leakage
of

refrigerant
gas
happens
the

leakage
of

compressor
oil
is
also
considered

There

will
be

no

compressor
oil
leak

age
from
a

completely
sealed

system

When

system
operates
under

satisfying

condition
the

compressor
oil
level

check
is

unnecessary

When

checking
the
level

of
com

pressor
oil
or

when

replacing
any

component
part
of
the

system
use
the

following
service

procedure
This

fa

cilitates
to
return
oil
to

compressor

I

Operate
compressor
at

engine

idling
speed
1
000

rpm
or

below

with
controls
set

for
maximum

cooling
Air

Conditionin
j

and

high
blower

speed
for
10
to

15

minutes
in

order
to
return

compressor

oil
to

compressor

2

Stop
the

engine
and

discharge

refrigerant
of

system
and
then

remove

compressor
from

the
vehicle

3
Remove

compressor
fIller

plug

Drain

compressor
oil
from

compres

sor
oil

sump
and

measure
the

amount

4

Compressor
oil
is

satisfactory
if

the

following
amount
of
oil

remains
in

the

compressor

Residual
oil

S5
to
128

gr
3
to
4
oz

5
Check
the
cleanliness
of
the
oil
If

the
oil
contains

chips
or

other

foreign

material
clean
oil

5ump
with
new

oil

6
Discard
the

used
oil
and

fili
with

the
same
amount
of
new
oil
Add

oil
if

found
less
than
above
amount

Fig
AC
27

Filler

plug

If

compressor
is

inoperative
due
to

faulty
compressor
or

heavy
loss
of

refrigerant
remove

compressor
and

repair
as

necessary
Then

pour
oil

up

to
correct
level
and
install
on

engine

After
above

steps
have
been

complet

ed
recheck
oil
level
drain
oil
to

correct
level
if

level
is

excessively
high

PERFORMANCE
TEST

The
cooling

performance
of
the
air

conditioner

changes
considerably
with

changes
in

surrounding
conditions

Testing
must
be

performed
using
the

correct
method
This

test
is
used
to

judge
whether

system
is

operating
cor

rectly
and

can
also
be
used

as
a

guide

in

checking
for

problems

I

Park
the
vehicle
indoors
or
in
the

shade

AC
17
2

Open
all
the
windows
of
the

vehicle
fully
However

close
the

doors

3

Open
the
hood

4

Connect
manifold

gauge
to

high

and
low
side
service
valves
of
the

system
Refer
to

Handling
Manifold

Ga

uge

5

Set
fan
control
lever
to
maxi

mum

6
Set

temperature
control
lever

to

max
cool

position

7
Start
the

engine
and
hold

engine

speed
at
1
500

rpm

S
After
the
air

conditioner
has
been

operated
for
about
10
minutes

measure

system

pressures
at

high
pres

sure

discharge
side
and
low

pressure

suction
side

9
Measure
the

temperature
of
dis

charge
air
at

outlet

grille

10
Measure
the

temperature
of

capin

11
Measure
ambient

temperature

and

humidity
one
meter
3
3
ft

away

from
condenser
front
Be

careful
not

to

expose
dry
buib

and
wet
bulb

to

direct

sunlight

12
Check
for

any
abnormalities

by

comparing
the
test

results
with
stand

ard

pressure
in
Performance

Chart

Notes

a
The

pressure
will

change
in
the

followi

g
manner
with

changes
in

conditions

When

blower

speed
is

low
dis

charge

pressure
will

drop

When
the
relative

humidity
of
in

take
air
is
low

discharge
pressure

will

drop

b

The

temperature
will

change
in
the

following
manner
with

changes
in

conditions

When
the
ambient
air

temperature

is

low
the
outlet
air

temperature

will
become
low

If
the
test
reveals
that
there
is

any

abnormality
in

system
pressure
isolate

the

cause
and

repair
by
reference
to

the
Trouble

Diagnoses
and
Cor

rections

AC506

Fig
AC

59

Grounding
point

of
coil

5

If
clutch

assembly
must
lie
re

placed
remember
that

break
in

opera

tion
is

necessary
The
break
in

opera

tion

consists
of

engaging
and

disengag

ing
the

clutch

some

tirty
times

SHAFT

SEAL

ASSEMBLY

The

shaft
seal

assembley
of

this

compressor
is
of
a

simplified
design

yet
tight

sealing
and

long
lasting

REMOVAL

It
is

recommended
that
the

com

pressor
be
removed

from
the

vehicle

for

shaft
seal

replacement

I
Remove

oil
filler

plug
with
D

ring

and
drain

the

compressor
oil

Fig
AC

60

Removing
filler
plug

2
Remove

clutch
Refer
to

Com

pressor
Clutch

Removal

3

Remove

shaft

key
Air

Conditioning

jpL

Y
L

I
i
0

I
I

0

Ace07

Fig
AC
61

Removing
s
wft

key

4

Remove
seal

plate

AC80e

Fig
AC

62

Removing
seal

plate

5

With
the

Compressor
Seal

Puller

pull
out

seal

gland
and
discard

Notes

a

Discard
all

parts
of
the
seal

includ

ing
the
O

ring

b
Do

not
use
a

screwdriver
to

pry

shaft
seal
from
shaft

as

damage
to

shaft

may
result

AC809

Fig
A
C

63
Removing
s
wft
eal

INSTALLATION

1
Clean

shaft
and
seal

cavity
with

clean

lint
free
cloth

2

Dip
seal

gland
in

clean

refrigerant

oil

AC
36
3

Push
seal

assembly

except
carbon

ring
over
end
of
shaft
with

carbon

ring
retainer

facing
out

4
Move

seal

assembly
into

position

on
shaft

1

I

Fig
AC
64

Inserting
wft
al

ass

mbly

5

Place
carbon

ring
in

ring
retainer

so
lapped
surface
is

facing
outward

Note

The
indentions
in
outside

edge

of
carbon

ring
must

engage

driving

lugs
and
be

firmly
seated
in

re

tainer

6
Install
new
D

ring
in

groove
of

seal

plate

Note

Use

refrigeration
oil
to

make
it

adhere
to
surface

7

Space
seal

plate
with

equal
clear

ance
around

shaft
and

insert

cap

screws

8

Tighten
these

screws

evenly

Tightening

torque

Seal

plate
securing

cap
screws

0
7
to
1

0

kg
m

5
to
7
ft

Ib

AC811

Fig
AC
65

8p
cing
01

plate
and

tightening
cap
screws

9

Install

clutch
Refer
to
Com

pressor
Clutch
Installation