service DATSUN PICK-UP 1977 Manual Online

STEERING

SYSTEM

SPECIAL
SERVICE
TOOLS

No
Tool
number

tool

name
Description

Unit
mOl
in
For

use

on
Reference

page
or

Figure
No

ST27I80001

Steering
wheel

puller
This
tool

is
used
to

drive
out

steering
wheel

All

Fig
ST4

models

Caution
Do

not
hammer

on

steering
column
shaft

o
v

J

SE
116

2

ST29020001

Pitman
arm

puller
This
tool

is
used
to
remove

steering
pitman
arm
from

steering

sector

shaft
Fig
ST
6

SE401

3
ST3I

27S000
This
tool
is

used
to
measure

the
worm

bearing
preload

All

Page
ST
5

Preload

gauge
models

GG91030000

Torque

D

wrench

I

2
HT62940000

IJ

Socket

t

Y
ID

adaptor

114
3

8
Go

3

HT62900000
318
1
2

Socket

adaptor

4

HT72520000
This
tool
is

used
to

remove
ball

joint

All

Page
ST
6

Ball

joint
models

remover
620

B210

710

610

SE399

ST
10

Detail
A

Detail
D

REMOVAL
Engine
Control
Fuel

Exhaust

Systems

Detail
Bn
4

Detail
e

@

Detail
E

B

Fuel
tank
See

Figure
FE
a

I
Disconnect

battery

ground
cable

2
Remove
drain

plug
and
receive

the

remaining
fuel
into
a

suitable

container

3
Disconnect
filler
tube

fro
filler

hose

4
Remove

fuel
tank

securing
bolts

5
Disconnect

two
ventilation
hoses

fuel
return
hose
and
fuel
outlet
hose

from
fuel

tank

6
Disconnect
fuel
tank

gauge
unit

wires

at
connector

7
Remove

fuel
tank

Note

Plug
hose

and
tube

opening
l
to

prevent
entry
of
dust
or
dirt
while

removing

ReservoIr
tank

1

Disconnect

battery
ground
cable

2
Disconnect
two
ventilation
hoses

evaporation
hose
and
breather
hose

3
Remove
reservoir
tank

securing

bolts

and
remove
tank
with

protector
Note

Plug
hose
and
tube

opening
l
to

prevent
entry
of
dust
or

dirt
while

removing

Fuel

tank

gauge
unit

Disconnect

battery
ground
cable

2

Disconnect
wires

from
fuel
tank

gauge
unit

3

Remove
fuel

tank
For
details

refer
to
fuel
tank
removal

4

Unit

gauge
is
a

bayonet
type
and

can

be
removed

by

turning
it
counter

clockwise
with

screwdriver

Fuel

piping
See

Figure
FE
4

Fuel

tubes
are

serviced
as
an
as

sembly
so
that

replacement
of

fuel

tube
can

be

easily
done
However
do

not
disconnect

any
fuel
line
unless

absolu

tely

necessary

I

Drain
fuel
from
fuel
tank

2

Loosen
fuel

hose

clamps
and
dis

connect

fuel
tubes
on

each
end

Note

Plug
hose
and
tube

openings
to

FE

5
Detail
F
Detail

G

Detail
U

Detail
T

FE261

Fig
FE
4
Fuel

piping

prevent
entry
of

dust
or
dirt
while

removing

3
Unfasten

clips
that
hold
tube

on

under

body
and
remove
tube
from
the

vehicle

Fuel
filter

I
Disconnect
fuel
hoses
from
fuel

filter

by
removing
clamps
See

Figure

FE
5

FE18S

Fig
FE
S

Removing
fuel
filter
clamps

2

1

Back
trim

2

Back
inside

imisher

3

Clip
1

CENTER
CONSOLE

REMOVAL
AND

INSTALLATION

Except
for
air
conditioner

equipped
models

I
Remove
two

bolts
from
rear
of

center
console

2
Remove
center
console

by
pulling

it
back

3
To

properly
install

center

con

sole
insert
its
front

portion
into

bracket
on
the
floor
and
install
and

tighten
rear
attaching
bolts

SEAT

DESCRIPTION

There
are

two

types
of

seats
a
semi

separate
bench
seat
for
the
standard

wheelbase
and

long
wheelbase
models

and
a

separate
seat
for

the
Deluxe
Cab

models

CAUTION

In

conforming
with
M

Y
S
s
No

302
be
sure
to

remove
the
thin

polyethylene
covers
from
seat

cushions
seat
backs

and
head

restraints
at
the
time
of

a
Pre
delivery

service

b
Parts

replacement
Body
Frame

BF0328

Fig
BF
45

Back
trim
and
back

inside
finisher

BE033B

Fig
BF
46

Removing
center
console

SEAT

BENCH
SEAT

8F
19
Air
conditioner

equipped

models

I
Remove
two
bolts
from

front
of

center
console

2
Remove

two
bolts
from
the
rear

and
remove

center
console

CONSOLE

WITH

ARMREST

DELUXE
CAB

REMOVAL
AND

INSTALLATION

I
Remove

two
bolts
from

front
of

console

armrest
unit

2
Remove

one
bolt
in
the

console

box
and

remove
center
console

3
Installation
is

the
reverse
order
of

removal

BF034B

Fig
BF
47
Console

with
annrest

JJ

t

qJ

1
Seat

assembly

2
Seat
slide

3
Seat
slide
lock
handle

4
Seat
slide
lock
wire

BF474A

Fig
BF
48
Bench
seal

Body
Frame

Removal
and
installation

assembly

2
To
install

seat
reverse
above
re

moval

procedure
1
Remove

four
bolts

retaining
seat

slide

assembly
to

floor
take

out
seat

SEPARATE
SEAT

1

Head
re5traint

2
Seat
assembly

3

Reclining
device

4

Seat
slide
outer

5
eat
slide
inner
s

J

j

BF0358

Fig
BF

49

Separate
seat

Removal
and
installation

I

Remove
two

nuts

attaching
front

of
seat
slide
to
floor

2

Remove
two
bolts

attaching
rear

of

seat
slide
to
floor
3
Then

remove
seat
with

seat
slides

from
the

vehicle

4

Installation
is
the
reverse
order
of

removal

SEAT
BELT

1
Inner
belt

2

Tongue
stopper

3

Emergency
locking
retractor

4

Outer
anchor

plate

5

Lap
shoulder
belt

6
Shoulder

through
anchor
BF036B

Fig
BF
50

Seat
belt

BF

20
DESCRIPTION

The
seat
belt
is
a
three

point
type

consisting
essentiaily
of
a

lap
shoulder

belt
and
an
inner

lap
belt

The

lap
shoulder
belt

is
fitted
with

an

emergency
locking
retractor
which

senses
the

speed
at
which
the

webbing

is

being
pulled
and

the
deceleration
of

the
vehicle

The
inner

lap
belt
has
a
buckle
The

buckle
of
the
driver

s
seat
belt
includes

a
switch
which
functions
as
a
seat
belt

warning
device

CAlJI10NS

a
In

conformity
with
M
V

S
S
No

302
be
sure
to

remove
the
thin

polyethylene
covers
from
seat

belts

at
the
time
of

I
Pre
delivery
service

2
Parts

replacement

b
If

the
vehicle
has

overturned
or

been
in
a
collision

replace
the

entire

belt

assembly
regardless
of

nature
of
accident

c

If
the
condition

of

any

component

of
a

seat
belt
is

questionable
have

entire
belt

assembly
replaced
rather

than

attempting
to

repair
seat
belt

d
If

webbing
is
cut

frayed
or
dam

aged

replace
belt

assembly

e
Do
not

spill
drinks
oil
etc

on

inner

lap
belt
buckle
Never
oil

tongue
and
buckle

f

Use

only
a

genuine
Nissan
seat
belt

assembly

REMOVAL
AND

INSTAUATION

I

Disconnect

battery
ground
cable

2
Disconnect
buckle
switch
harness

at
connector
under
seat

3
Loosen

bolt

retaining
inner

lap

belt
and
remove
inner

lap
belt

4

Remove
bolt

securing
emergency

locking
retractor

5

Remove
shoulder
anchor
bolt

and
remove

lap
shoulder
belt
assem

bly

6
Installation
is

the
reverse
order
of

removal

Tightening
torque

Anchor
bolts

2
5
to
3
0

kg
m

18
to
22
ft
lb

DESCRIPTION

Cables
are
covered
with
color

coded

vinyl
for

easy
identification
In

the

wiring
diagram
colors
are
indicated

by

one
or

two

alphabetical
letters

It
is
recommended
that
the

battery

be
disconnected
before

performing

any
electrical
service
other
than

bulb

or
fuse

replacement

In
addition
to
fuses
a
fusible
link

has
been

installed
to

protect
wiring

The
fusible
link
functions
almost
the

same
as
a

fuse

though
its
eharac

teristics

are
slightly
different
than

normal
fuses

CABLE
COLORS

Cable
colors
are

indicated

by
one
or

two

alphabetical
letters

B

Black
Be
Brown

G
Green

L
Blue

Lg
Light

green

R

Red
W
White
Y
Yellow

The
main

cable
is

generally
coded

with

a

single
color
The

others
are

coded
with
a

two
tone
color
as

follows

BW

Black
with
white

stripe

gR

Light
green
with
red

stripe

INSPECTION

Inspect
all

electrical

circuits
refer

ring
to

wiring
or

circuit

diagrams

Circuits

should
be

tested
for
conti

nuity
or

short
circuit

with
a

conven

tional
test

lamp
or

low

reading
volt

meter
Before

inspection
of

circuit

ensure
that

I
Each
electrical

component

part
or

cable
is

securely
fastened
to

its
con

nector
or
terminal

2
Each
connection

is

firmly
in

place

and

free
from
rust
and
dirt

3

No
cable

covering
shows

any

evidence
of
cracks

deterioration

or

other

damage

4

Each
terminal

is
at

a
safe

distance

away
from

any
adjacent
metal

parts

5
Each

cable
is
fastened

to
its

proper
connector
or
terminal
Body
Electrical

System

BODY
ELECTRICAL

WIRING

6

Each

grounding
bolt
is

firmly

pbnted

7

Wiring
is

kept
away
from

any

adjacent
parts
with

sharp
edges
or

high

temperature
parts
such

as
exhaust

pipe

8

Wiring
is

kept
away
from

any

rotating
or

working
parts
fan

pulley

fan
belt
etc

9

Cables
between
ftxed

portions

and

moving
parts
are

long
enough
to

withstand
shocks
and

vibratory
forces

Notes

a
Before

starting
to

inspect
and

repair

any
part
of
electrical

system
or

other

parts
which

may
lead
to
a

short
circuit

disconnect
cables
at

battery
terminals
as
follows

Disconnect

cable
at

negative

terminal

and
then
disconnect
cable

at

positive
terminal

Before

connecting
cables
to

battery

terminal
be
sure
to
clean
terminals

with
a

rag
Fasten

cable
at

positive

terminal
and
then

ground
cable

at

negative
terminal

Apply

grease
to

top
of
these

terminals
to

prevent
rust
from

developing
on

them

b
Never

use
a

screwdriver
or
senrice

tool
to
conduct

a

continuity
test

Use
test
leads

c
Never

ground
an

open
circuit
or

circuits
under
no
load
Use

a
test

lamp
12V
3W

or
circuit
tester
as
a

load

FUSE
AND

FUSIBLE

LINK

DESCRIPTION

The
fuse
and
fusible
link

are

protec

tive

devices
used
in

an
electrical
cir

cuit

When
current

increases

beyond

rated

amperage
fusible
metal

melts

and

the

circuit
is

broken

BE
2
MAINTENANCE

INSTRUCTIONS

Fuse

The
fuse

block
is
installed

under

the
instrument

panel
on
the
left

hand

drive

vehicle

BE848A

Fig
BE
1

Fuse
block

When
for
one
reason

or
another

fuse

has
melted
use

systematic
pro

cedure
to
check
and
eliminate
cause
of

problem
before

installing
new
fuse

Notes

a
If
fuse
is

blown
be
sure
to
elimi

nate
cause
of

problem
before
in

stalling
new
fuse

b
Use

fuse
of

specified

rating
Never

use
fuse
of
more
than

specified

rating

Co

Check
condition
of

fuse
holders
If

much

rust
or
dirt
is
found

thereon

clean

metal

parts
with
fine

grained

sandpaper
until

proper
metal
to

metal
contact
is
made

Poor

contact
in

any
fuse
holder
will

often
lead
to

voltage
drop
or

heating
in
the
circuit
and
could

result
in

improper
circuit

operation

Fusible

link

Fusible
link

protects

lighting

starting
charging
and

accessory
cir

cuits

Condition

Inaccurate

speedometer

indication

Inaccurate
odometer

operation
Body
Electrical

System

Probable
cause

Inoperative
speedometer

Improperly
meshed
second
and
third

gear

worn

gears

Faulty
feeding
due
to
deformed
odometer

and

pinion
carrier

WATER
TEMPERATURE
AND
FUEL
GAUGES

Condition

Both
water

temperature

gauge
and

fuel

gauge

do
not

operate

Both
water

temperature

gauge
and
fuel

gauge

indicate

inaccurately

Water

temperature

gauge

Water

temperature

gauge
does

not

operate

Gauge
indicates

only

maximum

temperature

Water

temperature

gauge
does
not

operate
accurately
Probable
cause

Burnt

fuse

Inoperative
gauge
voltage
regulator

Inoperative
gauge
voltage
regulator
Gauge

pointer
fluctuates
excessively

Loose
of

poor
connection

Gauge
pointer

fluctuates
slightly

Correct
conn

Faulty
thermal
transmitter
or
loose
terminal

connection

When
thermal
transmitter

yellow
white

wire
is

grounded
gauge
pointer
fluctuates

Faulty
water

temperature
gauge

Open
circuit

Faulty
thermal
transmitter

Gauge
pointer
returns
to

original
position

when

ignition
switch
is
turned

off

Faulty
water

temperature
gauge

Gauge
pointer
indicates
maximum

tempera

ture
even
after

ignition
switch
is
turned

off

Faulty
water

temperature
gauge

Faulty
thermal
transmitter

Loose
or

poor
connection

BE
19
Corrective
action

Replace

Replace
speedometer

Replace
speedometer

Corrective
action

Correct

cause
and

replace
fuse

Replace
water

temperature

gauge

Replace
water

temperature
gauge

Correct
connector
contact

Replace
thermal
transmitter
or
correct

terminal
connection

Replace
wtater

temperature
gauge

Replace
thermal
transmitter

Replace
water

temperature
gauge

Connect
a
usn
resistance
between

ther

mal
transmitter

yellow
white
wire
and

ground
When

gauge
indicates

approximately

500C

i220F
gauge
is
serviceable

Correct

gauge
terminal
contact

Body
Electrical

System

WINDSHIELD
WIPER
AND
WASHER

REMOVAL
AND
INSTALLATION

Wiper
linkage

I

Remove
wiper
blade
and

arm

assembly
from

pivot

2
Remove
cowl

top
grille
See
Sec

tion
BF

3
Remove
two

flange
nuts

retaining

pivot
wiper
linka
e

to
cowl

top

4
Remove

stop
ring
that
retains

connecting
rod
to

wiper
motor
arm

5
Remove

wiper
motor

linkage
as

sembly

6
Install

wiper
motor

linkage
in
the

reverse

sequence
of
removal

Fig
BE
34

Removing
wiper
linkage

7
Install

wiper
arm
and
blade

assembly
in

correct

sweeping
angle

See

Figure
BE
35
for
correct

installing

dimensions

JC

I

i
25
mm
0

984
in
r

BE862A

Fig
BE
35

Wip
J

arm
irutallation
1

Windshield

wiper
blade

2
Windihield

wiper
arm

3

Wiper
motor

4

Wiper
motor
bracket

5

Connecting
rod

6
Pivot

BE685B

Fig
BE
33
Wind
hield

wiper

Wiper
motor

I
Remove

cowl

top
grille

3
Remove

stop
ring
that
connects

wiper
motor
arm
to

connecting
rod

3
From
under

instrument

panel

disconnect

wiper
motor
harness
at

connector
on

wiper
motor

body

4

Remove
three

retaining
screws

and

pull
out

wiper
motor
forward

5
Install

wiper
motor
in

the
reverse

sequence
of
removal

Fig
BE

36

Wiper
and
washer
switch

1
Press
in
switch
knob
turn
it

counterclockwise
and

pull
it
out
of

switch

2
Unscrew
escutcheon
and
remove

escutcheon
and

spacer

3
Reach

up
from
underneath
instru

ment

panel
disconnect

wiper
switch

multiple
connector
from
instrument

harness

wiring
assembly
and
remove

spacer
and
switch

4
Install

new
switch
in

the
reverse

sequence
of
removal

BE

23
Washer

pump

The
washer

pump
and
washer
fluid

tank
are

integral

parts
and
are
serviced

as
an

assembly

Caution
for
windshield
waBher

operation

I
Be
sure
to
use

only

washing
solu

tion

Never

use
mix

powder
soap
or

detergent
with
solution

2
Do

not

operate
windshield
washer

continuously
more
than
30

seconds
or

without
washer
fluid
This
often

causes

improper
windshield
washer

operation
Normally
windshield
wash

er
should
be

operated
10

seconds
or

less
at
one
time

I

Disconnect
two
washer

pump

lead
wires

at
connectors

2
Remove

hose
from
washer

pump

and
drain

washer
fluid

3

Pull
out
washer
tank
and
motor

assembly
from
tank
bracket

4
Install
washer
tank

and
motor

assembly
in
the

reverse

sequence
of

removal

Washer
nozzele

Access
for
washer
nozzle
removal
is

obtained

by
disconnecting
vinyl
tube

and

removing
washer
nozzle

retaining

screw
from
cowl

top

When
washer
nozzle
is
installed
or

when
washer
fluid
is

not

sprayed

properly
adjust
nozzle
direction
by

bending
nozzle
tube
so
that
washer

fluid
is

sprayed
in

range
indicated
in

Figure
BE
37

450
450

j217
72

r

l
1772

Ii
L

1

00
Li
L

J

270

1

to
63
3
94

1

Unit
nun

in

BE863A

Fif
BE

37
Waaher
nozzle

adjuatment

INSPECTION

Wiper
motor

I

Disconnect

wiring
connector

from

wiper
motor

2

Connect
test
lead
between
B
ter

minal
on
motor
ide
and

battery
posi

SE

B
V
I

C
E

1

M
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N
I
I

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W

u
71i

c

i

L

DATSUN
PICK
UP

MODEL
620

SERIES

lm

SSANJ

NISSAN
MOTOR
CO
LTD

TOKYO
JAPAN
SECTION
AC

AIR

CONDITIONING

DESCRIPTION
AC
2

TROUBLE
DIAGNOSES
AND

AC
19

CORRECTION

REMOVAL
AND

INSTALLATION
AC
25

COMPRESSOR
AC

33

SPECIAL
SERVICE
TOOLS
AC
39

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