Charging the System

CAUTION: Do not exceed the specification when charging the system with refrigerant. Doing so will decrease the efficiency of the air conditioner or damage the refrigeration cycle parts.

1. Install the manifold gauge set.
2. Connect the tap pin side of the charging hose to the air purge valve of the manifold gauge.
3. Connect the vacuum pump hose to the center joint of the manifold gauge.
4. Connect the vacuum pump hose to the vacuum pump.
5. Connect the charging hose to the refrigerant tank.




6. Place the refrigerant tank on the scale.

Regular amount of refrigerant
750 g {26.5 oz}

7. Open all the valves of the manifold gauge.

CAUTION: Close the manifold gauge valve immediately after stopping the vacuum pump. If the valve is left open, the vacuum pump oil will backflow into the refrigeration cycle and cause a decrease in the efficiency of the air conditioner.




8. Start the vacuum pump and let it operate for 15 minutes.




9. Verify that the high- and low-pressure side readings of the manifold gauge are at -101 kPa {-760 mmHg, -29.9 inHg}. Close each valve of the manifold gauge.
10. Stop the vacuum pump and wait for about 5 minutes.
11. Inspect the low-pressure side reading of the manifold gauge.
- If the reading has changed, inspect for leaks and then repeat from step 7.
- If the reading has not changed, go to next step.

12. Open the valve of the refrigerant tank.
13. Weigh the refrigerant tank.

WARNING:
- If the refrigerant system is charged with a large amount of refrigerant when checking for gas leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In order to prevent the accidental release of refrigerant which can destroy the ozone layer in the stratosphere, follow the proper procedures and charge with only a small amount of refrigerant when checking for gas leakage.
- If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.




14. Open the high-pressure side valve of the manifold gauge and charge with refrigerant until the low-pressure side reading is at 100 kPa {1 kg/sq.cm, 14 psi}




15. Close the high-pressure side valve of the manifold gauge.
16. Inspect for leaks using a gas leak tester.
- If there are no leaks, go to next step.
- If a leak is found at a loose joint, tighten the joint and inspect for leaks again.
- If there is still a leak at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from step 7.
- If there are no leaks after tightening the joint, go to next step.

WARNING: If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open Is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.




17. Open the high-pressure side valve of the manifold gauge and charge with refrigerant until the weight of refrigerant tank has decreased 400 g {13.5 fl oz} from the amount in step 13.




18. Close the high-pressure side valve of the manifold gauge.

WARNING: If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.

19. Start the engine and actuate the A/C compressor.




20. Open the low-pressure side valve of the manifold gauge and charge with refrigerant until the weight of the refrigerant tank has decreased 750 g {26.5 fl oz} from the amount in step 13.
21. Close the low-pressure side valve of the manifold gauge and the valve of the refrigerant tank.
22. Stop the engine and A/C compressor.
23. Check for leaks using a gas leak tester.
- If there are no leaks, go to next step.
- If a leak is found at a loose joint, tighten the joint and inspect for leaks again.
- If there is still a leak at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from step 7.
- If there are no leaks after tightening the joint, go to next step.

24. Disconnect the high- and low-pressure side quick couplers from the charging valves that are connected to cooler pipe No.1 and No.4 of the refrigerant system.




25. Install the caps to the charging valves of cooler pipe No.1 and No.4.