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1.3
Air conditioning system
Chemicals/ozone layer regulation
The chemicals/ozone layer regulation, which became
effective on 01.12.2006, supplements the still directly
applicable regulation (EG) no. 2037/2000 from
29.06.2000 concerning substances, which cause de-
composition of the ozone layer and at the same time
replaces the previously valid German CFC-halon
0prohibition from 06.05.1991.
Work on air conditioning systems must only be carried
out by persons who:
have proven to have sufficient expert knowledge,
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have the necessary equipment to undertake such
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tasks,
are reliable and
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are not any directives regarding their activities when
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carrying out inspection and maintenance work acc.
to § 4 section 2 of the chemical/ozone layer regula-
tion.
The inspection and maintenance tasks, including leak
tests and possible repair activities, must be recorded
in the operating instructions together with information
about the refrigerant quantities used and regained,
whereby the operator is obliged to keep these records
over a period of at least five years.
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Note
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system.
Tools used on refrigeration circuits must be of ex-
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cellent condition, thus to avoid the damage of any
connections.
During repairs on refrigerant lines and components,
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these must be kept closed, as far as this is possible,
to prevent the system from being contaminated by
air, moisture and dirt. The operational safety of the
system can only be assured as long as all compo-
nents in the refrigerant circuit are kept internally
clean and dry.
Connections, screw fittings and their immediate sur-
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rounding areas must be cleaned before removal.
Before loosening hoses, pipe lines etc. relieve all
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pressure from the system.
During repair work keep all openings closed with
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clean plastic plugs and caps.
All parts to be reused should be cleaned with a
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gasoline free solvent and blow-dried with clean
compressed air or dried with a lint-free cloth.
Before opening all components should have
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warmed up to ambient temperature, to avoid that
damp air is drawn into the component by the differ-
ence in temperatures.
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Damaged or leaking parts of the air conditioning
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must not be repaired by welding or soldering, but
must generally be replaced.
Do not fill up refrigerant, but extract existing refrig-
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erant and refill the system.
Different types of refrigerant must not be mixed.
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Only the refrigerant specified for the corresponding
air conditioning system must be used.
Refrigerant circuits with refrigerant type R134a
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must only be operated with the compressor oil / re-
frigeration oil approved for the compressor.
Used compressor oil/refrigeration oil must be dis-
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posed of in strict compliance with applicable envi-
ronmental regulations.
Due to its chemical properties compressor oil / re-
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frigeration oil must never be disposed of together
with engine or transmission oil.
Compressor oil / refrigeration oil is highly hydro-
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scopic. Oil cans must strictly be kept closed until
use. Oil rests should not be used, if the can had
been opened over a longer period of time.
All O-rings/seal rings as well as pipe/ hose fittings
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must be oiled with compressor/refrigeration oil bfore
assembly.
When replacing a heat exchanger, e.g. evaporator
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or condenser, any compressor oil/refrigeration oil
lost by exchanging the components, must be re-
placed with fresh oil.
A too high compressor oil / refrigeration oil level ad-
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versely affects the cooling performance and a too
low oil level has a negative effect on the lifetime of
the compressor.
Use new O-rings or seal rings for reassembly.
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Always used 2 spanners to work on pipes/hoses to
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avoid damages .
Tighten screw fittings with the specified torque.
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Check all pipes/hoses, screw fittings or components
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for damage, replace if necessary.
Do not leave the refrigerant circuit unnecessarily
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open to the atmosphere.
In case of a repair on the refrigeration system you
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should first evacuate the air conditioning system for
at least 45 minutes to remove any moisture from the
system, before you start to refill. Moisture bonded in
the compressor oil / refrigeration oil (PAG oil) can
only be removed from the system by changing the
oil.
Compressor valves must only be opened after the
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system has been properly sealed.
The use of leak detection spray is not permitted. If
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such substances are used the WARRANTY will be-
come null and void.
BOMAG
General repair instructions
008 917 09
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