AIR CONDITIONING SYSTEM TROUBLESHOOTING AND TESTING
Before testing operation of air conditioning system, make the following checks:
Ensure the refrigerant compressor drive belt is not damaged and is under proper tension (WP 0054 00). Check compres-
sor mountings for tightness.
Check for broken, burst, and cut hoses. Check for loose fittings on all parts.
Check for road debris buildup on condenser coil fins. Using air pressure and a whiskbroom or a soapy spray of water,
carefully clean condenser, using care not to bend fins.
Check color in moisture indicator sight glass. If color is a deep cobalt blue, refrigerant charge is dry. If moisture indica-
tor is not blue, system is contaminated with moisture. Notify your supervisor.
If there is not enough airflow, ensure that leaves and other debris has not entered fresh air ports under windshield. If
debris is present, it could clog fins of evaporator core and block airflow. Ensure that all ducts are connected to dash lou-
vers and air-control flaps in heater housing are moving properly (this requires removal of right and center dash panel).
Whenever repairs are made to any air conditioner parts that hold refrigerant, it is necessary to discharge, purge or flush
(if contaminated), evacuate, charge, and leak test system. In a good system, refrigerant lines are always under pressure
and should be disconnected only after air conditioning system has been discharged to a refrigerant recovery unit through
service valves on compressor.
Refrigerants are safe when used under proper conditions. Always wear safety goggles and non-leather gloves while dis-
charging, purging, flushing, evacuating, charging, and leak testing system. DO NOT wear leather gloves. When refriger-
ant gas or liquid contacts leather, leather will stick to skin.
Liquid refrigerant, when exposed to the air, quickly evaporates and will freeze skin or eye tissue. Use care to
prevent refrigerant from touching your skin or eyes. Serious injury or blindness result if you come in contact
with liquid refrigerant.
Refrigerant splashed in eyes should first be treated with a few drops of sterile mineral oil in eyes, and rinsed with a weak
boric acid solution. DO NOT rub eyes. Seek medical attention immediately.
Refrigerant splashed on skin should be treated the same as frostbite. Gently pour cool water on area, but do not rub skin.
Keep skin warm with layers of soft, sterile cloth. Seek medical attention immediately.
Even though refrigerant does not burn, when it contacts extreme heat or flame, poisonous phosgene gas is created. This
gas is also produced when an open flame leak detector is used. Phosgene fumes have an acrid (bitter) smell.
DO NOT work in an area where refrigerant may contact an open flame or any burning material such as a cig-
arette. When refrigerant contacts extreme heat, refrigerant breaks down into poisonous phosgene gas which,
if breathed, causes severe respiratory irritation. DO NOT breathe fumes from an open flame leak detector.
You must work in an area where there is a constant flow of fresh air when system is discharged, flushed, charged, and
leak tested using an open flame leak detector.