Case IH FARMALL 45C CVT User manual

Printedin U.S.A.
© 2016 CNH Industrial America LLC. All Rights Reserved.
Case IH is a trademark registered in the United States and many
other countries, owned by or licensed to CNH Industrial N.V.,
its subsidiaries or affiliates.
Part number 47851945
1st edition English
February 2016
SERVICE MANUAL
FARMALL® 45C CVT
FARMALL®
55C CVT
Tier 4B (final)
Compact Tractor

SERVICEMANUAL
Farmall®45CCVT
Farmall®55CCVT
4785194503/02/2016
EN
Find manuals at https://best-manuals.com

LinkProduct/Engine
ProductMarketProductEngine
Farmall®45CCVTFarmall45C
CVT,ROPS,TIER4B(FINAL)
NorthAmericaR753IE4
Farmall®45CCVTFarmall45C
CVT,Cab,TIER4B(FINAL)
NorthAmericaR753IE4
Farmall®55CCVTFarmall55C
CVT,ROPS,TIER4B(FINAL)
NorthAmericaR753IE4
Farmall®55CCVTFarmall55C
CVT,Cab,TIER4B(FINAL)
NorthAmericaR753IE4
4785194503/02/2016
Find manuals at https://best-manuals.com

Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.110]Balanceranddamper..............................................................10.2
[10.202]Aircleanersandlines..............................................................10.3
[10.400]Enginecoolingsystem.............................................................10.4
[10.501]ExhaustGasRecirculation(EGR)exhausttreatment..............................10.5
Transmission..............................................................................21
[21.504]ContinuouslyVariableTransmission(CVT)........................................21.1
Four-WheelDrive(4WD)system..................................................23
[23.101]Mechanicalcontrol.................................................................23.1
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.310]Finaldrives.........................................................................25.3
Rearaxlesystem........................................................................27
[27.100]Poweredrearaxle..................................................................27.1
[27.106]Rearbevelgearsetanddifferential................................................27.2
PowerTake-Off(PTO).................................................................31
[31.104]Rearelectro-hydrauliccontrol......................................................31.1
[31.110]One-speedrearPowerT ake-Off(PTO)............................................31.2
[31.120]CentralPowerTake-Off(PTO).....................................................31.3
Brakesandcontrols....................................................................33
[33.110]Parkingbrakeorparkinglock......................................................33.1
[33.120]Mechanicalservicebrakes.........................................................33.2
Hydraulicsystems.......................................................................35
4785194503/02/2016
Find manuals at https://best-manuals.com

[35.000]Hydraulicsystems..................................................................35.1
[35.104]Fixeddisplacementpump..........................................................35.2
[35.204]Remotecontrolvalves.............................................................35.3
[35.300]Reservoir,cooler,andlters........................................................35.4
Steering.....................................................................................41
[41.200]Hydrauliccontrolcomponents......................................................41.1
[41.206]Pump...............................................................................41.2
[41.216]Cylinders...........................................................................41.3
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.104]Ventilation..........................................................................50.2
[50.200]Airconditioning.....................................................................50.3
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.024]Transmissioncontrolsystem.......................................................55.2
[55.100]Harnessesandconnectors.........................................................55.3
[55.201]Enginestartingsystem.............................................................55.4
[55.301]Alternator...........................................................................55.5
[55.302]Battery..............................................................................55.6
[55.404]Externallighting....................................................................55.7
[55.408]Warningindicators,alarms,andinstruments......................................55.8
[55.518]Wiperandwashersystem..........................................................55.9
[55.640]Electronicmodules...............................................................55.10
[55.DTC]FAULTCODES..................................................................55.11
Platform,cab,bodywork,anddecals.............................................90
[90.100]Enginehoodandpanels...........................................................90.1
[90.116]Fendersandguards................................................................90.2
[90.124]Pneumatically-adjustedoperatorseat..............................................90.3
4785194503/02/2016
Find manuals at https://best-manuals.com

[90.150]Cab.................................................................................90.4
[90.151]Cabinterior.........................................................................90.5
[90.154]Cabdoorsandhatches............................................................90.6
4785194503/02/2016
Find manuals at https://best-manuals.com

4785194503/02/2016
Find manuals at https://best-manuals.com

INTRODUCTION
4785194503/02/2016
1
Find manuals at https://best-manuals.com

Contents
INTRODUCTION
Foreword........................................................................................3
Safetyrules.....................................................................................4
SafetyrulesServiceprecautionarystatements.................................................9
Basicinstructions-Importantnoticeregardingequipmentservicing.........................18
Basicinstructions-ShopandAssembly......................................................19
BasicinstructionsHardware..................................................................21
Specialtools..................................................................................22
TorqueWheelBoltTorques...................................................................23
Torque........................................................................................24
Specialtools..................................................................................28
BasicinstructionsTireballastandpressures.................................................29
Internationalsymbols.........................................................................30
TorqueSpecicationT ables...................................................................31
GeneralspecicationTirePressures.........................................................36
Generalspecication.........................................................................37
Capacities.....................................................................................38
Generalspecication.........................................................................39
Weight........................................................................................44
Generalspecication.........................................................................45
DimensionGeneral...........................................................................46
Generalspecicationwheeltreadsettings...................................................50
Consumables.................................................................................51
ProductidenticationGeneralinformation....................................................52
4785194503/02/2016
2
Find manuals at https://best-manuals.com

INTRODUCTION
Foreword
ThisrepairmanualprovidesthetechnicalinformationneededtoproperlyservicetheCASEIHFarmall45C,and50C
CVT(ConstantVelocityTransmission)modeltractors.Usethismanualinconjunctionwiththeoperator'smanualfor
completeoperation,adjustment,andmaintenanceinformation
OnCASEIHequipment,leftandrightaredeterminedbystandingbehindtheunit,lookinginthedirectionoftravel.
4785194503/02/2016
3
Find manuals at https://best-manuals.com

INTRODUCTION
Safetyrules
Precautionarystatements
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
Throughoutthismanualandonmachinedecals,youwillndthesignalwordsDANGER,WARNING,andCAUTION
followedbyspecialinstructions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworking
withyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjury.The
colorassociatedwithDANGERisRED.
WARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury.
ThecolorassociatedwithWARNINGisORANGE.
CAUTION,usedwiththesafetyalertsymbol,indicatesahazardoussituationwhich,ifnotavoided,couldresult
inminorormoderateinjury.ThecolorassociatedwithCAUTIONisYELLOW.
FAILURETOFOLLOWTHE"DANGER","WARNING",AND"CAUTION"INSTRUCTIONSMAY
RESULTINSERIOUSBODILYINJURYORDEATH.
MachineSafety
Theprecautionarystatement("IMPORTANT")isfollowedbyspecicinstructions.Thisstatementisintendedforma-
chinesafety.
NOTICE:Theword"IMPORTANT"isusedtoinformthereaderofsomethingtheyneedtoknowtopreventminor
machinedamageifacertainprocedureisnotfollowed.
Information
NOTE:Instructionsusedtoidentifyandpresentsupplementaryinformation.
Thismachinemaybeequippedwithspecialguardingorotherdevicesincompliancewithlocallegislation.Someof
theserequireactiveusebytheoperator.Therefore,checklocallegislationontheusageofthismachine.
ACCIDENTPREVENTION
Mostaccidentsorinjuriesthatoccurinworkshopsaretheresultofanoncompliancetosimpleandfundamental
safetyregulations.Forthisreason,INMOSTCASESTHESEACCIDENTSCANBEAVOIDEDbyforeseeingpossible
causesandconsequentlyactingwiththenecessarycautionandcare.
Accidentsmayoccurwithalltypesofmachines,regardlessofhowwellthemachineinquestionwasdesignedand
built.
Acarefulandinformedservicetechnicianisthebestguaranteeagainstaccidents.
4785194503/02/2016
4

INTRODUCTION
Decisiveawarenessofthemostbasicsafetyruleisnormallysufcienttoavoidmanyseriousaccident.
WARNING
Unexpectedmachinemovement!
Disengagepower,shutdownthetractor,andbesurethatallmovingpartshavestoppedbeforeser-
vicing,adjusting,cleaning,oruncloggingtheequipment.
Failuretocomplycouldresultindeathorseriousinjury.W0924A
SAFETYREQUIREMENTSFORFLUIDPOWERSYSTEMSANDCOMPONENTS-HY-
DRAULICS(EUROPEANSTANDARDPREM982)
Flexiblehoseassembliesmustnotbeconstructedfromhoseswhichhavebeenpreviouslyusedaspartofahose
assembly.
Donotweldhydraulicpiping.
Whenexiblehosesorpipingaredamaged,replacethemimmediately.
Itisforbiddentomodifyahydraulicaccumulatorbymachining,weldingoranyothermeans.
Beforeremovinghydraulicaccumulatorsforservicing,theliquidpressureintheaccumulatorsmustbereducedto
zero.
Pressurecheckonhydraulicaccumulatorsshallbecarriedoutbymethodrecommendedbytheaccumulatormanu-
facturer.
Caremustbetakennottoexceedthemaximumallowablepressureoftheaccumulator.Afteranycheckoradjustment
theremustbenoleakageofgas.
SAFETYRULES
Acarefuloperatoristhebestoperator.Mostaccidents
canbeavoidedbyobservingcertainprecautions.To
helppreventaccidents,readandtakethefollowing
precautionsbeforeoperatingthistractor.Equipment
shouldbeoperatedonlybythosewhoareresponsible
andinstructedtodoso.
THETRACTOR
1.ReadtheOperator'sManualcarefullybeforeusingthetractor.Lackofoperatingknowledgecanleadtoaccidents.
2.Useanapprovedrollbarandseatbeltforsafeoperation.Overturningatractorwithoutarollbarcanresultin
deathorinjury.Ifyourtractorisnotequippedwitharollbarandseatbelt,seeyourCASEIHDealer.
3.Alwaysusetheseatbelt.Theonlyinstancewhentheseatbeltshouldnotbeusedisiftherollbarhasbeen
removedfromthetractororfoldingROPSisindownposition.
4.Ifafrontendloaderistobeinstalled,alwaysuseaFOPS(FallingObjectProtectiveStructure)canopytoavoid
injuryfromfallingobjects.
5.Usethehandholdsandstepplateswhengettingonandoffthetractortopreventfalls.Keepstepsandplatform
clearedofmudanddebris.
6.Donotpermitanyonebuttheoperatortorideonthetractor.Thereisnosafeplaceforextrariders.
7.Keepallsafetydecalscleanofdirtandgrime,andreplaceallmissing,illegible,ordamagedsafetydecals.See
thelistofdecalsintheDecalsectionofthismanual.
SERVICINGTHETRACTOR
1.Thecoolingsystemoperatesunderpressurewhichiscontrolledbytheradiatorcap.Itisdangeroustoremove
thecapwhilethesystemishot.Alwaysturnthecapslowlytotherststopandallowpressuretoescapebefore
removingthecapentirely.
2.Keepanytypeofopenameawayfromthetractoranddonotsmokewhilerefueling.Waitfortheenginetocool
beforerefueling.
3.Keepthetractorandequipment,particularlybrakesandsteering,maintainedinareliableandsatisfactorycon-
ditiontoensureyoursafetyandcomplywithlegalrequirements.
4785194503/02/2016
5

INTRODUCTION
4.Keepopenameorcoldweatherstartingaidsawayfromthebatterytopreventresorexplosions.Usejumper
cablesaccordingtoinstructionstopreventsparkswhichcouldcauseexplosion.
5.Stoptheenginebeforeperforminganyserviceonthetractor.
6.Escapinghydraulic/dieseluidunderpressurecanpenetratetheskincausingseriousinjury.Ifuidisinjected
intotheskin,obtainmedicalattentionimmediatelyorgangrenemayresult.
•DONOTuseyourhandtocheckforleaks.
•Useapieceofcardboardorpapertosearchforleaks.
•Stoptheengineandrelievepressurebeforeconnectingordisconnectinglines.
•Tightenallconnectionsbeforestartingtheengineorpressurizinglines.
7.Donotmodifyorpermitanyoneelsetomodifyoralterthistractororanyofitscomponentsorfunctionswithout
rstconsultingaCASEIHDealer.
8.Thefueloilintheinjectionsystemisunderhighpressureandcanpenetratetheskin.Unqualiedpersonsshould
notremoveorattempttoadjustapump,injector,nozzle,oranyotherpartofthefuelinjectionsystem.Failureto
followtheseinstructionscanresultinseriousinjury.
9.Continuouslong-termcontactwithusedengineoilmaycauseskincancer.Avoidprolongedcontactwithused
engineoil.Washskinpromptlywithsoapandwater.
10.Somecomponentsofyourtractor,suchasgasketsandfrictionsurfaces(brakelinings,clutchlinings,etc.)
maycontainasbestos.Breathingasbestosdustisdangeroustoyourhealth.Youareadvisedtohaveany
maintenanceorrepaironsuchcomponentscarriedoutbyanauthorizedCASEIHDealer.However,ifservice
operationsaretobeundertakenonpartsthatcontainasbestos,theessentialprecautionslistedbelowmust
beobserved:
•Workoutofdoorsorinawellventilatedarea.
•Dustfoundonthetractororproducedduringworkonthetractorshouldberemovedbyextraction,notby
blowing.
•Dustwasteshouldbedampened,placedinasealedcontainer,andmarkedtoensuresafedisposal.
•Ifanycutting,drilling,etc.isattemptedonmaterialscontainingasbestos,theitemshouldbedampenedand
onlyhandtoolsorlowspeedpowertoolsused.
OPERATINGTHETRACTOR
1.Beforestartingthetractor,applytheparkingbrake,placethePTOleverinthe'OFF'position,theliftcontrollever
inthedownposition,theremotecontrolvalveleversintheneutralposition,andthetransmissioninneutral.
2.Alwayssitinthetractorseatwhenstartingtheengineoroperatingcontrols.Donotstarttheengineoroperate
controlswhilestandingbesidethetractor.
3.Donotbypasstheneutralstartswitches.ConsultyourCASEIHDealerifyourneutralstartcontrolsmalfunction.
Usejumpercablesonlyintherecommendedmanner.Improperusecanresultintractorrunaway.
4.Avoidaccidentalcontactwiththegearshiftleverwhiletheengineisrunning,asthiscancauseunexpectedtractor
movement.
5.Beforegettingoffthetractor,disengagethePTO,turntheengineoff,andapplytheparkingbrake.Nevergetoff
thetractorwhileitisinmotion.
6.Donotparkthetractoronasteepincline.
7.Donotoperatethetractorengineinanenclosedbuildingwithoutadequateventilation.Exhaustfumescancause
deathorillness.
8.Ifthepowersteeringorengineceasesoperating,stopthetractorimmediately.
9.Pullonlyfromthedrawbarorthelowerlinkdrawbarinthedownposition.Useonlyadrawbarpinthatlocksin
place.Pullingfromthetractorrearaxleoranypointabovetheaxlemaycausethetractortoupset.
10.1Ifthefrontendofthetractortendstorisewhenheavyimplementsareattachedtothethree-pointhitch,install
frontendorfrontwheelweights.Donotoperatethetractorwithalightfrontend.
11.Alwayssetthehydraulicselectorleverinpositioncontrolwhenattachingortransportingequipment.Ensure
hydrauliccouplersareproperlymountedandwilldisconnectsafelyincaseofaccidentaldetachmentofimplement
12.Donotleaveequipmentintheraisedposition.
4785194503/02/2016
6

INTRODUCTION
13.Usetheasher/turnsignallightsandSMVsignswhentravelingonpublicroadsbothdayandnight(unlesspro-
hibitedbylaw).
14.Whenoperatingatnight,adjustlightstopreventblindingoncomingdrivers.
DRIVINGTHETRACTOR
1.Watchwhereyouaregoing,especiallyatrowends,onroads,aroundtreesandlowhangingobstacles.
2.T oavoidupsets,drivethetractorwithcareandatasafespeed.Useextracautionwhenoperatingoverrough
ground,whencrossingditchesorslopes,andwhenturningcorners.
3.T oprovidetwo-wheelbraking,locktractorbrakepedalstogetherwhentransportingonroads.
4.Donotcoastorfreewheeldownhills.Usethesamegearwhengoingdownhillasisusedwhengoinguphill.
5.Anytowedvehiclewithatotalweightexceedingthatofthetowingtractorshouldbeequippedwithbrakesforsafe
operation.
6.Ifthetractorbecomesstuckorthetiresbecomefrozentotheground,backupthetractortopreventupset.
7.Alwayscheckoverheadclearance,especiallywhentransportingthetractor.
8.Whenoperatingatnight,adjustlightstopreventblindingoncomingdrivers.
OPERATINGTHEPTO
1.WhenoperatingPTOdrivenequipment,shutofftheengineandwaituntilthePTOstopsbeforegettingoffthe
tractoranddisconnectingtheequipment.
2.Donotwearlooseclothingwhenoperatingthepowertake-offorwhennearrotatingequipment.
3.WhenoperatingstationaryPTOdrivenequipment,alwaysplaceallgearshiftleversinneutralposition.
4.T oavoidinjury,donotclean,adjust,unclog,orservicePTOdrivenequipmentwhenthetractorengineisrunning.
5.EnsurethePTOmastershieldisinstalledatalltimes.AlwaysreplacethePTOshieldcapwhenthePTOisnotin
use.
DIESELFUEL
1.UNDERNOCIRCUMSTANCESshouldgasoline,alcohol,orblendedfuelsbeaddedtodieselfuel.Thesecom-
binationscancreateanincreasedreorexplosivehazard.Suchblendsaremoreexplosivethanpuregasoline
inaclosedcontainersuchasafueltank.DONOTUSETHESEBLENDS.
2.Neverremovethefuelcaporrefuelwiththeenginerunningorhot.
3.Donotsmokewhilerefuelingorwhenstandingnearfuel.
4.Maintaincontrolofthefuelllerpipenozzlewhenllingthetank.
5.Donotllthefueltanktocapacity.Allowroomforexpansion.
6.Wipeupspilledfuelimmediately.
7.Alwaystightenthefueltankcapsecurely.
8.Iftheoriginalfueltankcapislost,replaceitwithaCASEIHapprovedcap.Anon-approved,proprietarycapmay
notbesafe.
9.Keepequipmentcleanandproperlymaintained.
10.Donotdriveequipmentnearopenres.
11.Neverusefuelforcleaningpurposes.
12.Arrangefuelpurchasessothatwintergradefuelsarenotheldoverandusedinthespring.
SAFETYFRAME(ROPS)
YourCASEIHtractorisequippedwithasafetyframe.Itmustbemaintainedinaserviceablecondition.Becareful
whendrivingthroughdoorwaysorworkinginconnedspaceswithlowheadroom.
UNDERNOCIRCUMSTANCESshouldyou:
•Modify,drill,oralterthesafetyframeinanyway.Doingsomayrenderyouliabletolegalprosecution.
4785194503/02/2016
7

INTRODUCTION
•Attempttostraightenorweldanypartofthemainframeorretainingbracketswhichhavesuffereddamage.Doing
somayweakenthestructureandendangeryoursafety.
•Secureanypartsonthemainframeorattachyoursafetyframewithanythingotherthanthespecialhightensile
boltsandnutsspecied.
•Attachchainsorropestothemainframeforpullingpurposes.
•Takeunnecessaryriskseventhoughyoursafetyframeaffordsyouthemaximumprotectionpossible.
4785194503/02/2016
8

INTRODUCTION
SafetyrulesServiceprecautionarystatements
SERVICEPRECAUTIONARYSTATEMENTS
LeakTesting
Recharginganairconditioningsystemthatleakssimplyallowsmorerefrigeranttoescapeintotheatmosphereand
ultimatelyleavesthesystemnon-functioningandinneedofadditionalcharging.
Therefore,theproperserviceprocedureistolocateandxanyleaksbeforeputtinganymorerefrigerantintothe
system.
Ifalargeamountofrefrigeranthasleakedout,thesystempressurewillbetoolowtoidentifyallbutthelargestleaks.
Inthiscase,partiallyrechargethesystemwithnomorethanonepoundofrefrigeranttocheckforleaks.
NOTICE:•Anyrefrigerantintroducedintothesystemforthepurposeofndingleaksmustalsoberecoveredwithout
releasingitintotheatmosphere.
•AlwaysusethesametypeofrefrigerantforcheckingleaksaswasoriginallyinstalledintotheACsystembythe
manufacturer.
•Neverusecompressedairtodetectsystemleaks.Theintroductionofairintothesystemmaycreateareor
explosionhazard,mayoverloadthedesiccantwithmoisture,andcouldcontaminatethesystemwithdirtandimproper
oil.
Allautomotivetypeairconditioningsystemsleaktosomeextent.Whenservicingthemitisimportantthatleakagebe
minimized.Muchofthenormalleakagecomesfromtheslowseepageofrefrigerantthroughtheexiblehoses.Other
commonsourcesofleaksareatjointsbetweentheexiblehoseandmetaltubingoratthreadedhoseconnections.
Theseareusuallymuchlargerleaksthanthenaturalseepagethroughthewallsofthehoseandarealmostalways
repairable.
ResearchbytheEPAhasfoundthatleakdetectioncanbedifcult,butexistinghalogenleakdetectionsystemsare
adequateforthemajortaskofndingandrepairingleakscausingcomplaints.Dyestainsarenotverysatisfactoryfor
ndingsmallleaks.
Newerelectronicleakdetectorsmayofferevenbetterleakdetectioncapabilities.However,nosinglemethodcannd
everyleak.Electronicleakdetectorsmaynotdetectleaksofallrefrigerants.Forexample,olderunitsdesignedto
detectR12maynotdetectR134A.Besurethattheleakdetectoryouuseisstate-of-the-artandthatitisdesignedto
detecttherefrigerantinthesystemyouareservicing.
Serviceprofessionalsmustbeextremelydiligentintheirworktocorrectallpossibleleaks.Diligenceisessentialto
ensurethatnosmall,difcult-to-ndleaksgoundetected.
Beforeleavingajob,makeonelastleakcheck.Catchingaleakjustafterservicewillsaveaninconvenientand
expensivereturnvisit.
Relling
Relltheairconditioningsystemusingtheweightmethod.ThelubricantsusedinR134atendtolayerontothewalls
oftherefrigerationsystem.Thislayeringobscurestheviewthroughthesightglass.VisualmethodsofrellingR134a
systemswillresultinimpropersystemcharging.Forthisreason,wedonotrecommendtheoldpracticeoftoppingoff
apartiallydischargedairconditioningsystemusingthesightglass.TheFarmalltractorsuse1.0kg(2.2lb)ofR134A
refrigerant.
4785194503/02/2016
9

INTRODUCTION
CONTAMINANTS
General
Nomobileairconditioningsystemcanoperateforlongwithoutpickingupsomecontaminantsintherefrigerant.The
exiblehoses,forexample,allowmoistureandairtomigrateintotherefrigerantfromtheoutsideatmosphere.Mois-
tureandnon-condensablegases(air)arethemostcommoncontaminantsfoundinmobileairconditioningsystems.
NOTICE:ContaminatingR134AwithR12orCFCwillleadtocopperplatingofsteelcomponentsandmajorcompres-
sorfailure.
Lubricantandrefrigerantthatremaininserviceequipmentcanbecontaminants.Whenyourecoverarefrigerant,you
alsowillcaptureacertainamountoflubricantintheextractionorrecoveryequipment.Theequipmentwilldrainthe
lubricantinacatchbottleorreservoirformeasurementandpropernaldisposal.
Neverusealubricantthathascomeoutofanairconditioningsystem.Reusingthisoilwillresultincontaminationof
theairconditioningsystemwithrefrigerant,moistureandairfromtheoldoil.Instead,relltheairconditioningsystem
usingfreshoilinthesameamountasthatremovedduringservice.Disposeoftheusedoilsinamannerthatcomplies
withfederal,stateandlocaldisposalrequirements.
Toavoidcontaminationbetweensystemsusingdissimilarrefrigerants,theextractionandrecyclingequipmentMUST
bededicatedtoasinglerefrigerant.
PreventingMixingofServiceEquipment
Tohelpavoidthemistakeofchargingasystemwithanincorrect,incompatiblerefrigerant,thecompressorttingsare
differentforrefrigerantsR12andR134A.SystemsusingR134Ahavequickcoupleserviceconnections,whileR12
systemsusescrewthreads.Thispreventstheuseofthesametoolsfordifferentrefrigerants,therebyhelpingtoavoid
themixingofrefrigerantsinserviceequipment.
Ifrefrigerantsbecomemixed,thethermodynamicandchemicalcharacteristicswillchange.Thischangeresultsin
excessivepressureandpoorlubricationandleadstofailureofthecompressor,desiccant(drier)andothersystem
components.
Ultimately,systemfailureandanexpensiverepairbillwillresultifrefrigerantsbecomemixedinasinglesetofservice
equipment.
REFRIGERANTEXTRACTIONANDRECYCLINGEQUIPMENT
Bothextractionandrecyclingequipmentareinuseandavailabletoservicetechnicians.Bothtypesofequipment
willremovetherefrigerantfromanairconditioningsystem.However,extractionequipmentonlypullstherefrigerant
fromtheairconditioningsystemandstoresitinanappropriatecontainer.Extractionequipmentdoesnotcleanthe
refrigerant.Itsonlypurposeistorecovertherefrigerantfromanairconditioningsystempriortodisassemblingand
servicingit.
Alwaysrecycleorreclaimrecoveredrefrigerantbeforeputtingitbackintoanairconditioningsystem.Duringservice
operationsinvolvingapartialrecharge,orwhiletheairconditioningsystemisinuse,refrigerantcanpickupmoisture,
lubricants,microscopicmetalchips,andotherpotentialcontaminants.Inmanycasesthecontaminantscontributeto
oraretheprimarycauseofthesystemfailure.Puttingused,uncleanrefrigerantbackintoanairconditioningsystem
mayresultinpoorsystemperformance.
NOTICE:Reuseofunrecycled,unreclaimedrefrigerantwillvoidthewarranty.
Equipmentthatremovesrefrigerantfromamobileairconditioningsystem(recoveryequipment)mayallowyoutoput
theusedrefrigerantbackinthesystemwithoutrstcleaningittominimizeperformance.Youmayalsousesuchcon-
ditioningsystems.Non-mobileairconditioningsystemsuserefrigerantsandcontaincontaminantsthataredifferent
fromthoseinmobileairconditioningsystems.Recoveryequipmentmaythereforeallowthemixingofdifferenttypes
ofrefrigerantsorintroducecontaminantsthatmaynotberemovablebyrecyclingequipmentavailableintheservice
shop.
Ifyouwanttoremove,cleanandreuseR134Arefrigerant,youmustuseamachinethatbothextractsandrecycles
refrigerantfrommobileairconditioningsystems.DedicatethatmachinetoR134aonly.
4785194503/02/2016
10

INTRODUCTION
RecyclingequipmentmeetingSAEstandardsJ1990andJ2210isdesignedtoextractandrecyclerefrigerantsthat
havebeeninmobileairconditioningsystemsonly.R134Arefrigerantthatalsoisusedinnon-mobilesystemsmay
introducecontaminantstotherefrigerantthatequipmentmeetingSAEJ1990andJ2210cannotremove.Thisequip-
mentisnotintendedforuseonnon-mobilesystems.
UsingExtractionEquipment
Extractionequipmentisrelativelysmallandeasilyportable.Itisbestusedifashopmustservicevehicles,suchas
agriculturaloroff-highwayequipment,thatcannoteasilybebroughtintotheshop.Itisalsoconvenientforshopsthat
mustdealwithavarietyofdifferentrefrigeranttypesandexchangerecoveredrefrigerantatsomecentrallocation.
Alwaysuseextractionequipmentonthoserefrigerantsforwhichitwasdesigned.Thelubricants,hoses,andsealsin
thisequipmenthavebeendesignedtoworkwithonlyonerefrigerant.
Tohelpavoidamix-upofserviceequipmentandrefrigerants,equipmenthosesdesignedforusewhicheachrefrig-
erantareeasilyidentiable.NewservicehosesusedwithR134Amusthaveablackstripealongthehoselengthand
carrythedesignation"SAEJ2196/R134A"(hoseslabeled"SAEJ2196"andlackingtheblackstripewereusedfor
R12.)
Ifyouuseextractionequipmentandsendyourrecoveredrefrigeranttoareclamationfacility,reclaimedrefrigerantyou
purchasemustmeettheAirConditioningandRefrigerationInstitutestandardsofpurity(ARIStandard700-88).This
willensurethattherefrigerantyouareusingnotonlymeetsthepurityrequirementsofSAEJ1991(forR12)ORJ2099
(forR134A),butalsothatitdoesnotcontainincompatiblelubricantsorothercontaminantsfromnon-automotiveair
conditioningsystems.
UsingRecyclingEquipment
Recyclingequipmentextractsandremovescommoncontaminantsfromrefrigerants.Recyclingequipmentdesigned
andcertiedtomeetSAEstandardscanmakerefrigerantrecoveryfrommobileairconditioningsystemssuitablefor
reuseinautomotiveairconditioningsystems.Likeextractionequipment,SAEstandardsrequirethateachpieceof
recyclingequipmentbededicatedtoasinglerefrigerant.
NOTICE:OnlyequipmentcapableofrecoveringandcleaningR134AtomeetSAEJ2099puritylevelscarriesalabel
withthephrase"DesigncertiedbyUnderwriters"Laboratories,Inc.forcompliancewithSAEJ2099.
TheUnderwriters'Laboratorieslabelmustbespecicthattheequipmentis"designcertied"fortheSAEJ2099stan-
dard.Ifnot,itcertiesonlythatthemachineisfreeofreasonableshockorotherelectricalhazardstotheuser.
Recyclingvs.Reclaiming
Recycledrefrigeranthasbeenrecoveredfromamobileairconditioningsystemandiscleanedbythesameshop
thatrecoveredittomeetJ2099forR134A.Theequipmentdesignedtorecyclerefrigerantintheshopenvironment
removesonlycontaminantspickedupduringtheoperationofamobileairconditioningsystem.
Refrigerantthatiseitherproperlyrecycledorreclaimedisadequateforuseinmobileairconditioningsystems.
4785194503/02/2016
11

INTRODUCTION
CONTAINMENTOFAIRCONDITIONINGREFRIGERANTS
Thefollowingprocedureisaguidetoservicingmobileairconditioningsystemsinawaythatminimizesthepotential
forlosingrefrigeranttotheatmosphere.Followingtheproceduresinthissectionwillhelpensurecompliancewith
SAEJ2211forR134Asystems.
DANGER
Avoidinjury!
ObserveALLprecautionslistedbelowwhenservicingtheair-conditioningsystemandhandlingre-
frigerant.
Failuretocomplywillresultindeathorseriousinjury.D0043A
FireorexplosionhazardexistswithR-134aundercertainconditions.R-134ahasbeenshowntobenonammableat
ambienttemperatureandatmosphericpressure.However,testsundercontrolledconditionshaveindicatedthat,at
pressuresaboveatmosphericandwithairconcentrationsgreaterthan60%byvolume,R-134acanformcombustible
mixtures.Whileitisrecognizedthatanignitionsourceisalsorequiredforcombustiontooccur,thepresenceof
combustiblemixturesisapotentiallydangeroussituationandshouldbeavoided.
R-134aserviceequipmentorvehicleairconditioningsystemsshouldnotbepressuretestedorleaktestedwithcom-
pressedair.MixturesofairandR-134ahavebeenknowntobecombustibleatelevatedpressures.Thesemixtures
arepotentiallydangerousandcouldresultinreorexplosioncausinginjuryorpropertydamage.Additionalhealth
andsafetyinformationmaybeobtainedfromrefrigerantandlubricantmanufacturers.Failuretocomplycouldresult
indeathorseriousinjury.
Recovery
1.Besurethatallserviceequipmenthoselineshaveshutoffvalvesorcheckvalveswithin30cm(12in)oftheir
ends.Thiswillensurethatonlyminimalquantitiesofrefrigerantescapetotheatmospherewhentheequipment
isdisconnectedfromtheairconditioningsystem,andonlysmallamountsofmoistureandothercontaminants
canenterthesystem.
2.Besurethatallequipment,includingtheconnectinghoselinesandmanifold,arecompatiblewiththerefrigerant
inthesystemwithwhichyouaregoingtowork,andthatyourequipmenthaspreviouslybeenusedonlywiththe
refrigerantyouareabouttoservice.
3.Besurethatallshutoffvalvesaretightbeforeconnectingthemtotheairconditioningsystem.
NOTE:Keepshutoffvalvesclosedatalltimesunlesstheyareconnectedtoavehicle'sairconditioningsystem,
arefrigerantstoragecontaineroranotherpieceofserviceequipmentcontainingthesamerefrigerant.Thispre-
ventsrefrigerantfromescapingintotheatmosphere,damagingtheenvironment,contaminatingtheequipment,
andcostingyoumoney.
4.Connecttheextractionorrecoveryequipmenttotheairconditioningsysteminaccordancewiththeinstructions
suppliedbytheequipmentmanufacturer.
5.Starttherecoveryprocessbyturningontheextractionequipmentandextractingtherefrigerantfromtheair
conditioningsysteminaccordancewiththeequipmentmanufacturer'sinstructions.
6.Continuetoextractrefrigerantuntiltheairconditioningsystemisunderavacuumandthereisnorefrigerant
remaininginthevehiclesystem.
7.Verifythatthereisnorefrigerantremaininginthesystemby:
a)Shuttingofftheextractionunitandobservingthesystempressurelevel.
b)Waitingveminutesandobservingthesystempressureagain.Ifthesystempressurehasnotrisenabove
atmosphericpressure(0gaugepressure),allrefrigeranthasbeenremovedandyoumayproceedtostep8.
Ifafterveminutes,thesystempressurereadinghasrisenaboveatmosphericpressure(0gaugepressure),the
extraction/recoveryprocessmustberepeateduntilthepressurereadingremainsatorbelowatmosphericfor
atleasttwominuteswiththeextractionequipmentshutoffbeforeproceedingtostep8.
8.Closetheshutoffvalveintheservicelines.
9.Removetheservicelinesfromthevehiclesystem.Iftherecoveryequipmenthasautomaticclosingshutoffvalves,
verifythattheyareoperatingproperlyanddonotleak.
4785194503/02/2016
12

INTRODUCTION
10.Determinetheamountoflubricantremovedfromtheairconditioningsystemduringtherefrigerantextraction
process.Replenishtheairconditioningsystemwithanequalvolumeofnew,correctlubricant.
11.Thesystemisnowreadyforserviceorrepair.
Flushing
Donotushthissystem.Intheeventofamajorcompressorfailure,replacethecompressoroutputpressurelineand
receiver/driertocollectmostofthedebris.
DANGER
Avoidinjury!
ObserveALLprecautionslistedbelowwhenservicingtheair-conditioningsystemandhandlingre-
frigerant.
Failuretocomplywillresultindeathorseriousinjury.D0043A
Flushingshouldneverbedonewithcompressedair.CertainmixturesofairandR-134aarecombustible.Using
compressedairtoushR-134asystemscouldresultinreorexplosion.Airfromashopcompressoralsocontains
moisturethatwouldcontaminatethesystem.
NOTICE:NeveruseCFC11,R11,CFC12,R12,CFC113,R13oranyothersubstancetoushanR134asystem.To
dosowouldbreakdownthelubricantandcausesystemcorrosion.
Useofotherushingsolventsmaycauseotherproblems.Ifavacuumpumpdoesnotremovethesolvent,itcould
affectthechemicalstabilityoftherefrigerantandlubricant.
4785194503/02/2016
13