New Holland Boomer 40D CVT Tier 3 User manual

Part number 47975091
1st edition English
July 2016
SERVICE MANUAL
Boomer™40D CVT
Boomer™45D CVT
Boomer™50D CVT
Tier 3
Compact Tractor
Printedin U.S.A.
© 2016 CNH Industrial America LLC. All Rights Reserved.
NewHolland 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.

SERVICEMANUAL
Boomer™40DCVT
Boomer™45DCVT
Boomer™50DCVT
47975091_06/07/2016
EN

LinkProduct/Engine
ProductMarketProductEngine
Boomer™40DCVT40HP ,TIER
3,CVT ,compacttractor,builtin
MexicofortheCanadianmarket
NorthAmericaN844
Boomer™45DCVT45HP ,TIER
3,CVT ,compacttractor,builtin
MexicofortheCanadianmarket
NorthAmericaN844L
Boomer™50DCVT50HP ,TIER
3,CVT ,compacttractor,builtin
MexicofortheCanadianmarket
NorthAmericaN844L
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.101]Cylinderheads.....................................................................10.2
[10.102]Panandcovers....................................................................10.3
[10.103]Crankshaftandywheel............................................................10.4
[10.105]Connectingrodsandpistons.......................................................10.5
[10.106]Valvedriveandgears..............................................................10.6
[10.110]Balanceranddamper..............................................................10.7
[10.114]Pumpdrives........................................................................10.8
[10.218]Fuelinjectionsystem...............................................................10.9
[10.254]Intakeandexhaustmanifoldsandmufer.......................................10.10
[10.304]Enginelubricationsystem........................................................10.11
[10.400]Enginecoolingsystem...........................................................10.12
[10.414]Fananddrive....................................................................10.13
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
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PowerTake-Off(PTO).................................................................31
[31.104]Rearelectro-hydrauliccontrol......................................................31.1
[31.110]One-speedrearPowerTake-Off(PTO)............................................31.2
[31.120]CentralPowerT ake-Off(PTO).....................................................31.3
Brakesandcontrols....................................................................33
[33.110]Parkingbrakeorparkinglock......................................................33.1
[33.120]Mechanicalservicebrakes.........................................................33.2
Hydraulicsystems.......................................................................35
[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
[55.010]Fuelinjectionsystem...............................................................55.2
[55.024]Transmissioncontrolsystem.......................................................55.3
[55.100]Harnessesandconnectors.........................................................55.4
[55.201]Enginestartingsystem.............................................................55.5
[55.301]Alternator...........................................................................55.6
[55.302]Battery..............................................................................55.7
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[55.404]Externallighting....................................................................55.8
[55.408]Warningindicators,alarms,andinstruments......................................55.9
[55.518]Wiperandwashersystem........................................................55.10
[55.640]Electronicmodules...............................................................55.11
[55.DTC]FAULTCODES..................................................................55.12
Platform,cab,bodywork,anddecals.............................................90
[90.100]Enginehoodandpanels...........................................................90.1
[90.116]Fendersandguards................................................................90.2
[90.124]Pneumatically-adjustedoperatorseat..............................................90.3
[90.150]Cab.................................................................................90.4
[90.151]Cabinterior.........................................................................90.5
[90.154]Cabdoorsandhatches............................................................90.6
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INTRODUCTION
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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cationTables...................................................................31
GeneralspecicationTirePressures.........................................................36
Generalspecication(*)......................................................................37
Capacities.....................................................................................38
Generalspecication(*)......................................................................39
Weight(*).....................................................................................44
Generalspecication(*)......................................................................45
DimensionGeneral(*)........................................................................46
Consumables.................................................................................51
ProductidenticationGeneralinformation....................................................52
(*)Seecontentforspecicmodels
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INTRODUCTION
Foreword
ThisrepairmanualprovidesthetechnicalinformationneededtoproperlyservicetheNEWHOLLANDBoomer40D,
Boomer45D,andBoomer50DCVT(ConstantVelocityTransmission)modeltractors.Usethismanualinconjunction
withtheoperator'smanualforcompleteoperation,adjustment,andmaintenanceinformation
OnNEWHOLLANDequipment,leftandrightaredeterminedbystandingbehindtheunit,lookinginthedirectionof
travel.
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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.
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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,seeyourNEWHOLLANDDealer.
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.
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INTRODUCTION
4.Keepopenameorcoldweatherstartingaidsawayfromthebatterytopreventresorexplosions.Usejumper
cablesaccordingtoinstructionstopreventsparkswhichcouldcauseexplosion.
5.Stoptheenginebeforeperforminganyserviceonthetractor.
6.Escapinghydraulic/dieseluidunderpressurecanpenetratetheskincausingseriousinjury.Ifuidisinjected
intotheskin,obtainmedicalattentionimmediatelyorgangrenemayresult.
•DONOTuseyourhandtocheckforleaks.
•Useapieceofcardboardorpapertosearchforleaks.
•Stoptheengineandrelievepressurebeforeconnectingordisconnectinglines.
•Tightenallconnectionsbeforestartingtheengineorpressurizinglines.
7.Donotmodifyorpermitanyoneelsetomodifyoralterthistractororanyofitscomponentsorfunctionswithout
rstconsultingaNEWHOLLANDDealer.
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
maintenanceorrepaironsuchcomponentscarriedoutbyanauthorizedNEWHOLLANDDealer.However,
ifserviceoperationsaretobeundertakenonpartsthatcontainasbestos,theessentialprecautionslisted
belowmustbeobserved:
•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.ConsultyourNEWHOLLANDDealerifyourneutralstartcontrols
malfunction.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.
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INTRODUCTION
13.Usetheasher/turnsignallightsandSMVsignswhentravelingonpublicroadsbothdayandnight(unlesspro-
hibitedbylaw).
14.Whenoperatingatnight,adjustlightstopreventblindingoncomingdrivers.
DRIVINGTHETRACTOR
1.Watchwhereyouaregoing,especiallyatrowends,onroads,aroundtreesandlowhangingobstacles.
2.Toavoidupsets,drivethetractorwithcareandatasafespeed.Useextracautionwhenoperatingoverrough
ground,whencrossingditchesorslopes,andwhenturningcorners.
3.Toprovidetwo-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.Toavoidinjury,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,replaceitwithaNEWHOLLANDapprovedcap.Anon-approved,proprietary
capmaynotbesafe.
9.Keepequipmentcleanandproperlymaintained.
10.Donotdriveequipmentnearopenres.
11.Neverusefuelforcleaningpurposes.
12.Arrangefuelpurchasessothatwintergradefuelsarenotheldoverandusedinthespring.
SAFETYFRAME(ROPS)
YourNEWHOLLANDtractorisequippedwithasafetyframe.Itmustbemaintainedinaserviceablecondition.Be
carefulwhendrivingthroughdoorwaysorworkinginconnedspaceswithlowheadroom.
UNDERNOCIRCUMSTANCESshouldyou:
•Modify,drill,oralterthesafetyframeinanyway.Doingsomayrenderyouliabletolegalprosecution.
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INTRODUCTION
•Attempttostraightenorweldanypartofthemainframeorretainingbracketswhichhavesuffereddamage.Doing
somayweakenthestructureandendangeryoursafety.
•Secureanypartsonthemainframeorattachyoursafetyframewithanythingotherthanthespecialhightensile
boltsandnutsspecied.
•Attachchainsorropestothemainframeforpullingpurposes.
•T akeunnecessaryriskseventhoughyoursafetyframeaffordsyouthemaximumprotectionpossible.
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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.TheBoomertractorsuse1.0kg(2.2lb)ofR134A
refrigerant.
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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.
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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.
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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.
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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.
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