Charging the system [Toyota Duet M100]

Note:

• Do not operate the vehicle before the system is charged, otherwise the air conditioning compressor will be damaged (due to lack of lubrication).
• See the figure "Charging the system".
• After charging, let the engine run for 2 minutes at 2000 rpm.
• After charging, check that there are no leaks in the system.

Install the charging cylinder.

Note: When working with the charging cylinder, always follow the requirements described in its instructions.

a) Fill the charging cylinder with the required amount of refrigerant.

• Amount of refrigerant - 400 ±30 g

b) Connect the central hose to the charging cylinder.

Caution: Do not open the valves on the pressure gauge block!

c) Open the valve on the charging cylinder.

d) Press the valve core located on the side of the gauge block and release air from the central hose.

Checking the tightness of the system

1. Open the high pressure valve on the gauge block and charge the system with refrigerant.

2. When the pressure on the low pressure side reaches 100 kPa, close the high pressure valve.

3. Check the tightness of the system with a leak detector.

If leaks are detected after repair, repeat the vacuuming procedure.

Refrigerant top-up

Top up the system with refrigerant. After checking for leaks, top up the refrigerant to the standard.

Attention:

• Never charge the system through the high pressure side while the engine is running.
• Do not open the low pressure valve when the system is being charged with liquid refrigerant.

1. Fully open the high pressure valve of the pressure gauge block.

2. Fill the system completely, then close the high pressure valve.

Note: A fully charged system is indicated by the absence of bubbles in the service window.

Removal the pressure gauge block

1. Close both valves of the pressure gauge block.

2. Disconnect the quick release adapter from the coolant line service valves as shown.



3. Install plugs on the cooling system service valves.

Checking the system with a block of pressure gauges

1. Connect the pressure gauge block.

2. Read pressure gauge readings under the following conditions.

a) The air temperature in the air intake is 30 - 35°C.

b) The engine operates at 1500 rpm.

c) Fan speed control switch in the "HI" position (high speed).



d) Temperature regulator in the maximum cooling position "COOL".

Note: The instrument readings may vary slightly depending on the ambient temperature.

Presence of water in the system

The pressure in the low pressure line changes from normal to vacuum (cooling works only intermittently, then stops working).



Reason: Water freezes in the expansion valve, temporarily stopping the cycle (blocks the circulation of the refrigerant). After defrosting, the system returns to normal.

Solution:

• a) Replace the receiver.
• b) Evacuate the system to remove water.
• c) Charge the system with refrigerant.

Lack of refrigerant

Low pressure throughout the system. Insufficient cooling. Constant bubbles in the service window.



Reason: Lack of refrigerant.

Solution:

• a) Check the system for leaks.
• b) Top up the refrigerant to the required level (disappearance of bubbles in the window).

Poor circulation of refrigerant



Low pressure in the entire system. Frost on the pipeline from the receiver to the cooling unit. Insufficient cooling.



Reason: The circulation of the refrigerant is difficult due to clogging of the receiver.

Solution: Replace the receiver.

No cooling or refrigerant not circulating

This material is taken from a resource toyotaman.ru

Vacuum in the low pressure line, low pressure in the high pressure line (no cooling or cooling only periodic; frost or condensation near the receiver or expansion valve).



Cause: The refrigerant is not circulating due to moisture or contamination in the system, or refrigerant is leaking from the expansion valve.

Solution:

• a) Check the temperature sensitive tube and expansion valve.
• b) If contamination is the cause, remove and clean the expansion valve with an air jet. Replace the valve if the contamination cannot be removed.
• c) Replace the receiver.
• d) Evacuate and fill the system. If gas leaks from the temperature-sensitive tube, replace the expansion valve.

Excess refrigerant or insufficient condenser cooling



Increased pressure in the entire system. Insufficient cooling. No bubbles in the service window, even when the engine is running at low speeds.



Causes: Insufficient circulation of refrigerant. Insufficient cooling of the condenser.

Solution:

• a) Clean the capacitor plates.
• b) Check the operation of the fan.
• c) If points "a" and "b" are completed, check the amount of refrigerant.

Presence of air in the cooling system

Increased pressure throughout the system. Insufficient cooling. Low pressure line is hot. Bubbles in the service window.



Reason: Air in the system (perhaps the system was not evacuated before charging).

Solution:

• a) Check for contamination and the amount of compressor oil.
• b) Evacuate and fill the system.

Incorrect installation of expansion valve and temperature sensitive tube



Increased pressure throughout the system, insufficient cooling, frost or heavy condensation on the low pressure line.



Cause:

• a) The temperature sensitive tube is not adjusted.
• b) The expansion valve is not installed correctly.

Solution:

Check the heat sensitive tube; if it is in good condition, check the expansion valve. Replace any faulty parts.

Compressor failure

There is increased pressure in the low pressure line, decreased pressure in the high pressure line. No cooling.



Reason: Compressor is faulty (valve leaks or wear of parts).

Solution: Repair or replace the compressor.

Checking the amount of refrigerant

1. Test mode:

a) Open all doors.

b) Set the temperature controller to maximum cooling mode - "COOL".



c) Set the air intake flap to the "FRESH" position.

d) Maintain idle speed at 1000 rpm.

d) Turn on the air conditioner.

2. Check the amount of refrigerant by the presence of bubbles in the service window of the receiver.

a) If bubbles are visible in the service window (lack of refrigerant), then check for leaks in the system and top up the system to the norm.

b) If the bubbles are not visible (either the amount of refrigerant is normal, or the system is overcharged, or there is no refrigerant), then the method of elimination - see points "c" and "d".

c) If there is no temperature difference between the compressor inlet and outlet (either there is no refrigerant or the amount of refrigerant is minimal), then check for refrigerant leaks, then charge the system to normal.

d) If there is a large temperature difference between the compressor inlet and outlet (either the amount of refrigerant is normal, or the system is being recharged), then the method of elimination - see points "d" and "e".

d) If the refrigerant in the service window becomes transparent immediately after turning off the air conditioner (system recharge), then remove all the refrigerant, vacuum and fill the system to the norm.

e) If after turning off the air conditioner the refrigerant foams and then becomes transparent, then the amount of refrigerant is normal.

• Amount of refrigerant - 400 ±30 g