1996-2006 Volkswagen LT Van Generalnotesonairconditioningsystems -> 1.10 General safety User Manual
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Generalnotesonairconditioningsystems -> 1.10 General safety for Your Volkswagen LT Van Second Generation (1996-2006)

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
ditioner compressor on the refrigerant increases its heat content  
and its temperature. Its temperature is now considerably higher  
than that of the ambient air.  
The hot refrigerant flows with its heat content to the condenser.  
There the refrigerant looses its heat through the condenser to the  
surrounding air due to the temperature gradient between the re‐  
frigerant and the surrounding air.  
Thus, the refrigerant is a means of heat transport. Because it will  
be needed again, it returns to the evaporator.  
All air conditioning systems basically depend on the circulation of  
refrigerant. However, there are differences in the construction of  
the system.  
1.10  
General safety  
♦ In accordance with VBG 20, the Federation of Employers Li‐  
ability Insurance Associations.  
♦ Observe instructions specific to the workplace; ⇒ Volkswagen  
ServiceNet; Handbooks; Service handbook; Environmental  
protection . Refrigerant from air conditioning systems / refrig‐  
erant oils - to be displayed at refrigerant designated working  
area.  
1.10.1  
Product characteristics  
Refrigerants used in car air conditioning systems belong to the  
new generation of refrigerants, the chlorine-free, partially-fluori‐  
dated hydrocarbons (H-CFC, R134a).  
lk  
In regard to their physical behaviour, they are refrigerants which  
can be liquefied under pressure. They are subject to Regulations  
for Pressure Tanks and may be charged only into approved and  
identified pressurised gas containers.  
Specific conditions which apply for safe and proper use must be  
maintained.  
1.10.2  
Handling refrigerants  
WARNING  
Danger of freezing injuries.  
The refrigerant can emerge as liquid or as vapour.  
Do not open containers in which this refrigerant is present.  
If refrigerant containers are opened, the contents may escape in  
liquid or vapour form. The higher the pressure in the container,  
the more energetic the emergence will be.  
How high the pressure is depends on two factors:  
•
What type of refrigerant is in the container. “This is because  
the lower the boiling point, the higher the pressure.”  
•
How high the temperature is. “This is because the higher the  
temperature, the higher the pressure.”  
1.10.3  
Wear protective glasses  
Put on protective glasses. This will prevent the refrigerant enter‐  
ing the eyes, which in certain circumstances can cause severe  
injury due to frostbite.  
10  
Rep. gr.00 - Technical data  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
1.10.4  
Wear protective gloves and apron  
Refrigerants dissolve fats and oils very well. Therefore, when they  
come in contact with the skin, they take away the protective layer  
of fat. Skin from which the natural lokil and fat have been removed  
is vulnerable to cold and germs.  
1.10.5  
Do not allow liquid refrigerant to come in  
contact with the skin  
The refrigerant will draw its latent heat of evaporation from its  
surroundings. That can be your skin. This can result in very low  
temperatures. The result is local frostbite (boiling point of R134a  
is -26.5°C at normal atmospheric pressure).  
1.10.6  
Do not breath in refrigerant vapour  
Note  
In high concentrations, emerging refrigerant vapours can mix with  
the air and displace the oxygen necessary for breathing.  
1.10.7  
Absolutely NO SMOKING  
Refrigerant can decompose in a burning cigarette. The resulting  
substances are poisonous and must not be breathed in.  
1.10.8  
Welding and soldering on refrigeration  
systems  
Before welding and brazing on vehicles (in the vicinity of the air  
conditioning system components), extract the refrigerant and  
then purge the system by blowing through with compressed air  
and using nitrogen.  
The products of decomposition of refrigerants under heat are not  
only poisonous but are strongly corrosive, so that pipework and  
system parts could be attacked. This refers primarily to hydrogen  
fluoride.  
1.10.9  
Pungent smell  
A pungent odour indicates that the products of decomposition  
mentioned above are already present. Breathing in these sub‐  
stances must be avoided under all circumstances, or the bron‐  
chial tubes, lungs and other organs could be injured.  
1.10.10 First aid  
•
In the event of contact with the eyes or mucous membranes,  
wash immediately with copious running water and summon an  
eye specialist.  
•
•
In the event of contact with the skin, remove wetted clothing  
and wash the affected skin with copious water.  
If refrigerant vapours are breathed in high concentrations, take  
the patient immediately into the fresh air. Summon a doctor. If  
the patient has trouble breathing, administer oxygen. If the  
patient's breathing is restricted or stops, bend the head at the  
neck and commence resuscitation.  
1.10.11 Handling pressure tanks  
•
Secure vessels against falling over!  
Secure standing cylinders against falling over and lying cylinders  
from rolling away.  
1. General notes on air conditioning systems  
11  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
lk  
Air conditioning system with refrigerant R134a - Edition 10.2014  
•
Do not throw pressure vessels!  
When falling, the containers may become severely deformed so  
that they may be torn open. The refrigerant evaporates immedi‐  
ately, releasing violent forces. Flying fragments of cylinders can  
cause severe injuries.  
Bottle valves can brake during improper transport. To protect cyl‐  
inder valves, bottles may be transported only with protective  
covers screwed on.  
•
Do not place near radiators!  
High temperatures can occur near radiators. Higher temperatures  
however also mean higher pressures, which may exceed the rat‐  
ed pressure of the vessel.  
1.10.12 Do not heat above 50°C  
To prevent danger, the Regulations for Pressure Tanks provide  
that tanks shall not be heated to more than 50°C.  
1.10.13 Do not apply uncontrolled heat  
Do not heat with an open flame under any circumstance. The local  
overheating that will result can change the structure of the con‐  
tainer's materials, thereby reducing the safe maximum pressure  
limit of the container. In addition, the danger arises that the re‐  
frigerant decomposes due to localised overheating.  
1.10.14 Seal empty containers  
Empty refrigerant containers must in all cases be sealed so as to  
prevent intrusion of moisture. Moisture causes steel containers to  
rust. This weakens the walls of the containers. In addition, rust  
particles which enter the refrigerant system from the container  
cause malfunctions.  
1.10.15 Safety instructions for using extraction  
and charging equipment  
•
Before connecting the charging system to the air conditioning  
system, make sure that all existing shut-off valves are closed.  
•
Before the charging equipment is decoupled from the air con‐  
ditioning system, ensure that the process has finished. The  
reason for this is to ensure that no refrigerant oil escapes into  
the atmosphere.  
•
After the cleaned refrigerant from the charging system has  
been charged into an external pressurised gas cylinder, close  
the hand shut-off valves on the bottle and the charging system.  
•
•
•
Do not expose charging system to moisture or use it in a wet  
environment.  
Before performing service work and the charging system, dis‐  
connect the current supply.  
To reduce danger of fire, avoid using extension cords. If nev‐  
ertheless it is necessary to use an extension cable, use an  
2
extension cable with a cross-section of at least 2.5 mm .  
•
•
In case of fire, remove external cylinder.  
If entrained oil from the air conditioning system suction accu‐  
mulator is trapped in the measuring beaker supplied, be sure  
subsequently to pour the oil into a container that can be  
sealed, since the oil contains a small amount of refrigerant.  
Refrigerants must not be released into the environment.  
•
When the air conditioner service station is switched off, it must  
be secured against rolling away.  
12  
Rep. gr.00 - Technical data  

Related Topics

Generalnotesonairconditioningsystems
1.1 Introduction 1.2 Additional information 1.3 Basics of air conditioning 1.4 Vapour pressure table for refrigerant R134a 1.5 Refrigerant R134a 1.6 Characteristics of refrigerant R134a 1.7 Refrigerant machine oil 1.8 Comfort 1.9 How air conditioning works 1.11 Safety precautions for when working on vehicles... 1.12 Basics for working on refrigerant circuit

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