Draining and recycling refrigerant

WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.

Volvo uses environmentally friendly refrigerant R134a in the air conditioning (A/C) system. This refrigerant may only be used in the systems it is intended for.

WARNING: Different refrigerant types must not be mixed

In order to meet legal requirements for the environment and safety, Volvo has developed a system for draining, cleaning and recycling the refrigerant. In addition, the unit can be used to vacuum-pump, test and fill the air conditioning (A/C) system in the car.

WARNING: Always use protective goggles with good coverage. Protect exposed skin (hands) to avoid frostbite injuries.

CAUTION: Follow the safety precautions when working on the climate control system. See Safety instructions when handling refrigerant .

RSH 850 draining/filling station

Fig 1: RSH 850 Draining/Filling Station

Courtesy of VOLVO CARS OF NORTH AMERICA.

This station has been specially developed for Volvo cars.

The different settings allow the station to be used on all Volvo cars equipped with a system for R134a refrigerant.

The station allows refrigerant to be recycled and reused.

Draining the air conditioning (A/C) system

Fig 2: Draining Air Conditioning (A/C) System

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE: The temperature must be above 20°C to drain the system rapidly. Run the engine briefly (5 minutes) to reduce the time required for drainage.

Lock the wheels on the draining station.

Check the oil level in the draining station compressor and vacuum pump.

Check that there is oil in the station: Open the cock (15).

Ensure that all cocks are closed.

Set the switch (11) to the PV position.

Switch on the main switch (1) (the white indicator lamp will light).

Connect the high-pressure hose (9, red) to the high pressure line for the air conditioning (A/C) system.

Connect the low pressure hose (10, blue) to the low pressure line for the air conditioning (A/C) system.

Slowly open the cock (7).

The cock (8) must be closed when draining.

Draining

Fig 3: External Gas Tube

Courtesy of VOLVO CARS OF NORTH AMERICA.

Turn the switch (2) to the recycling position.

The station drains the system automatically and is then ready for use.

NOTE: If the RHS 850 unit needs filling with R134a from an external gas tube, it must be filled through the upper high pressure connection (9). This can be carried out while the system is being drained via the low pressure connection.

The refrigerant level can be checked with the glass cylinder measuring pipe (13).

If the reservoir is full (4 kg), the red indicator lamp lights and the compressor in the station stops.

The recycling lamp (4) remains lit as long as there is refrigerant in the system.

The compressor stops if there is no longer any pressure.

The air conditioning (A/C) system will empty in approximately 25 minutes.

After draining

The low pressure gauge (14) will display low pressure (-0.2 - 0.4 bar) if the system is empty.

NOTE: The engine must then be kept at room temperature.

Check that the low pressure gauge (14) displays 0 bar.

NOTE: If the gauge is displaying low pressure, any oil that ran out when draining the air conditioning (A/C) system cannot be drained.

Filling the air conditioning (A/C) system with oil

Fig 4: Filling Air Conditioning (A/C) System With Oil

Courtesy of VOLVO CARS OF NORTH AMERICA.

After 5 minutes the pressure in the station has evened out. The oil that also came out of the air conditioning (A/C) system can then be drained.

Check the drain cock (15) on the station to see whether any oil ran out with the refrigerant when the system was drained.

Measure the amount of oil drained (using the glass gauge). Fill with the corresponding amount of new oil.

NOTE: Oil can only be filled prior to evacuation (vacuum pumping) of the system.

Fill with PAG oil, P/N 1161407

Disconnect the filling valve on the station.

Remove the Schrader valve.

Use tool 9811994

Then use the refilling nozzle (without the plastic hose) supplied with the station.

NOTE: Clean the nozzle thoroughly to prevent different oils from mixing.

Measure the corresponding amount of oil that was drained.

Reinstall the Schrader valve.

NOTE: Tighten the Schrader valve with tool 9811994 . Use only the thumb and index finger on the tool to tighten the valve.

Measuring low pressure in order to localize a fault

Fig 5: Measuring Low Pressure In Order To Localize Fault

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE: Both high and low pressure can be measured. Connect both the high and low pressure hoses (red and blue)

Connect the blue hose between terminal 10 on the station and the low pressure connection on the air conditioning (A/C) system.

Turn the switch (1) to the PV position.

Turn the switch (2) to the test position.

Start the engine. Start the air conditioning (A/C) system.

The low pressure valve now operates depending on the value displayed by the low pressure gauge (14).

Vacuum pumping

Fig 6: Vacuum Pumping

Courtesy of VOLVO CARS OF NORTH AMERICA.

CAUTION: Check the oil level in the compressor. Fill with new oil if necessary according to Oil in the A/C system , before vacuum pumping the system.

Turn the switch to the evacuation position.

Cocks 7 and 8 must be shut so that no air is sucked into the station.

Let the vacuum pump run for at least 50 minutes to ensure that all moisture is evacuated from the system.

The pressure is then 1 - 3 mbar.

Press the "vacuum test" button (6). Hold it pressed in for 4 minutes.

The value displayed by the vacuum gauge (dial 16) may only rise slightly (0.1 - 0.3 mbar).

Release the "vacuum test" button (6). The station returns to its original mode.

Refilling with refrigerant

Fig 7: RHS 850 Unit

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 8: External Gas Tube

Courtesy of VOLVO CARS OF NORTH AMERICA.

Check the amount of refrigerant that the air conditioning (A/C) system should contain.

Check that there is sufficient refrigerant in the station's reservoir for filling.

Use the rubber ring on the glass gauge (13) to mark the amount of refrigerant the system must be filled with.

Compensation must be made for the volume of refrigerant in the pipe system on the station and the filling connection on the system. This is achieved by increasing the amount of refrigerant in the glass gauge by 50 cm³ . When recycling, more than 50 cm³ may be displayed in the glass gauge. This is because gas flows out of the station condenser.

Turn the switch (2) to the filling position.

The lower cock (8) must be closed and the upper cock (7) must be open. Monitor the level in the glass gauge on the station continuously. Close the cock (7) when the marked level is reached.

Close the connection to the car.

This prevents the valve from deploying and the Schrader valve in the car remains unaffected. Otherwise the system will empty again.

Turn the switch (2) to the recycling position.

Open the "recycling" cock again.

Wait until the indicator lamp (4) goes out. There is no longer any refrigerant in the hose.

Close the cock (7).

Turn the switch (2) to the test position.

NOTE: Use a fault-tracing instrument to carry out further leak tests on the connections on the replaced components.

The amount of refrigerant required to fill the air conditioning (A/C) system

Identification plate in the engine compartment.

The refrigerant capacity of the air conditioning (A/C) is listed on the identification plate in the engine compartment, close to the filling connection.

NOTE: The refrigerant capacity of the air conditioning system is given in the table below. Apply a new decal.

Refrigerant (R134a)	-97	98-	B4184SM
Type	R134a	R134a	R134a
Amount as weight, g	900	900	750

Filling the collection tank

Fig 9: Filling Collection Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

Only used if draining several cars that will not be refilled.

WARNING: Use only approved refrigerant containers (bottles). Do not overfill the refrigerant holder (bottle). Fill to only 80% of the listed volume (the gases may expand when the temperature rises).

Switch on the main switch (1).

Connect the red hose to the outlet (9) on the equipment.

The cock (7) must be closed.

Close cock 8 and open cock 7.

Turn the switch (2) to the filling position.

The station now automatically drains the cylinder into the container (bottle).

When draining is complete, close the cock on the refrigerant container (bottle).

Turn the switch (2) to the recycling position.

Close cock 8 and open cock 7.

The hose now releases automatically.