Tools & consumables
- Refrigerant recovery/recycling machine (required by law in many jurisdictions)
- Manifold gauge set rated for the refrigerant used (low & high side hoses, center port)
- Vacuum pump (33–60 CFM recommended for truck systems) with service hose to manifold center
- Refrigerant cylinder of correct type (confirm Hino spec: R134a or other) and correct charge mass (see Hino 500 Series workshop manual)
- Electronic refrigerant scale (accurate to 10 g)
- Refrigerant identifier (optional, recommended if unknown refrigerant)
- Electronic leak detector and/or UV dye + UV lamp
- Thermometers or clamp‑on evaporator outlet sensor
- Shop air (for pressure checks only) and a Schrader valve core tool
- Basic hand tools, torque wrench, line wrenches, safety wire/caps
- PAG compressor oil (type & amount per compressor spec) and spare O‑rings (nitrile/HNBR compatible; sizes as per ports)
- Replacement receiver‑drier/accumulator or orifice tube if system opened or contaminated
- PPE: safety goggles, nitrile gloves, long sleeves, refrigerant‑rated gloves if available

Safety & legal
- Do not vent refrigerant to atmosphere — use recovery machine. Many places require certified operators (e.g., EPA 608 in US).
- Verify refrigerant type and system capacity from the Hino 500 Series workshop manual before starting.
- Work in a well‑ventilated area. Refrigerant can displace oxygen and may cause frostbite on contact.
- Wear eye protection and gloves; avoid skin contact with liquid refrigerant.
- Never mix refrigerant types. Use dedicated hoses and recovery equipment or purge/flush appropriately.
- Relieve system pressure with recovery machine before opening lines.
- Disconnect battery if performing major component replacement; otherwise keep battery connected to run A/C during charge.

Step‑by‑step procedure
1) Preliminary checks
- Verify refrigerant type and charge amount from the Hino 500 Series manual for the specific model/year.
- Inspect condenser, condenser fan, evaporator, lines, compressor drive belt, and electrical connectors. Repair obvious damage.
- Check compressor operation (clutch engagement) with engine on and A/C turned to max. If clutch doesn’t engage, diagnose electrical/low‑pressure switch/fuse first.
- If system has been open, plan to replace receiver‑drier/accumulator and any O‑rings.

2) Recover existing refrigerant (if present)
- Connect recovery machine to the service ports via manifold center if required or to recovery service fittings per machine instructions.
- Open low and high service valves on manifold and start recovery machine. Recover until system is empty (follow machine manufacturer instructions).
- Weigh recovered refrigerant if needed and log. Do not reuse contaminated refrigerant.

3) Leak detection & repair
- With system empty and dry, pressurize with dry nitrogen to a safe test pressure (refer to workshop manual). Use an inline regulator.
- Use electronic leak detector and soap solution on hose/connection joints to locate leaks. Repair leaks (replace O‑rings, flare fittings, or braze lines as necessary). Re‑pressure test after repair.
- If leaks were in replaceable components (compressor, evaporator, condenser), replace and pressure test again.

4) Replace service components if opened
- Replace receiver‑drier/accumulator whenever the system has been opened to atmosphere or a compressor has been replaced.
- Replace orifice tube or expansion device if contaminated. Replace O‑rings at any opened service ports — lubricate new O‑rings with correct PAG oil before installation and torque fittings to spec.

5) Evacuate (vacuum) the system
- Connect manifold low to low port, high to high port. Connect center (yellow) to vacuum pump using appropriate hose. Ensure valves on manifold are closed to the machine until ready (manifold valves normally closed when handles are mid).
- Turn on vacuum pump and open both low and high manifold valves to pull vacuum through the whole system.
- Pull down to at least 500 microns (0.5 torr) if possible; acceptable minimum is commonly 500–1000 microns. Hold vacuum for at least 30 minutes (some techs do 45–60 min for truck systems).
- Close manifold valves, turn off pump, and watch for rise in micron gauge for at least 10–15 minutes. Any rise indicates moisture or leak — if so, recheck for leaks and re‑evacuate.

How to use the vacuum pump & manifold:
- Connect pump directly to manifold center port. With manifold valves closed, run pump briefly to purge hoses, then open both service valves to vacuum the system. If using a vacuum gauge, monitor microns on the gauge mounted to manifold or inline micron gauge.

6) Charge with refrigerant by weight
- Place the refrigerant cylinder on the scale; tare the scale to zero.
- Connect the cylinder to the manifold center hose or recovery machine charge port using a liquid‑charging adapter if required. For R134a, charge as vapor into the low side with the engine running and A/C on max — do not overfill.
- Start engine, set blower to high, temp to cold, A/C on. With compressor running, open the low‑side manifold valve slowly to allow refrigerant to flow as vapor. Do not charge through the high side unless specifically indicated by equipment notes.
- Add refrigerant until the exact mass per the Hino workshop manual is reached. Charge by weight — not by pressure. Use the thermometers on the suction line near evaporator outlet and on the discharge line to confirm system performance.
- Monitor low‑side & high‑side pressures using the manifold only as a check; refer to PT chart for appropriate pressures at current ambient temperature. Stop at specified mass.

How to use the refrigerant scale & manifold for charging:
- Keep the cylinder upright for vapor charging if instructed. If the procedure calls for liquid charging (rare for compressor protection situations), follow manual. Open cylinder valve slowly; operate the manifold low valve to control flow. Watch scale to deliver the precise weight.

7) Performance verification
- After charging to spec, run system for 10–15 minutes; measure evaporator outlet temperature and vent temps. Typical evaporator exit temps will be cold (~2–8°C depending on conditions). Check for steady suction and discharge pressures and adequate cooling at cab vents.
- Check compressor amperage, clutch engagement, and any abnormal noises.
- Recheck for leaks with electronic leak detector while system is running.

8) Finish up
- Close manifold valves, remove hoses (replace Schrader valve caps), and document charge mass and refrigerant serial numbers per regulations.
- Properly store or reclaim any recovered refrigerant and clean tools.

Common replacement parts & when to change them
- Receiver‑drier/accumulator: replace when system opened or compressor replaced, or if moisture suspected.
- O‑rings and seals: always replace when disconnecting lines; lubricate with correct PAG oil.
- Orifice tube/expansion valve/TXV: replace if contaminated or if metering device suspected.
- Compressor oil: add or replace oil per compressor service instructions, especially if compressor replaced.
- Compressor clutch or belt: replace if worn or slipping.

Common pitfalls & how to avoid them
- Charging without recovering/evacuating: causes moisture and contaminants to remain — always recover then vacuum.
- Charging by pressure instead of weight: leads to over/undercharge and possible compressor damage. Always charge by weight.
- Venting refrigerant: illegal and dangerous. Use recovery equipment.
- Adding oil blindly: too much or wrong type of oil will harm system. Use correct type and amount from manual.
- Not replacing receiver‑drier/accumulator after opening system: allows moisture to remain — replace it.
- Charging into high side or adding liquid into low side incorrectly: can slug compressor. Follow recommended vapor vs liquid charging method.
- Ignoring ambient temperature & PT charts: pressures vary with ambient; use weight and temperature readings not just pressure numbers.
- Using contaminated recovery cylinder/equipment: can contaminate the system — dedicated or properly evacuated equipment only.

Quick tool‑use notes
- Manifold gauge: low port (blue) = suction/low side. High port (red) = discharge/high side. Center (yellow) = vacuum/recovery/charge. Close both gauge valves before connecting; open slowly when in use. Never interchange hoses without purging.
- Vacuum pump: connect to center hose, purge by running briefly with manifold valves closed, then open both service valves to evacuate system. Monitor microns with a micron gauge.
- Recovery machine: follow manufacturer procedures; connect to low and high or service fittings as required; run until recovery complete and machine shows empty.
- Scale: place cylinder on scale, tared to zero, monitor weight continuously during charge and stop at specified weight.
- Leak detector: probe around fittings, condenser, evaporator core, compressor seals — move slowly; avoid false positives from refrigerant traces.

Final notes
- Always refer to the Hino 500 Series workshop manual for exact refrigerant type, system charge mass, test pressures, torque specs and component part numbers before proceeding.
- If you find a leak that requires brazing, flush the system afterward and replace the drier/accumulator and likely the orifice/expansion valve.

Done.
rteeqp73

Test Driving Hino 500 Series Wide Cab Steve Brooks takes the all-new Hino 500 Series Wide Cab for a run from western Sydney up to the Hunter Valley Hino Motor ...

painting old rust truck hino truck 1996 restoration japanese truck . mongol zasvar

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