FIELD LEVEL TROUBLESHOOTING INTRODUCTION - Continued
e. AC System Leak Repair. The majority of all AC system services will consist of locating and repairing AC
system leaks. Many leaks will be located at points of connections, and are caused by vibration. Occasionally, an
AC hose will rub on a structural part or deteriorate, creating a leak. Or, an AC system component will develop a
leak. These leaks can be repaired in the following manner.
1. Minor leaks at connectors. Most minor leaks at connectors can be repaired by tightening the
connectors or replacing the preformed packing. Use two wrenches when loosening or tightening
connectors to avoid strain on AC hoses. Recover refrigerant before tightening connectors or replacing
2. Defective AC hoses. Damaged or deteriorated AC hoses must be replaced. See work package 0039
for AC hose replacement.
3. AC component leaks. If an AC component develops a leak, which cannot be repaired by tightening
fittings or replacing preformed packing, the component may have to be replaced. See the associated
work package for component replacement.
f. Safety Precautions.
1. Whenever repairs are made to any AC part that holds refrigerant, you must recover, purge or flush (if
contaminated), evacuate, charge, and leak test the system. In a good system, refrigerant lines are
always under pressure and you should disconnect them only after the refrigerant has been recovered
with an AC test set recovery/recycling unit through service valves. See work package 0053.
Use care to prevent refrigerant from touching skin or eyes. Liquid refrigerant, when
exposed to air, quickly evaporates and will freeze skin or eye tissues. Serious
injury or blindness may result if you come in contact with liquid refrigerant.
2. Refrigerants are safe when used under the right conditions. Always wear safety goggles and nonleather
gloves while discharging, purging, flushing, evacuating, charging, and leak testing the system. Do not
wear leather gloves. When refrigerant gas or liquid contacts leather, the leather will stick to your skin.
3. Refrigerant splashed in the eyes should be treated with a few drops of sterile mineral oil in the eyes, then
rinsed with a weak boric acid solution. Do not rub the eyes. Call a doctor immediately.
4. Refrigerant splashed on the skin should be treated the same as for frostbite. Gently pour cool water on
the area, but do not rub the skin. Keep the skin warm with layers of soft, sterile cloth. Call a doctor
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