TIGOR EV_ZIPTRON_SERVICE MANUAL

FATC 32 21.DO’s & DONT’s DO’S  Keep suction discharge hose assembly and liquid line capped until right before assembly of joint.  Ensure that protective sleeves are in proper loca- tion where specified  Lubricate all pre-installed O-rings with specified refrigerant mineral oil (Reference assembly in- structions) prior to assembly of joints. Pre- lubricated, preinstalled O-rings do not require lu- brication prior to installation unless the oil has absorbed into the O-ring and the surface is dry.  Seat O-ring in its female cavity prior to hand start- ing and torquing joint nuts.  Seat male end form with O-ring in its female cavi- ty prior to torquing the mini block-fitting joint.  Use two wrenches for making each refrigerant joint connection - a calibrated torque wrench on the nut and a backup wrench on the mating nut or a block fitting wrench on the block.  Clip or secure hoses and lines as specified.  Be sure caps are tight on access valves. To in- sure tightness, screw caps down until cap seal contacts valve housing and then give it ¼ to ½ turn more.  Assemble dual O-ring fitting joints as follows: a) Oil bore with a specified oiling tool using mineral oil. b) Do not oil O-rings. c) Align end forms and then push together com- pletely d) Tighten joint to specified torque using a backup wrench.  Rotate stock on a first-in first-out basis.  Finger start all mounting bolts that thread into compressor or brackets. Also finger start the bolt securing the block fitting on the suction discharge hose assembly to the compressor.  DO: Oil O-rings with mineral oil prior to assem- bling a refrigerant joint. Pre-oiled O-rings do not require oiling unless the oil has been absorbed in- to the O-ring and the surface is dry.  DO: Use specified mineral oil to lubricate O-rings (Reference assembly instructions )  DO: Use correct refrigerant O-rings in the vehicle refrigerant system . (Refer to assembly instruc- tions for part numbers). DON’TS  Make connections with bends, kinks, or obstruc- tions in lines.  Use bolt or nut to “walk” manifold block or mini block into it’s mating part. Proper technique is with O-ring in seat, push blocks together trapping seal washer before running up and tightening the fastener.  Allow hoses and lines to rub against adjacent parts.  Bend metal lines to ease assembly. Do not use lines as a handle to lift the compressor or con- denser.  Use lines contaminated with water.  Allow hoses and lines to directly contact sheet metal or touch hot bonnet components.  Use bent twisted, kinked or damaged hoses and lines.  Combine refrigerant joint assembly operations with “dirty” operations such as gritty brackets, oily suspension components, etc.  Process “broken” operations where one operator loosely assembles a joint and a subsequent op- erator tightens the joint to required torque.  Use PAG oil to lubricate O-rings.  Lubricate seal washers prior to attaching refriger- ant lines to components.  Use PAG lubricant to lubricate O-rings.