3R-134a Refrigerant KM811227 06/00

KENWORTH HVAC SYSTEMS

Section

R-134a Refrigerant

3A Background
3B Differences Between R-12 and R134a Systems
3C Containers
3D Markings
3E Contamination

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Section 3A Background

Over the last ten years, scientists have noticed that the earth's ozone
layer is disappearing. Ozone is an oxygen molecule with three oxygen
atoms (O3), instead of the usual two atoms (O2). The ozone layer is part
of the earth's atmosphere between 10-20 miles from the earth's surface.
The ozone molecules in that part of the atmosphere absorb part of the
ultra-violet light from the sun. Too much ultra-violet light can cause skin
cancer and blindness. Scientists believe that the chlorine in CFC
(Cloro-Fluro-Carbon) chemicals, like R-12 refrigerant, is destroying the
ozone layer by chemically breaking up the O3 ozone molecules into O2
oxygen molecules.

In 1991 The Clean Air Act and other regulations came into effect. This law
phases out the manufacture of CFC chemicals. That means we will not be
able to buy new R-12 refrigerant and the supply of old R-12 will gradually
run out. Engineers have redesigned our truck air conditioning systems
using a new refrigerant called R-134a. The R-134a parts do the same
things as on R-12 systems, they have the same names and they look sim-
ilar.

All new Kenworths are built with R-134a systems. Eventually the old R-12
systems will disappear as the trucks are retired, or their air conditioning
systems are retrofitted with R-134a systems. During the time when we'll
be seeing both systems it will be extremely important not to mix parts or
refrigerants.

Section 3B Differences Between R-12 and R134a Systems

R-134a air conditioning systems are replacing R-12 air conditioning sys-
tems in our Kenworths. As the air conditioning systems for each model
are re-engineered, we will be seeing fewer and fewer R-12 systems in our
shops. During the several years where there are both types of air condi-
tioning systems on the road, we will have to be able to tell the difference
between the two types of systems. This is important for three reasons:
• Mixing R-12 and R-134a will create a new refrigerant that will not
work in the system designed for Kenworth.
• Allowing the R-12 mineral oil lubricant to contaminate a R-134a sys-
tem can create system damage.
• The parts of each air conditioning system are engineered for a spe-
cific refrigerant and they generally cannot be exchanged.

The only general exceptions for part exchange are using R-134a hoses
and o-rings in an R-12 system. Some newer receiver/dryers and expan-
sion valves have been engineered for both systems and are marked
clearly for use on both types of systems. R-134a expansion valves can be

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used on R-12 systems, but R-12 expansion valves cannot be used on
R-134a systems. Still, it is strongly recommended that components
designed for specific refrigerants be only used in those systems.

The Differences in the Truck

Between R-12 and R-134a
Systems
Label The refrigerant identification label on the radiator is the best place to find
out if the air conditioning is a R-12 or R-134a system. See Figure 3-1. The
exact location of the label may vary with the model.

Figure 3-1 Refrigerant Identification Label

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R-134a Truck
Compressor

The lubricant used

in the R-134a com-
pressor will be
printed on the com-
The R-134a com- pressor nameplate.
pressor usually will R-134a systems will
have a sky blue list a PAG or POE
plastic tag on the lubricant. Currently,
suction port. Kenworth trucks use
both PAG and POE
lubricants.

Figure 3-2 Compressor Identification Tag

R-134a Truck There will be a different sized fitting on the service ports. R-12 service
Service Ports valve fittings will not fit on an R-134a system, and R-134a service valve
fittings will not fit on an R-12 system.

HIGH SIDE SERVICE PORT

LOW SIDE SERVICE PORT

Figure 3-3 Low Side and High Side Service Ports

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R-134a Truck R-134a hoses will have a SAE J2064 stamped on them. Some R-12
Hoses trucks may be using R-134a hoses, so rely on more information to make a
decision.

A special liner inside the hose prevents the R-134a from escaping
through the hose.

R-134a HOSE

R-12 HOSE

Figure 3-4 R-134a and R-12 Hoses

R-134a Truck Buna and some black neoprene o-rings will react with the PAG and POE
O-Ring lubricants. Using them will quickly lead to a major leak.

Kenworth HNBR o-rings (tinted green) are specifically made for use with
Kenworth R-134a systems. Always use the HNBR o-rings. They may not
always be green in color.

In the real world there are a number of other o-rings that you may find in
equipment that are compatible with R-134a including:
• HNBR Light Blue: Ford
• H4C Black with a yellow dot (that rubs off): John Deere
• HNBR Orange emerlon coating: Caterpillar

Differences in the Shop
Between R-12 and R-134a
Systems
• There is R-134, R-134a and R-134A. They are all different refriger-
ants. Our Kenworth systems use R-134a. Do not confuse it with
R-134 or R-134A.
• R-134a will generally come in larger containers than R-12. When you
order R-134a, make sure you ask for the container for mobile or
vehicle use. R-134A for commercial or stationary HVAC systems will
have a different size fitting on the container than your charging sta-
tion.
• Kenworth R-134a systems take less refrigerant than the Kenworth
R-12 systems take. Always charge by weight because overcharging a
R-134a system will effect the performance.

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• The Refrigerant system is also sensitive to over-filling the oil reservoir
in the compressor. Excess oil will circulate through the system. Extra
oil in the system forms barriers in the condenser and evaporator that
interfere with heat exchange. Do not over-fill the oil reservoir in the
compressor.
• The lubricant will come in smaller cans and bottles. The lubricant
must be stored in a light-proof, sealed container. Do not re-use lubri-
cant. Fresh lubricant is a light yellow. If your lubricant turns brown or
black, dispose of it.
• R-134a molecules are much smaller than R-12 molecules. Hoses
need special barriers to prevent the R-134a from escaping through
the hose material. Always use factory made “barrier” hoses assem-
bled. Dirt in fittings may cause o-rings to distort enough to allow the
R-134a to escape. Keep service hose fittings clean and prevent
dirt and grease from getting on o-rings and fittings.
• You must use HNBR o-rings with R-134a systems. Many types of
black neoprene or rubber o-rings will quickly fail. Although there are a
number of black HNBR o-rings on the market, always be sure by
using green o-rings.
• Always lubricate the o-rings with a little mineral oil before install-
ing. If the o-rings are not lubricated they will distort, cut or tear when
you tighten the fitting.
• The distance the condenser is set from the radiator and after cooler is
a critical measurement set at the factory that effects the heat
exchange capability of the condenser. Always check condensers
for blockage when inspecting a truck.
• The receiver/dryer fittings on our R-134a Kenworths are reversed
fr o m t h e fit ti ng s o n R - 1 2 tr uck s. Alw ays u se th e correct
receiver/dryer for R-134a systems. Always check that the flow
direction is correct when you install the receiver/dryer.
• Do not discharge R-134a into the air. It must be recovered just like
R-12.
• Do not mix R-134a and R-12 service equipment. You must use
separate gauge sets, recovery stations and charging stations. The
only exception is a stand-alone vacuum pump that may be modified
for R-134a fittings.
• Make sure your leak detector will work with R-134a. Some leak
detectors will only find CFC materials (like R-12) and will not detect
HFC materials (like R-134a).

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Section 3C Containers

Storing Refrigerant R-134a will come from the manufacturer in sky-blue colored tanks. The fit-
ting sizes will be different from R-12 containers, so it will be difficult to
confuse the two refrigerants.

When ordering R-134a make sure you order R-134a (little “a”) for auto-
motive or transportation use. The fittings on R-134a tanks for stationary
use are a different size than tanks for automotive use.

There are different refrigerants with similar names. There is also R-134
(with no letter) and R-134A (with a big A). These are different refrigerants.
They are not interchangeable.

Section 3D Markings

Table 3-1 Refrigerant Markings

CONTAINER CHEMICAL
REFRIGERANT
COLOR SYMBOL
R-134a Sky Blue CH2FCF3
R-12 White CCI2F2

R-11 Orange CCL3F

R-22 Pale Green CHCIF2

R-502 Light Purple Mixture of R-22 and

R115

Containers with used R-134a that has not been recycled should be
clearly marked: DIRTY REFRIGERANT DO NOT USE WITHOUT RECY-
CLING or CONTAMINATED REFRIGERANT. Used R-134a containers
must be completely evacuated before disposal.

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Storage Tips
Table 3-2 Storage Tips

ALWAYS NEVER
Always use DOT or UL approved Never attempt to re-use shipping
containers. containers.

Always store containers where they Never drop a tank, damage a fitting or
are safe from damage. puncture the tank.

Always store R-134a in a stable Never store R-134a tanks in direct

environment with temperatures below sunlight or next to a heat source.
125°F.

Always evacuate empty storage Never place R-134a in a tank with an

cylinders before re-filling. unknown refrigerant.

Always fill a container by weight Never fill a container to more than

80% of its rated weight.

Always mark recovery tanks as Never recharge a truck’s system with

contaminated until they have been refrigerant from an unmarked tank.
recycled.

Never use a fitting adapter to place

R-134a in an R-12 tank or R-12 in a
R-134a tank.

Never mix R-134a and R-12.

Section 3E Contamination

The Unmarked If you find an unmarked R-134a tank, always assume it is contaminated.
Tank You can test for contamination by a temperature/pressure test. You will be
using the fact that every pure gas has a specific pressure at a specific
temperature. The pressure for R-134a at specific temperatures is a known
quantity. A contaminated tank of R-134a will have air and other gasses
that will not condense in it, so the pressure will be quite different from a
tank of pure R-134a.

To Check an • Let the tank sit at a constant temperature, above 65°F for 12 hours.
Unknown Tank
• Keep the tank away from direct sunlight or other heat source.
• Hook up an accurate gauge to the tank or use the low side gauge on
a manifold gauge set.
• Measure the ambient temperature next to the tank (within 3-4 inches).
• Read the pressure on the gauge.
• Find the ambient temperature measurement in Table 2-13, “Maximum
Pressures for Uncontaminated R-134a” on page 2-8.

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• If the pressure you measured is higher than the one in the table for
the temperature, purge the air from the tank.
• Purge the tank by bleeding enough air from the top of the tank until
the pressure drops below the pressure listed in the table.
• Let the tank sit at a stable temperature for another 12 hours and
repeat the measurement.
• If the pressure is still above the table pressure for that temperature,
the tank is contaminated with air and should be recycled.

Maximum See Table 2-13, “Maximum Pressures for Uncontaminated R-134a” on

Pressues for page 2-8.
Uncontaminated
R-134a

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