Volkswagen Golf Service & Repair Manual: Statutes and regulations

Note The laws and regulations listed below are valid in the Federal Republic of Germany. Other or additional laws and regulations may apply in other countries.

Sources in other countries may be obtained from the responsible authorities.

The effects concerning the changing climate can be seen world-wide. The protection of the climate is therefore one of the most important tasks for the human race. This task is a massive challenge for all concerned. The so called Kyoto Protocol defines, amongst other items, world-wide targets to protect the climate. This protocol defines apart from the reduction targets for carbon dioxide, the reduction targets for fluoride containing greenhouse gases e.g. for refrigerant R134a due to the high greenhouse potential. Within Europe a large number of respective statutes exist for the motor industry. Nationally (Federal Republic of Germany) for example in addition to European legislation, from the 1st of August 2008 the climate protective regulation concerning chemicals comes into force.

Regulation (EU) No. 1005/2009

Regulation (EU) No. 2037/2000

Regulation (EU) No. 517/2014

Regulation (EU) No. 706/2007

Regulation (EU) No. 307/2008

Guideline 2006/40/EU

Climate protective regulation concerning chemicals; closed substance cycle waste management and ensuring environmentally compatible waste disposal (only Germany)

Maintenance and repairs to refrigerant circuits for air conditioning systems

All personnel performing maintenance and repairs on air conditioning systems for motorized vehicles must have attended the respective training programme and have the appropriate knowledge (certified). Other legislation may apply outside the European Union.

In general the following applies:

Operation, maintenance, decommissioning, duty to accept returned material

It is prohibited to allow the release into the atmosphere of materials contained in products containing refrigerants during the operation, maintenance or removal from service of such products. The quantities used during operation and maintenance work should be documented (see Refrigerant Logbook, → Volkswagen InfoNet, Service handbook; Environmental protection; Environmental protection in the dealership and in the workshop; Emission protection; Air contaminating substances, refrigerant for vehicle air conditioning systems) so that a proof of use document is available for presentation to the responsible authorities upon request. A record sheet need no longer be kept within the EU due to respective European parliament legislation from 2005. Other legislation may apply in countries not belonging to the EU. Companies which sell materials and preparations listed in the above mentioned legislation have the duty of accept returned materials and preparations after they have been used, or to ensure that a specified third party will accept them. Maintenance work and decommissioning of products that contain refrigerant referred to in the above mentioned legislation as well as the acceptance of returned substances and preparations referred to in this legislation may only be carried out by persons who have the necessary specialist knowledge and technical equipment.

Offences and breaches of the regulations

A person is in breach of the regulations and laws referred to if that person performs acts of wilful misconduct or negligence when operating, performing maintenance work on or decommissioning products that contain the refrigerants referred to, contrary to the norms of technical practice, allows the substances contained in them to escape into the atmosphere or wilfully or negligently breaches the applicable regulations and laws mentioned above. Make sure to observe the corresponding technical rules (e.g. TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725, TRBS 3145) when handling compressed gases and, in particular, when filling compressed gases from one compressed gas container into another one. Note The following paragraphs are only extracts from the Technical Rules for Hazardous Substances (TRGS) (relevant for automobile manufacturers and workshops).

TRGS 400 (Risk assessment for activities involving hazardous substances).

TRGS 402 (Identification and assessment of the risks from activities involving hazardous substances: inhalation exposure).

TRGS 407 (Risk assessment for activities involving gaseous substances).

TRGS 510 (Storage of hazardous substances in non-stationary containers).

TRBS 3145/TRGS 725 (Non-stationary compressed gas containers – charging, storage, in-house transportation, emptying). Note The Technical Rules for Compressed Gases (TRG), the Technical Rules for Hazardous Substances (TRGS) and the Technical Rules for Operational Safety (TRBS) reflect the state of technology, occupational safety and health, occupational hygiene as well as other definite knowledge relating to provision and use of work equipment, operation of facilities requiring supervision and activities involving hazardous substances. The technical rules stated here are valid in Germany and do not necessarily reflect the rules and regulations valid in other countries. Make sure to observe the corresponding technical rules (e.g. TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725, TRBS 3145) when handling compressed gases and, in particular, when filling compressed gases from one compressed gas container into another one.

Filling stations – general provisions.

Terms and definitions.

Filling stations – set-up and operation.

Filling stations

This does not apply to vehicle manufacturers and workshops.

Filling stations are systems for charging non-stationary compressed gas containers. A filling station comprises its corresponding premises and equipment. Charging systems that require authorisation are charging systems which are filled with compressed gases in mobile compressed gas containers for transfer to other containers. Filling stations that do not require authorisation are filling stations in which compressed gases are filled into non-stationary compressed gas containers for exclusive use within a company.

Employees and their instruction

Employees are to be instructed in the following points before beginning work as well as at regular, appropriate intervals, but at least annually:

The particular hazards arising when handling compressed gases;

The safety regulations, particularly the existing Technical Rules for Hazardous Substances (TRGS) and the Technical Rules for Operational Safety (TRBS);

The actions to be taken in the event of defects, damage or accidents;

The handing of fire extinguishers and protective equipment;

The operation and maintenance of filling stations, with particular reference to the user's manual.

Filling stations may be operated and maintained only by persons who

are at least 18 years of age;

possess the required technical knowledge;

can be expected to fulfil their duties reliably.

Supervised work may be done by persons who do not fulfil the requirements according to item 2.1, figures 1 and 2. Charging pressure tanks (for tanks from other countries, other technical rules that are not mentioned here may apply). A compressed gas container may be charged only with the compressed gas that is listed on its label, and only up to the quantity indicated on the container in terms of pressure, weight and volume (see Regulations for Pressure Tanks). A container that can be used for different types of compressed gas must have a label on it listing the compressed gases with which it may be charged. If the compressed gas concerned has a tc ≥ -10°C (tc = critical temperature), the max. permissible charging weight in accordance with TRGS must also be indicated on the container before it is connected for charging. Compressed gas containers for which the max. permissible charge overpressure at 15 °C is given in bar must be charged by pressure gauge (manometer). If during charging the temperature differs from 15 °C, the pressure corresponding to the different temperature should be determined by the charging equipment; it must be ensured that the permissible positive pressure for charging at 15 °C in the compressed gas container is not exceeded. To determine possible overcharging, the charged containers must be checked through random pressure tests. Compressed gas containers on which the maximum permissible charging quantity is indicated by the net weight (charged weight, permissible weight of the contents) in kilograms must be charged according to weight (gravimetrically). The containers must be weighed during charging and, to determine possible overcharging subsequently subjected to a weight check on a special scale. Scales for control weighing must be calibrated. Under particular conditions, gases with tc ≥ +70 °C from compressed gas containers with a capacity of no more than 150 l may be charged into a compressed gas container with a capacity of no more than 1000 cc. The conditions of the TRGS apply to charging mechanic's bottles with liquid gas.

For vehicle containers, different TRGS apply:

For gases with tc ≥ +70 °C.
For technical gas mixtures with tc ≥ +70 °C.
Liquid, deep-cooled compressed gases in variance to those stated under item 4 may be charged by volume (volumetrically), if the charging device and/or the container with equipment is equipped with devices for measuring or limiting the volume of the charge and (except vehicle containers as specified under item 3) for measuring the temperature of the charge. When charging by volume it must be ensured that the permitted charge weight shown on the container is not exceeded. To determine possible overcharging, the charged containers are to be checked gravimetrically on a calibrated scale or – provided that the pressurised gases are not highly toxic – volumetrically. Volumetric checking presupposes that the appropriate equipment is in place; charging and checking equipment must be independent of each other.

The charge and check measurements must not be performed by the same person. Check measurements must be performed immediately upon conclusion of the charging process. Overcharged containers must be discharged immediately to the permissible charge quantity and in a manner without hazard. Following this, the quantity of compressed gas charged must be determined once again. Some regulations of the TRGS 407 do not (fully) apply to containers for liquid, deep-cooled compressed gases which are neither flammable nor toxic; regulations for traffic law remain unaffected. When compressed gas containers are to be charged with gases in the liquid state at a charging temperature of ≤ -20°C, the compressed gas container must not be released from the charging system for transportation until the container wall has achieved a temperature ≥ +20 °C (applies for vessel materials not tested for temperatures ≤ -20°C). Converting R12 refrigerant circuits to R134a refrigerant circuits and repairing them (retrofitting)

Note Due to the environmental situation and the consequent legislation, refrigerant R12 is currently neither in production nor available. Refrigerant R134a was developed as a replacement for R12. However, air conditioning systems developed and designed for refrigerant R12 cannot simply be charged with refrigerant R134a. To ensure trouble-free operation of the air conditioning system following a retrofit, various components of the refrigerant circuit must be replaced. An exact description of the procedure for conversion and instructions for repair of converted refrigerant circuits can be found in the → Repair manual for air conditioning systems with refrigerant R12 parts 2 and 3. This workshop manual is only available as a hard copy.

Maintaining records on refrigerant

According to the environmental statistics law, a record concerning the use of refrigerants must be kept. Car manufacture and repair businesses must be prepared to furnish information concerning use of refrigerants to the statistical office for the country in which the work is being performed. It is therefore recommended to keep records of the amounts of refrigerant handled during operation and maintenance (Refrigerant Logbook) → Volkswagen ServiceNet, Environmental Protection; Service handbook; Emission protection; Air contaminating substances, refrigerant for vehicle air conditioning systems) which must be available for presentation to the responsible authorities upon request.

Note A record sheet need no longer be kept within the EU due to respective European parliament legislation from 2005. Other legislation may apply in countries not belonging to the EU.

Statutes and regulations