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MAHLE

ACX380/480

EN

Service Manual

A/C Service Equipment

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Summary of Contents for ACX380

Page 1: ...MAHLE ACX380 480 EN Service Manual A C Service Equipment...

Page 2: ...rigerant fluid circuit 17 11 1 Refrigerant fluid circuit 17 11 2 Operational cycles 18 11 3 Receiving tank refrigerant cylinder 18 11 4 Manifold charts 18 11 5 NITROGEN TEST and FORMING GAS LEAK TEST...

Page 3: ...ing of the planet The release of refrigerant gas R134a into the atmosphere is forbidden by laws that were enacted within the framework of the Kyoto protocol For information only we will mention in par...

Page 4: ...h an original spare part or equivalent by a MAHLE centre Before opening the service station extract completely the supply cable from the plug or you can get an electric shock Do not tamper with or byp...

Page 5: ...f instructed or certified for the equipment open the equipment The equipment parts which can cause electrocution shut off power to the equipment before servicing repairing it 2 3 Safety devices The A...

Page 6: ...by the vehicle s manufacturer Charge filling of refrigerant into the A C system in the amount specified by the manufacturer System flushing Cleaning phase for the removal of possible polluting substa...

Page 7: ...ant recovery and recharging Vacuum generation Flushing 4 2 Scope of delivery Description Service hose high pressure Service hose low pressure Quick release coupling high pressure Quick release couplin...

Page 8: ...are available on the display Icon Description Device connected via WiFi The residual refrigerant weight in kg and with visual bar to enable disable the bar by vertically swiping your finger from top t...

Page 9: ...menu The Main menu of the graphical user interface allows to select the following functions Vehicle selection OneClick Cycles Additional Functions Maintenance Setup Secured Service not available for u...

Page 10: ...014 68 EU IV Pneumatic fittings Net length of external HP and LP hoses 4 5 m HP and LP Analog 80 mm pressure gauges pulse free 1 0 class Display Touch screen 7 TFT colours Keypad Touch screen Software...

Page 11: ...for correct handling shall be ensured as provided for by accident prevention provisions POSITIONING Place the unit in a stable place The location must be well ventilated with a good rate of change of...

Page 12: ...coupler Tanks without plunger have only one valve so they must be turned upside down to transfer the liquid refrigerant The LP gauge indicates the pressure inside the external tank After some minutes...

Page 13: ...side the auto vehicle A C system To fill the UV dye bottle Fig 1 Pos 9 it has to be extracted from its housing by means of the quick coupler on the top of the bottle slightly press downward the couple...

Page 14: ...the garage data to be printed at the bottom of the cycle report LANGUAGE by selecting this entry any language present in the database may be set In case you choose a language with unintelligible char...

Page 15: ...ot connected to the bottle station accessories kit when the next message is displayed Fig 16 LP quick coupler opening Turn the LP quick coupler clockwise to open it and press enter OK so that air gets...

Page 16: ...pening Turn the LP quick coupler clockwise to open it and press enter OK so that air gets into the LP hose Wait for the message to connect the reference gauge contained in the service kit and by rotat...

Page 17: ...far from the value of the certified reference weight the result is negative in this case is not possible to update calibration It is necessary to carry out the 3 points Gas weight calibration mention...

Page 18: ...ation is not jeopardized VESSEL 20l Category III Dir 2014 68 EU Fig 20 Refrigerant internal bottle SAFETY VALVE GAS AIRTEK VS14NPT20HNBRPED4 PS 20 bar R 1 4 NPT Category IV Dir 2014 68 EU 11 4 Manifol...

Page 19: ...n MAHLE Fig 22 Manifold circuit Fig 23 Manifold valves Fig 24 Manifold with pressure sensors installed V A I R L1 V A I L2 R T1 T1 L1 R A V PS TP PS HP PS LP One way valve L2 V A I L2 R T1 L1 R A V PS...

Page 20: ...LD The unit has a second manifold dedicated to nitrogen test the identification letters of the sectioning valves are highlighted is reported as follows T2 nitrogen input N IN X nitrogen output N OUT X...

Page 21: ...izes when air is absent and when in contact with metal its aim is preventing slackening caused by impacts and vibrations Yet after application and fixing onto the junction thread you must tighten and...

Page 22: ...and scroll to MAINTENANCE and then select Fig 26 Maintenance screens Only for model ACX380 REFRIGERANT TYPE CHANGE With this function allows the service assistance technician to change the Refrigeran...

Page 23: ...he main menu select MAINTENANCE and press PRESSURES ZERO This function allows to determine and store the at pressure value We recommend running this procedure every time the A C service station will b...

Page 24: ...er to zero and to start the filter replacement procedure Insert the code of the new filter Now you can replace the filter Required tools 1 flat screwdriver 1 cross screwdriver 1 regular or torque Hex...

Page 25: ...and press CALIBRATION CHECK This function allows to check the status of gas weight scale measure with a reference weight from 100 g to 10000 g maximum not included in the scope of delivery When reque...

Page 26: ...ovide for a the bodies in charge after the results of the previous checks performed of commissioning or period requalification do not establish different The checks must be performed by the bodies in...

Page 27: ...install the specific components for use of R1234yf He will also carry nfigurations and verifications required by the the MAINTENANCE 14 17 Replacing white sample filter Refrigerant identification unit...

Page 28: ...ronic power board Replacement of power supply board 15 2 Extraordinary maintenance 15 2 1 Replacement of component connected to refrigerant circuit The components pressurised equipment constituting co...

Page 29: ...tery Evident damage to board components and circuits For the replacement of the board it is recommended to position the new board alongside the one to be replaced Disconnect and reconnect the cables i...

Page 30: ...C SERVICE STATION ACX380 480 Blue LP quick coupler and red HP quick coupler Active Oil Protection kit 2 pcs New Oil 1 UV dye rts are available through the Service Centers USING NON ORIGINAL UNAPPROVE...

Page 31: ...en 31 ACX380 480 APPENDIX 1 REFRIGERANT FLUID CIRCUIT ACX380 480 H...

Page 32: ...ACX380 480 32 en APPENDIX 2 REFRIGERANT FLUID CIRCUIT ACX380 480 OPERATIONAL CYCLES Uncondensable gases H...

Page 33: ...en 33 ACX380 480 Recovery cycle H...

Page 34: ...ACX380 480 34 en Vacuum H...

Page 35: ...en 35 ACX380 480 Recharge H...

Page 36: ...load cell dye 1 10 LC New Oil1 input load cell new oil 1 11 PS Tank input pressure sensor tank 12 LC Ex Oil input load cell 13 PS LP input pressure sensor LP 14 PS HP input pressure sensor HP 15 TS Ta...

Page 37: ...7 ACX380 480 APPENDIX 4 ACX380 480 ELECTRICAL CONNECTION POWER ELECTRONIC BOARD AND POWER SUPPLY POWER ELECTRONIC BOARD POWER SUPPLY BOARD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 2...

Page 38: ...ng 9 OUT H Heat exchanger fan 10 OUT I HP LP solenoid interconnection valve 11 OUT N Solenoid valve for draining of tank s uncondensable gases 12 OUT V Vacuum pump 13 OUT V Vacuum solenoid valve coupl...

Page 39: ...n 39 ACX380 480 APPENDIX 5 ACX380 480 ELECTRICAL CONNECTION STATUS AND WARNING INDICATOR LIGHT ELECTRONIC BOARD Item label Description Connected Unused x 1 SER I O serial I O interface to power board...

Page 40: ...compressor check for leaks from valves R or check compressor functioning Pressure sensor not Altitude compensation and or full pressure calibration Mistake during procedure Altitude compensation and...

Page 41: ...acuum pump oil When the filter capacity is the filter capacity is finished Change filter with new one During the setting of the inner tank charge amount Amount required greater than that available in...

Page 42: ...d or damaged To check electrical connections or change with new spare part During vacuum bottle filling or leak test phase in vacuum The vehicle A C system is pressurized Recover the refrigerant gas f...

Page 43: ...leak test Empty the vehicle follow the procedure guided by the displayed messages A048 HP LEAKAGE During the gas recovery and hoses emptying phase At the end of the gas charging in the E3 Connect qui...

Page 44: ...nalisys not possible Check with virgin refrigerant bottle if the refrigerant gas identifier is working properly If yes and the refrigerant of the car is not R1234yf empty in a safety way and in compli...

Page 45: ...MAHLE Aftermarket Italy S p A Via Quasimodo 4 a 43126 Par ma ITALY 2019 10 28...

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