background image

© MAHLE

 

 

 

 

 

 
QUICK COUPLERS CLOSING/OPENING:  

 

 

 

 

MAINTENANCE/GENERAL  CLEANING:  The  equipment 
has  to  be  serviced  at  the  intervals  indicated  by  the 
equipment itself.  
The  service  station  maintenance  has  to  be  performed 
according  to  the  procedures  described  in  this  manual  and 
to the current safety regulations. 
Use only MAHLE original parts. 
When the equipment requires the drier filter and the vacuum 
pump  oil  to  be  changed,  you  have  to  be  careful  in  the
replacement. 
A/C  service  station  maintenance  can  be  carried  out 
exclusively  by  a  trained  operator  or  by  a  service  man  of  a 
MAHLE certified seller.  
Do not use chemical agents for the service station cleaning 
as they could attack the material or the surface. 
 

 

STOP  FOR  LONG  PERIOD:  Store the equipment in a safe 
place,  disconnected  from  the  mains,  away  from  excessive 
temperatures, humidity and the risk of damaging impact.
Contact  the  Technical  Service  to  run  a  safety  shutdown  of 
the  equipment,  and  if  scrapping  the  unit,  to  drain  and 
recycle  the  R134a  or  R1234yf  refrigerant  as  required  by 
local legislation. 
To  resume  operation,  repeat  the  installation  (there  is  no 
need  to  register  the  unit  anew  on  the  website)  and  run  the 
commissioning  trials  and  regular  operational  checks  as 
required by local legislation. 
 

2.2 

Important information on service 
equipment safety 

 
When using the equipment, the following operations are not 
allowed  as  they  might  cause,  under  certain  circumstances, 
danger  for  persons  and  cause  permanent  damage  to  the 
equipment itself. 

 

 

-  Do  not  remove  or  make  unreadable  labels, 
signs  and/or  dangers  signs  placed  on  the 
equipment and in the area nearby. 

 

- Do not disable the unit's safety equipment.

 

-  The  electrical  system  to  which  the  service 
equipment is connected must be configured as 
provided by local legislation.  
 

Closing (detach from 
the vehicle):  
counter clockwise 

Opening (connect to 
the vehicle): 
clockwise 

| AIR-

The  equipment 

has  to  be  serviced  at  the  intervals  indicated  by  the 

has  to  be  performed 

according  to  the  procedures  described  in  this  manual  and 

When the equipment requires the drier filter and the vacuum 
pump  oil  to  be  changed,  you  have  to  be  careful  in  the 

A/C  service  station  maintenance  can  be  carried  out 
exclusively  by  a  trained  operator  or  by  a  service  man  of  a 

Do not use chemical agents for the service station cleaning 

Store the equipment in a safe 

place,  disconnected  from  the  mains,  away  from  excessive 
temperatures, humidity and the risk of damaging impact. 
Contact  the  Technical  Service  to  run  a  safety  shutdown  of 

scrapping  the  unit,  to  drain  and 

recycle  the  R134a  or  R1234yf  refrigerant  as  required  by 

To  resume  operation,  repeat  the  installation  (there  is  no 
need  to  register  the  unit  anew  on  the  website)  and  run  the 

r  operational  checks  as 

Important information on service 

When using the equipment, the following operations are not 
allowed  as  they  might  cause,  under  certain  circumstances, 

permanent  damage  to  the 

Do  not  remove  or  make  unreadable  labels, 

signs  and/or  dangers  signs  placed  on  the 

Do not disable the unit's safety equipment.

 

The  electrical  system  to  which  the  service 

equipment is connected must be configured as 

 

 

- Only operators or qualified staff 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/C  service  station  is  equipped  with  the  following  safety 
devices: 

 

SAFETY  PRESSURE  SWITCH
in case of excessive pressure. 
 
SAFETY  VALVE:  The  safety  valve  opens  when  the 
pressure inside the system reaches a level higher than the 
fixed limits. 
 
MAIN  SWITCH:  Switches  the  equipment  off  by 
interrupting  the  power  supply.  It  is  advisable  to  pull  the 
power  cord  plug  out  of  the  mains  socket  in  any  case 
before starting maintenance work.

 

ANY  TAMPERING  WITH  THE  ABOVE
SAFETY DEVICES IS PROHIBITED.

 

Failure to observe any of the above safety instructions voids the 
equipment's  warranty. 
 

3  Layout of the manual

 

3.1 

Use of the manual 

 

 

This  manual  is  an  integral  part  of  the  equipment  and 
must  be  kept  in  the  equipment's  immediate  vicinity  by 
the purchaser 

 

 

This manual shall accompany the equipment in case this is 
passed on to a new user. 

 

The  content  of  this  manual  has  been  drawn  up  in 
compliance  with  the  guide  lines  of  the  UNI  standard 
10893:2000. 

 

Diffusion, modification or use of this manual for own aims is
forbidden. 

 

The manual uses symbols which call the reader's attention 
to specific points to facilitate its use.

 

It includes all technical, operating, shutdown, maintenance, 
spare parts and safety information.

 

In  case  of  doubts  on  the  correct  interpretation
instructions,  please  contact  our  technical  service  to  obtain 
the required clarifications. 

 

 

Operations  which  are  potentially  hazardous  for  the 
operator are highlighted with this symbol.
Such operations can cause serious injury.

 

Operations requiring special attention are highlighted with 
this symbol. 
Such  operations  shall  be  carried  out  correctly  to  avoid 
causing  damage  to  objects  or  to  the  surrounding 
environment.  This  symbol  also  highlights  information  to 
which special attention must be pa

-NEX 9380/9480 | 5    en

 

Only operators or qualified staff instructed or 

equipment  maintenance  can 

.  The  equipment  contains 

parts  which  can  cause  electrocution:  shut  off 
power 

to 

the 

equipment 

before 

is  equipped  with  the  following  safety 

SAFETY  PRESSURE  SWITCH:  It  stops  the  compressor 

 

The  safety  valve  opens  when  the 

pressure inside the system reaches a level higher than the 

Switches  the  equipment  off  by 

interrupting  the  power  supply.  It  is  advisable  to  pull  the 
power  cord  plug  out  of  the  mains  socket  in  any  case 
before starting maintenance work. 
ANY  TAMPERING  WITH  THE  ABOVE-MENTIONED 
SAFETY DEVICES IS PROHIBITED. 

Failure to observe any of the above safety instructions voids the 

Layout of the manual 

This  manual  is  an  integral  part  of  the  equipment  and 
must  be  kept  in  the  equipment's  immediate  vicinity  by 

This manual shall accompany the equipment in case this is 

The  content  of  this  manual  has  been  drawn  up  in 
compliance  with  the  guide  lines  of  the  UNI  standard 

Diffusion, modification or use of this manual for own aims is 

The manual uses symbols which call the reader's attention 
to specific points to facilitate its use. 
It includes all technical, operating, shutdown, maintenance, 
spare parts and safety information. 
In  case  of  doubts  on  the  correct  interpretation  of  the 
instructions,  please  contact  our  technical  service  to  obtain 

Operations  which  are  potentially  hazardous  for  the 
operator are highlighted with this symbol. 
Such operations can cause serious injury. 

requiring special attention are highlighted with 

Such  operations  shall  be  carried  out  correctly  to  avoid 
causing  damage  to  objects  or  to  the  surrounding 
environment.  This  symbol  also  highlights  information  to 
which special attention must be paid. 

Summary of Contents for AIR-NEX 9380

Page 1: ...MAHLE AIR NEX 9380 9480 EN Service Manual A C Service Equipment...

Page 2: ...7 10 Equipment and simulator 17 11 Refrigerant fluid circuit 17 11 1 Refrigerant fluid circuit 17 11 2 Operational cycles 17 11 3 Receiving tank refrigerant cylinder 17 11 4 Manifold charts 18 11 5 Su...

Page 3: ...bal warming 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 mentio...

Page 4: ...th 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 by...

Page 5: ...g repairing it 2 3 Safety devices The A C service station is equipped with the following safety devices SAFETY PRESSURE SWITCH in case of excessive pressure SAFETY VALVE The safety valve opens when th...

Page 6: ...val of possible polluting substances from the A C system or parts of it Non condensable gas Refrigerant stored in gaseous phase including air and nitrogen 3 4 Guidelines for the handling of refrigeran...

Page 7: ...ed Refrigerant 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 rele...

Page 8: ...ollowing icons 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 fi...

Page 9: ...Vehicle selection OneClick Cycles Additional Functions Maintenance Setup Secured Service not available for user reserved only for customer service personnel Each function will be described in the nex...

Page 10: ...ype 13 18bar 1 4SAE Trip pressure 18 bar PED category Dir 2014 68 EU IV Pneumatic fittings Net length of external HP and LP hoses 4 5 m HP and LP pressure gauges Analog 80 mm pulse free 1 0 class Disp...

Page 11: ...imum devices required 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 g...

Page 12: ...plunger shall remain upright to be able to transfer liquid refrigerant for this type of tanks connect to the L liquid coupler Tanks without plunger have only one valve so they must be turned upside do...

Page 13: ...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 coupler ring nut to extract it standard UV Dye UV...

Page 14: ...in 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 c...

Page 15: ...apter alone not 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...

Page 16: ...r opening 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 ro...

Page 17: ...nt fluid circuit 11 1 Refrigerant fluid circuit For components and circuit layout ref APPENDIX 1 REFRIGERANT FLUID CIRCUIT 11 2 Operational cycles For components and circuit layout ref APPENDIX 2 OPER...

Page 18: ...system and closed that a pipe emptying operation has been made and the manifold has been completely emptied Fig 21 Manifold components NOTE on the manifold drawing above the position of the pressure s...

Page 19: ...product can get its maximum performance in terms of hold resistance For one s own and other people s safety the operator user of the Loctite 577 product must consider that it must be employed in well...

Page 20: ...AINTENANCEfromtheMAIN MENU press and scroll to MAINTENANCE and then select Fig 26 Maintenance screens Only for model AIR NEX 9380 REFRIGERANT TYPE CHANGE With this function allows the service assistan...

Page 21: ...to determine and store the at pressure value We recommend running this procedure every time the A C service station will be moved from a location to another with a different altitude 14 6 Self leak te...

Page 22: ...eplacement comply with the instructions outlined below 1 disconnect the HP and LP hoses from other systems circuits or vehicles and close the quick couplers 2 wait the ends the hoses emptying 3 confir...

Page 23: ...the lid of the printer as shown note press the green led as in picture and only after that open the lid 2 Position the roll of paper inside the housing in the rotation direction indicated in the pictu...

Page 24: ...dies in charge after the results of the previous checks performed of commissioning or not establish different The checks must be performed by the bodies in charge in the country where the station is c...

Page 25: ...c components for use of R1234yf He will also carry nfigurations and verifications required by the the MAINTENANCE 14 16 Replacing white sample filter Refrigerant identification unit The need to replac...

Page 26: ...electronic 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 constituti...

Page 27: ...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 in se...

Page 28: ...OF A C SERVICE STATION AIR NEX 9380 9480 ECO LOCK optional LP quick coupler and red Active Oil Protection kit 2 pcs New Oil 1 UV dye rts are available through the Service Centers USING NON ORIGINAL UN...

Page 29: ...en 29 AIR NEX 9380 9480 APPENDIX 1 REFRIGERANT FLUID CIRCUIT AIR NEX 9380 9480 H...

Page 30: ...AIR NEX 9380 9480 30 en APPENDIX 2 REFRIGERANT FLUID CIRCUIT AIR NEX 9380 9480 OPERATIONAL CYCLES Uncondensable gases H...

Page 31: ...en 31 AIR NEX 9380 9480 Recovery cycle H...

Page 32: ...AIR NEX 9380 9480 32 en Vacuum H...

Page 33: ...en 33 AIR NEX 9380 9480 Recharge H...

Page 34: ...Dye1 input 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...

Page 35: ...EX 9380 9480 APPENDIX 4 AIR NEX 9380 9480 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...

Page 36: ...ed oil draining 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 solenoi...

Page 37: ...ing to the 20 minutes vacuum time Gas leakage from internal or compressor check for leaks from valves R or check compressor functioning Pressure sensor not Altitude compensation and or full pressure c...

Page 38: ...Change vacuum 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 avai...

Page 39: ...disconnected 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 refrig...

Page 40: ...le fittings 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...

Page 41: ...is phase Analisys 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...

Page 42: ...MAHLE Aftermarket Italy S p A Via Quasimodo 4 a 43126 Par ma ITALY 2019 11 07...

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