background image

 

 

 

Operations which require careful reading of the manual's 
instructions are highlighted with this symbol.

 

3.2 

Symbols 

 

This paragraph describes the safety symbols which may be 
posted on the service equipment. 
 

3.2.1 

Safety  

 

 

 

ALTERNATING 
CURRENT 

 

SAFETY GROUNDING 

 

CONSULT 

THE 

INSTRUCTIONS 
MANUAL 

 

ATTENTION! 
ELECTROCUTION 
HAZARD 

 

 

 

CAUTION  !:  DO  NOT 
REMOVE  THE  COVER 
(maintenance 
technicians only) 

     

 

USE 

PROTECTIVE 

GLOVES 
WEAR 

PROTECTIVE 

GOGGLES 

 

USE 

ANTI-SMASH 

SAFETY SHOES 
 

3.3 

Glossary 

 

To  make  the  reading  of  this  manual  easier,  we  have 
prepared the list of the most important technical terms used 
in the manual. 
 
Refrigerant:  Refrigerant  fluid  used  in 
advanced motor vehicle A/C systems.  
                The  following  refrigerant  fluids 
may be used:  

 

R-1234yf  CH2CFCF3  2,3,3,3-
Tetrafluoropropene. 

 

R-134a    C2H2F4    -  1,1,1,2-
Tetrafluoroethane 

 
A/C system: air conditioning system. 
 
Equipment:  A/C  service    station  for 
recovering, 

recycling, 

draining 

and 

charging the A/C system. 
 
External tank: Refrigerant bottle used to 
fill the internal tank. 
 
Internal  cylinder:  cylinder  for  refrigerant 
storage. 
 
Phase: Performance of a single function. 
 

| AIR-NEX 9380/9480 

Operations which require careful reading of the manual's 
instructions are highlighted with this symbol. 

This paragraph describes the safety symbols which may be 

To  make  the  reading  of  this  manual  easier,  we  have 
prepared the list of the most important technical terms used 

Cycle: Sequence of steps. 
 
Recovery:  Extraction  of  refrigerant  from 
the vehicle. 
 
Recycling: 

Cleaning 

of 

refrigerant, 

includes:  separating  out  oils,  removal  of 
non-condensable 

gas 

and 

single/multiple  pass  through  filters  to 
reduce  humidity,  acidity  and  particulate 
content of the fluid. 
 
Disposal:  disposal  of  refrigerant  for 
storage 

followed 

by 

destruction/scrapping  by  an  authorised 
waste management centre. 
 
Vacuum  cycle:  Draining  out  of  a  motor 
vehicle A/C system and separation out of 
condensed  matter  and  humidity,  using 
only the vacuum pump. 
 
Oil  charge:  Charge  of  oil  into  an  A/C 
system  to  ensure  the  correct  charge  as 
specified 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 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 refrigerant

 

3.4.1 

Precautions for refrigerant storage

 

The refrigerant removed from the A/C system must be handled with 
care to prevent or minimise the risk of mixing with other refrigerants.
This  machine  is  suitable  for  treating  R134a  or  R1234yf 
refrigerants, individually (not simultaneously).
The external cylinders used to store the refrigerants must be clearly 
marked to prevent mixing different refrigerants.
Cylinders  shall  be  free  from  oil  or  other  contaminants  and  clearly 
marked so as to identify the refrigerant contained.
 

 

ATTENTION: when handling, using and storing 
R-1234yf  refrigerant  and  dealing  with  emergency 
situations,  MAKE  SURE  to  refer  to  the  product’s  safety 
sheet. 

GET  THE  SAFETY  SHEET  FROM  YOUR  REFRIGERANT 
SUPPLIER AND FOLLOW ITS INSTRUCTIONS.
REFRIGERANT  R1234YF  IS  DEFINED  AS  FLAMMABLE 
REFRIGERANT.

 

 
 

NEX 9380/9480 | 6   en

 

rigerant  from 

Cleaning 

of 

refrigerant, 

includes:  separating  out  oils,  removal  of 

condensable 

gas 

and 

single/multiple  pass  through  filters  to 
reduce  humidity,  acidity  and  particulate 

refrigerant  for 

storage 

followed 

by 

destruction/scrapping  by  an  authorised 

Draining  out  of  a  motor 

vehicle A/C system and separation out of 
condensed  matter  and  humidity,  using 

Charge  of  oil  into  an  A/C 

system  to  ensure  the  correct  charge  as 

filling of refrigerant into the A/C 

system  in  the  amount  specified  by  the 

Cleaning phase for the 

ossible polluting substances 

Refrigerant 

stored  in  gaseous  phase,  including  air 

Guidelines for the handling of refrigerant 

Precautions for refrigerant storage 

ed from the A/C system must be handled with 

care to prevent or minimise the risk of mixing with other refrigerants. 
This  machine  is  suitable  for  treating  R134a  or  R1234yf 
refrigerants, individually (not simultaneously). 

the refrigerants must be clearly 

marked to prevent mixing different refrigerants. 
Cylinders  shall  be  free  from  oil  or  other  contaminants  and  clearly 
marked so as to identify the refrigerant contained. 

when handling, using and storing  R-134a or 

refrigerant  and  dealing  with  emergency 

to  refer  to  the  product’s  safety 

GET  THE  SAFETY  SHEET  FROM  YOUR  REFRIGERANT 
SUPPLIER AND FOLLOW ITS INSTRUCTIONS. 
REFRIGERANT  R1234YF  IS  DEFINED  AS  FLAMMABLE 

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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