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MAHLE ACX480 - User Manual

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MAHLE
ACX380/480
EN
Service
Manual
A/C Service Equipment

Table of Contents

Questions and Answers

Summary

Safety Conditions

Personal Safety and Definitions

Definitions of hazardous areas, exposed persons, operator classifications, and general safety.

Workplace, Electrical, and PPE Safety

Workplace safety, electrical connection, PPE, and use limitations.

Hose Connections and Coupler Operation

Precautions for hose connections and quick coupler operation.

Key Safety Devices Explained

Details on safety pressure switch, safety valve, and main switch.

Safety Device Details

Safety Pressure Switch Function

Stops compressor in case of excessive pressure.

Safety Valve Function

Opens when system pressure exceeds fixed limits.

Main Switch Function

Switches off the equipment by interrupting power supply.

Installation Procedures

Unpacking and Scale Release

Step-by-step guide for unpacking and releasing the refrigerant scale screw.

Risk of Overturning Warning

Disclaimer regarding responsibility for improper handling during unpacking.

Commissioning the Unit

Connections and Positioning

General instructions for connecting the unit to power and ensuring correct operation and placement.

Initial Setup and Updates

Initial Verification Steps

Steps for performing initial verification before first use.

Service Menu Operations

Pressure Calibration Procedure

Procedure for calibrating pressure sensors using a service kit.

Calibration Procedures

OOB Pressures Calibration

Procedure for out-of-box pressure calibration.

Gas Weight Calibration

Procedure for calibrating the gas weight scale.

Calibration Checks and Tests

Oil Weight Calibration Procedure

Procedure for calibrating the oil weight scale.

Compressor and Vacuum Pump Test

Testing the compressor and vacuum pump performance.

Nitrogen and Forming Gas Leak Tests

Nitrogen and Forming Gas Leak Test Details

Details on performing nitrogen and forming gas leak tests.

Maintenance Procedures

Refrigerant Type Change Procedure

Procedure for changing the refrigerant type.

Specific Maintenance Tasks

Self Leak Test and E³ PUMP Function

Performing internal leak tests and optimizing vacuum pump oil life.

Component Replacement: Oil and Filter

Pump Oil Change Procedure

Step-by-step instructions for changing the vacuum pump oil.

Dryer Filter Change Procedure

Procedure for replacing the dryer filter.

Cartridge Replacement and Calibration Check

Active Oil Protection Cartridge Replacement

Procedure for replacing the active oil protection cartridge.

Calibration Check Procedure

How to check the status of the gas weight scale measure.

Periodic Checks and Safety Compliance

Periodic Checks Overview

Requirements for regular checks of pressure equipment components.

Component-Specific Safety Checks

Checks for suction unit, vessel, safety valve, pressure switch, and hoses.

Other Maintenance Verification Checks

Verification of lubricants and filters replacement.

Specialized Procedures and Counters

Refrigerant Type Change (ACX 380)

Procedure for adapting the unit for R1234yf refrigerant.

White Sample Filter Replacement

Procedure for replacing the white sample filter.

Replacement Interventions

Component Replacement Precautions

General precautions before replacing components in the refrigerant circuit.

Electronic Board Replacements

Appendix 1 - Refrigerant Fluid Circuit

Appendix 2 - Refrigerant Fluid Circuit Operational Cycles

Recovery Cycle Diagram

Vacuum Cycle Diagram

Recharge Cycle Diagram

Appendix 3 - Electrical Connection: Logic Electronic Board

Appendix 4 - Electrical Connection: Power Electronic Board and Power Supply

Power Board Electrical Connections

Appendix 5 - Electrical Connection: Status and Warning Indicator Light Electronic Board

Appendix 6 - Trouble Shooting Guide

Failure List and Solutions

MAHLE ACX480 Specifications

General IconGeneral
BrandMAHLE
ModelACX480
CategoryService Equipment
LanguageEnglish

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