MAHLE ACX380 Service Manual
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MAHLE ACX380 Service Manual

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

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Summary of Contents for MAHLE ACX380

  • Page 1 MAHLE ACX380/480 Service Manual A/C Service Equipment...

  • Page 2: Table Of Contents

    INDICATOR LIGHT ELECTRONIC BOARD ..39 Spare parts & consumables ...... 17 APPENDIX 6 – TROUBLE SHOOTING ......40 Equipment and simulator ......17 APPENDIX 7 – FAILURE LIST ACX380/480 ....41 Refrigerant fluid circuit ......17 11.1 Refrigerant fluid circuit ......17...

  • Page 3: General Instructions

    MAHLE and resources used for the drawing up of this dispersed in the environment and they must not be disposed of with manual will not be held responsible for the incorrect use of urban waste.
  • Page 4 Scrupulously follow the instructions on the equipment's display. 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.

  • Page 5: Important Information On Service Equipment Safety

    | ACX380/480 | 5 - Only operators or qualified staff instructed or Only operators or qualified staff instructed or QUICK COUPLERS CLOSING/OPENING: certified for the equipment equipment maintenance can open the equipment. The equipment . The equipment contains Opening (connect to...

  • Page 6: Symbols

    | ACX380/4850 ACX380/4850 | 6 en causing damage to objects or to the surrounding causing damage to objects or to the surrounding environment. This symbol also highlights information to environment. This symbol also highlights information to Phase: Performance of a single function.

  • Page 7: Conditions Of Refrigerant And System

    | ACX380/480 | 7 REFRIGERANT. Description of the unit 3.4.2 Conditions of refrigerant and system The condition of the refrigerant is critical to the operation of the vehicle's A/C system. Running repairs properly following failure or damage safeguards the quality of the refrigerant itself (particulates, acids and water).

  • Page 8: User Interface

    Amount of UV on the touch screen (Fig. 3, Pos. 3). dye injected The menu selection and the necessary entries are made on the touch screen (Fig. 3, Pos. 3). MAHLE provides a USB stick for ACX station to activate an additional Vacuum time database (e.g.

  • Page 9: Main Menu

    | ACX380/480 | 9 If you need to enter free text or identify a set of data, a keypad automatically appears (for example, for entering workshop data or at the end of the service cycle). Status Light (Fig. 1, Pos. 3)

  • Page 10: Technical Features

    | ACX380/4850 | 10 en pressure gauges pulse-free, 1.0 class Technical features Display Touch screen 7” TFT colours Cylinders for R134a or R1234yf Keypad Touch screen fluids Software updating Via Wi-Fi R134a or R1234yf 20 l Printer via Nexusprint cylinder capacity...

  • Page 11: Installation

    | ACX380/480 | 11 Installation REFRIGERANT SCALE SCREW RELEASE REFRIGERANT SCALE SCREW RELEASE Equipment installation 6.1.1 Unpacking The unit is transported, with the scale blocked by a locking screw to The unit is transported, with the scale blocked by a locking screw to avoid damaging the load cell.

  • Page 12: Software Update

    | ACX380/4850 ACX380/4850 | 12 en Fig. 4: Rear view (detail) Let us consider as first filling the one carried out during the initial Let us consider as first filling the one carried out during the initial Power cord connector and Power switch...

  • Page 13: Uv Dye Bottle Filling

    | ACX380/480 | 13 After filling, close the bottle and place it back in its seat. UV dye bottle filling The UV Dye is a substance made up of a yellow-green coloured fluorescent pigment, which means that, when lit by an ultraviolet lamp, it becomes fluorescent and thus visible.

  • Page 14: Setup

    To print are available two printing modes available: using the printer station MAHLE reserves the right to add new parameters to make available or, for all models, via Wi-Fi using the the equipment increasingly versatile and adaptable to printer software named NexusPrint to be installed on PC market’s needs.

  • Page 15: Service Menu

    | ACX380/480 | 15 9 Service Menu Pressures calibration (service kit) calibration (service kit) To carry out calibration the service kit (tooling set) calibration the service kit (tooling set) From the SECURED SERVICE menu, (insert the password “DEBUG”), (insert the password “DEBUG”), described at chapter 10 is required.

  • Page 16: Oob Pressures Calibration (Service Kit)

    | ACX380/4850 | 16 en Measure the pressure reached by the reference gauge and, insert the value on the screen of ACX unit when required by software and press enter OK. Subsequently the equipment will execute the vacuum, at the end of which one will be asked to check that the gauge reaches -1 bar, when requested by the guided procedure press enter OK to confirm calibration.

  • Page 17: Calibration Check

    | ACX380/480 | 17 Calibration check Oil weight calibration The refrigerant gas weight scale is calibrated with a 3 points From the SECURED SERVICE menu, (insert the password “DEBUG”), select the OIL WEIGHT CALIBRATION. procedure during manufacturing and it is possible to replace...

  • Page 18: Operational Cycles

    | ACX380/4850 | 18 en SAFETY VALVE GAS AIRTEK - VS14NPT20HNBRPED4 11.2 Operational cycles PS 20 bar R 1/4 NPT - Category IV (Dir. 2014/68/EU) For components and circuit layout ref. APPENDIX 2 – OPERATIONAL CYCLES. 11.3 Receiving tank (refrigerant cylinder) The tank is the component which determines the category of the entire equipment according to the PED directive.
  • Page 19 | ACX380/480 | 19 PS TP PS LP PS HP Fig. 22: Manifold circuit Fig. 24: Manifold with pressure sensors installed. One-way valve Fig. 23: Manifold valves © MAHLE...

  • Page 20: Nitrogen Test And Forming Gas

    | ACX380/4850 | 20 en 11.5 NITROGEN TEST and FORMING GAS LEAK TEST - MANIFOLD 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);...

  • Page 21: Suction Circuit Components

    O-ring/seal, before to apply it clean well the surfaces. 13 Electrical connections The electrical connections are described on the following APPENDIX: APPENDIX 3 – ACX380/480 - ELECTRICAL CONNECTION – LOGIC ELECTRONIC BOARD APPENDIX 4 – ACX380/480 - ELECTRICAL CONNECTION – POWER ELECTRONIC BOARD AND POWER SUPPLY APPENDIX 5 –...

  • Page 22: 14 Maintenance

    To access MAINTENANCE from the MAIN MENU, press scroll to MAINTENANCE and then select. Only for model ACX380 – “REFRIGERANT TYPE CHANGE” With this function allows the service assistance technician to change the Refrigerant Type from R134a to R1234yf with the empting and cleaning of the A/C service station and with use of a specific transformation kit.

  • Page 23: Hoses Emptying

    | ACX380/480 | 23 The LP gauge indicates the pressure inside the external tank. gauge indicates the pressure inside the external tank. 14.2 Hoses emptying After some minutes the unit will automatically end the function. automatically end the function. At the end the weight of the charged refrigerant will be displayed.

  • Page 24: Pump Oil Change

    | ACX380/4850 | 24 en For replacement, comply with the instructions outlined below: 14.8 Pump oil change disconnect the HP and LP hoses from other Required tools: systems/circuits or vehicles and close the quick couplers • 1 flat screwdriver wait the ends the hoses emptying.

  • Page 25: Replacement Of Active Oil Protection Cartridge

    | ACX380/480 | 25 14.10 Replacement of Active Oil Protection 14.12 Maintenance of printer Cartridge To change the roll of paper follow instructions below: After one year or after injecting 2 kg of New Oil or UV dye, the station will show a reminder suggesting the replacement Open the lid of the printer as shown of the cartridge.

  • Page 26: Periodic Checks

    | ACX380/4850 ACX380/4850 | 26 en 14.13 Periodic checks SUCTION UNIT - Art. 4.3 (Dir. 2014/68/EU Dir. 2014/68/EU) A/C service stations (pressure equipment set) must be A/C service stations (pressure equipment set) must be checked over regularly as provided by local legislation.

  • Page 27: Refrigerant Type Change (Only For Acx 380)

    The adaptation must be performed by a technician of an The adaptation must be performed by a technician of an Authorised MAHLE Service Centre, who will install the Authorised MAHLE Service Centre, who will install the Position the filter into the retaining clip on the unit case and Position the filter into the retaining clip on the unit case and press to attach new filter.

  • Page 28: Replacement Interventions

    | ACX380/480 | 28 Switch off the machine, remove the power supply cable and open the cover and the front panel. Replacement interventions Close tap/knob (outlet) of the tank/cylinder (where there is 15.1 Extraordinary maintenance list the hose that connect the vessel to the manifold).

  • Page 29: Replacement Of Logic Electronic Board With Display

    | ACX380/480 | 29 as reference the APPENDIX 3 – ACX380/480 - ELECTRICAL CONNECTION – LOGIC ELECTRONIC BOARD After electronic board replacement: • Switch ON the station with new Logic Electronic board, • Connect the ACX station to the WiFi when required, •...

  • Page 30: 16 Spare And Wearing Parts

    Additional spare/replacement parts are available through the Spare parts available to the user: service centers authorized by MAHLE or by its reseller. Contact service centers authorized by MAHLE or by its reseller. Contact technical support for replacement parts not listed above.

  • Page 31: Appendix 1 - Refrigerant Fluid Circuit Acx380/480

    31 | ACX380/480 | APPENDIX 1 – REFRIGERANT FLUID CIRCUIT ACX380/480...

  • Page 32: Appendix 2 - Refrigerant Fluid Circuit Acx380/480 Operational Cycles

    | ACX380/480 | 32 APPENDIX 2 – REFRIGERANT FLUID CIRCUIT ACX380/480 OPERATIONAL CYCLES Uncondensable gases...
  • Page 33 33 | ACX380/480 | Recovery cycle...
  • Page 34 | ACX380/480 | 34 Vacuum...
  • Page 35 35 | ACX380/480 | Recharge...

  • Page 36: Appendix 3 - Acx380/480 - Electrical Connection - Logic Electronic Board

    | ACX380/480 | 36 APPENDIX 3 – ACX380/480 - ELECTRICAL CONNECTION – LOGIC ELECTRONIC BOARD Item label Description Connected ( ) Unused (x) Tachometric fan connector SER I/O serial I/O interface to power board PAR I/O parallel I/O interface (not used)

  • Page 37: Appendix 4 - Acx380/480 - Electrical Connection - Power Electronic Board And Power Supply

    37 | ACX380/480 | APPENDIX 4 – ACX380/480 - ELECTRICAL CONNECTION – POWER ELECTRONIC BOARD AND POWER SUPPLY POWER ELECTRONIC BOARD POWER SUPPLY BOARD...
  • Page 38 | ACX380/480 | 38 POWER ELECTRONIC BOARD Item Label Description Connected ( ) Unused (x) OUT X Nitrogen test input OUT L2 Oil injection L2 electro-valve OUT T2 Nitrogen test output OUT A Solenoid valves couple for refrigerant gas absorbing...

  • Page 39: Appendix 5 - Acx380/480 - Electrical Connection - Status And Warning Indicator Light Electronic Board

    39 | ACX380/480 | APPENDIX 5 – ACX380/480 - ELECTRICAL CONNECTION – STATUS AND WARNING INDICATOR LIGHT ELECTRONIC BOARD Item label Description Connected ( ) Unused (x) SER I/O serial I/O interface to power board...

  • Page 40: Appendix 6 - Trouble Shooting

    | ACX380/480 ACX380/480 | 40 APPENDIX 6 – TROUBLE SHOOTING TROUBLE SHOOTING Before approach the unit wear the personal protective Before approach the unit wear the personal protective systems The responsibility for the effects on people, animals or property resulting from inspection and repair work is entirely attri...

  • Page 41: Appendix 7 - Failure List Acx380/480

    41 | ACX380/480 | APPENDIX 7 – FAILURE LIST ACX FAILURE LIST ACX380/480 Before approach the unit wear the personal protective systems Before approach the unit wear the personal protective systems The responsibility for the effects on people, animals or property resulting from inspection and repair work is entirely attri...
  • Page 42 | ACX380/480 ACX380/480 | 42 Before approach the unit wear the personal protective systems Before approach the unit wear the personal protective systems The responsibility for the effects on people, animals or property resulting from inspection and repair work is entirely attri...
  • Page 43 43 | ACX380/480 | CODE MESSAGE When it occurs Possible situations Possible solutions A039 FURTHER OIL INJECTION NOT During oil injection Insufficient vacuum level Increase the vacuum phase POSSIBLE phase time, check the A/C system tightness. A040 FURTHER UV DYE INJECTION...
  • Page 44 | ACX380/480 | 44 CODE MESSAGE When it occurs Possible situations Possible solutions A060 GAS TYPE NOT SUPPORTED During the refrigerant Analisys not possible Check with virgin refrigerant BY THE REFRIGERANT analysis phase bottle if the refrigerant gas ANALYZER identifier is working properly. If...
  • Page 45 MAHLE Aftermarket Italy S.p.A. Via Quasimodo 4/a 4 3 1 2 6 P a r m a ITALY...

This manual is also suitable for:

Acx480

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