MAHLE ACX1280M AC Service Unit Original instructions

MAHLE ACX1280M

EN

Original instructions

AC Service Unit

en 2 | ACX1280M |

Contents

1. Symbols used 4

1.1 In the documentation 4

1.1.1 Warning notices—Structure and meaning 4

1.1.2 Symbols in this documentation

1.2 On the product

4

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2. Important notes

2.1 User group

2.2 Agreement

2.3 Obligation of contractor

2.4 Safety regulations

2.4.1 ACX1280M

2.4.2 Refrigerant identification unit

2.5 Safety devices

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4. Commissioning

4.1 Removing transportation packaging

4.2 Attaching handles

4.3 ACX1280M

4.3.1 Setting language

4.3.2 Setting date and time

4.3.3 Setting workshop data

4.3.4 Activating / deactivating printer,

4.4

4.5

4.3.5 workshop info, buzzer, operator list

Maximum service data records

Checking type of connection of external refrigerant bottle

Filling internal refrigerant bottle

5. A/C service preparation

3. Product description

3.1 Application

3.2 Scope of delivery

3.3 Description of unit

3.3.1 Selection and function keys

3.3.2 Input keys

3.3.3 Printer

3.3.4 Service doors

3.3.5 Scales for used oil and refrigerant

3.3.6 Service quick-release couplings

3.3.7 Inline filters

3.3.8 Locking caster brakes

3.3.9 Power supply cable and switch

3.4 Refrigerant identification unit

3.4.1 Delivery

3.5 Functional description

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6. Operation

6.1 Service phases

6.2 My database

6.3 Refrigerant identification unit

6.3.1 Refrigerant analysis

6.3.2 Decontamination

6.3.3 Refrigerant verification

6.4 Automatic A/C service

6.5 Manual A/C service

6.6 Automatic/manual vehicle A/C service overview

6.6.1 Recovery

6.6.2 Vacuum

6.6.3 Charging with refrigerant

6.7 Flushing after changing type of oil

6.8 Draining service hoses

6.9 Setting service parameters

6.10 Non-condensable gases

6.11 System leak test

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© MAHLE

7. Troubleshooting

7.1 ACX1280M

7.2 Refrigerant identification unit

8. Maintenance

8.1 Maintenance interval

8.2 Maintenance protocol

8.3 Calibration of scales

8.3.1 Calibrating internal refrigerant bottle

8.3.2 Calibrating used oil bottle scale

8.4 Calibration check

8.5 Taring of Scales

8.6 Replacing inline filters

8.7 Vacuum pump

8.7.1 Changing vacuum pump oil

8.7.2 Resetting oil change interval

8.8 Combo filter

8.8.1 Changing Combo-Filter

8.8.2 Resetting filter replacement interval

8.9 Software update

8.10 Replacing printer paper

8.11 Replacing white sample filter

(Refrigerant identification unit)

8.12 Resetting the circuit breaker.

8.13 System information

8.14 Service Report

8.15 Spare and wearing parts

8.15.1 ACX1280M

8.15.2 Refrigerant identification unit

9. Disposal

9.1 Disposal of electronic parts

9.2 Disposal of LCD screen

9.3 Disposal of refrigerants, UV dye, lubricants and oils

9.4 Disposal of combo filter

10. Technical data

10.1 ACX1280M

10.2 Refrigerant identification unit

10.3 Electromagnetic compatibility

11. Glossary

12. Notes

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| ACX1280M | 3 en

© MAHLE

en 4 | ACX1280M | Symbols used

1. Symbols used 2. Important notes

1.1 In the documentation

1.1.1 Warning notices—Structure and meaning

Warning notices warn of dangers to the user or people in the vicinity. Warning notices also indicate the consequences of the hazard as well as preventive action. Warning notices have the following structure:

Warning symbol

KEY WORD – Nature and source of hazard!

Consequences of hazard in the event of failure to observe action and information given.

h

Hazard prevention action and information.

Before start up, connecting and operating

MAHLE products it is absolutely essential that the Original instructions/owner’s manual and, in particular, the safety instructions are studied carefully. By doing so you can eliminate any uncertainties in handling MAHLE products and thus associated safety risks upfront; something which is in the interests of your own safety and will ultimately help avoid damage to the device.

When a MAHLE product is handed over to another person,

not only the Original instructions but also the safety instructions and information on its designated use must be handed over to the person.

The key word indicates the likelihood of occurrence and the severity of the hazard in the event of non-observance:

Key word Probability of occurrence

Severity of danger if instructions not observed

Death or severe injury

DANGER

Immediate impending

danger

WARNING

Possible impending

danger

CAUTION

Possible dangerous

situation

Death or severe injury

Minor injury

2.1 User group

The product may be used by skilled and instructed personnel only. Personnel scheduled to be trained, familiarized, instructed or to take part in a general training course may only work with the product under the supervision of an experienced person.

All work conducted on pressurized equipment may be performed by persons with sufficient knowledge and experience in the field of refrigeration, cooling systems and coolants and, also be aware of the risks involved in the use of pressurized devices.

1.1.2 Symbols in this documentation

Symbol Designation Explanation

m

Attention Warns about possible property damage.

t

1.

2.

Information Practical hints and other useful information.

Instruction consisting of several steps.

h





Multi-step operation

One-step operation

Intermediate result

Final result

Instruction consisting of one step.

An instruction produces a visible intermediate result.

There is a visible final result on completion of the instruction.

2.2 Agreement

By using the product you agree to the following regulations:

Copyright

Software and data are the property of MAHLE or its suppliers and protected against copying by copyright laws, international agreements and other national legal regulations. Copying or selling of data and software or any part thereof is impermissible and punishable; in the event of any infringements MAHLE reserves the right to proceed with criminal prosecution and to claim for damages.

1.2 On the product

m

Observe all warning notices on products and ensure they remain legible.

h

Wear protective goggles.

h

Wear protective gloves.

© MAHLE

Symbols used | ACX1280M | 5 en

Liability

All data in this program is based—where possible—on manufacturer and importer details. MAHLE does not accept liability for the correctness and completeness of software and data; liability for damage caused by faulty software and data is ruled out. Whatever the event, MAHLE liability is restricted to the amount for which the customer actually pays for this product.

This disclaimer of liability does not apply to damages caused by intent or gross negligence on the part of MAHLE.

Warranty

Any use of non-approved hardware and software will result in a modification to our product and thus to exclusion of any liability and warranty, even if the hardware or software has in the meantime been removed or deleted.

2.3 Obligation of contractor

The contractor is obliged to ensure that all measures geared towards the prevention of accidents, industrial diseases, labor-related health risks are taken and measures towards making the workplace fit for people to work in are carried out.

Basic rules

The contractor is bound to ensure that all electrical equipment and operating material is set up, modified and maintained by skilled electricians only or under the guidance and supervision of a skilled electrician in accordance with electrical engineering principles.

Furthermore, the contractor must ensure that all electrical equipment and operating material is operated in keeping with electrical engineering principles.

No changes may be made to our products. Our products may only be used in combination with original accessories and original service parts. Failing to do so, will render null and void all warranty claims.

If a piece of electrical equipment or operating material is found to be defective, i.e. it does not or no longer complies with electrical engineering principles, the contractor must ensure that the fault is rectified immediately and, in the event that imminent danger exists, also ensure that the electrical equipment or the electrical operating material is not used.

This product may only be operated using MAHLE approved operating systems. If the product is operated using an operating system other than the approved one, then our warranty obligation pursuant to our supply conditions will be rendered null and void. Furthermore, we will not be held liable for damage and consequential damage incurred through the use of a non-approved operating system.

Tests:

y The contractor must ensure that all electrical systems and equipment are tested by a qualified electrician or under the guidance of a qualified electrician to ensure they are in proper working order:

—

Before starting for the first time.

—

After modification or repair before starting for the first time.

—

At given intervals. Set intervals such as to ensure that faults that can be expected to occur are determined in good time.

y The test is to take the electrical engineering principles relating hereto into account. y

Upon request of the trade association, a test manual is to be maintained into which specific entries are made.

© MAHLE

en 6 | ACX1280M | Symbols used

2.4 Safety regulations

2.4.1 ACX1280M

Always carefully study and follow all the safety regulations before using the MAHLE product.

Avoid all skin contact with the refrigerant. The low boiling point of the refrigerant (approx.

–30 °C) can lead to frostbite. Should refrigerant come into contact with the skin, remove any moistened clothing immediately and rinse the area of skin affected with generous amounts of water.

y

Avoid all skin contact with the UV dye. Should UV dye come into contact with the skin, remove any moistened clothing immediately and rinse the area of skin affected with generous amounts of water.

y R1234yf is colorless, with weak characteristic smell and heavier than air. It may flow into repair pits. Should refrigerant escape, provide for sufficient ventilation

(particularly in repair pits) and leave the workshop.

y The ACX1280M is provided with a refrigerant identification system designed to prevent contamination with other refrigerants.

y If the refrigerant has been contaminated by being mixed with other gases, remove the contaminated refrigerant and add fresh R1234yf before using the ACX1280M for

A/C service.

y

R1234yf is not to be used in areas in which there is a danger of explosion. Fire, open flames and smoking are prohibited.

Welding and soldering are not permitted.

y The ACX1280M unit should not be exposed to excess moisture or be operated in wet areas.

y

High temperatures and UV radiation may chemically separate R1234yf. The resultant products can cause coughing and nausea.

y R1234yf is not to be mixed with other refrigerants. The mixing of refrigerants could damage the vehicle air conditioning system.

If high-voltage components or high-voltage wires are handled incorrectly, there is a risk of fatal injury from high voltage and the possible transmission of current through the body.

Never inhale refrigerant, dye and oil vapors. The vapors can irritate the eyes, nose and respiratory system. If liquid refrigerant or UV dye comes into contact with the eyes, rinse them thoroughly with water for 15 minutes. Then obtain medical attention even if no pain is felt.

y Never swallow UV dye. Should it be swallowed inadvertently, never attempt to induce vomiting. Drink generous amounts of water and obtain medical attention.

y Before connecting the ACX1280M to a vehicle air conditioning system or an external refrigerant bottle, make sure the quick-release couplings are not leaking. Only ever use external refrigerant bottles provided with safety valves and certified inline with the applicable standards.

y Before switching off the ACX1280M, make sure all charging and drainage operations have been completed. This prevents damage to the unit and reduces risk of refrigerant escaping into the environment.

Never use compressed air with R1234yf. Certain mixtures of air and R1234yf are highly flammable. Such mixtures are a potential hazard and may lead to fire or explosions and thus cause damage or injury.

y

Refrigerant extracted from a vehicle air conditioning system may be contaminated with moisture, lubricant, dirt and traces of other gases.

y

De-energizing is only to be performed by a qualified electrician, a qualified electrician for specific tasks (hybrid) or a power systems engineer.

y

Work on vehicles with high-voltage components is only ever to be performed in a safe, de-energized condition by persons with the minimum qualification "Trained to perform electrical work".

y Even after deactivating a high-voltage vehicle electrical system, the high-voltage battery may still be live.

y Operating condition cannot be established from any running noise, as the electric machine is silent when stationary.

y In gear positions "P" and "N" the engine or electric motor may start spontaneously depending on the charge of the high-voltage battery.

y Never open or damage high-voltage batteries.

y

On vehicles that have been in an accident, never touch high-voltage components or exposed high-voltage wires before deactivating the high-voltage vehicle electrical system.

y The ACX1280M must be constantly monitored when in operation. Never leave the ACX1280M unattended when in operation.

y Vehicle A/C service using the ACX1280M must be prepared and implemented such that the vehicle air conditioning system circuit does not have to be opened (for example by removing the radiator or engine).

y Position the ACX1280M on all four wheels on a flat, vibration-proof surface so that proper operation of the scales is guaranteed.

© MAHLE

Symbols used | ACX1280M | 7 en

y The ACX1280M can be secured in position by locking the caster brake.

y

The ACX1280M must always be transported in its operating position. Never lay the ACX1280M on its side, as oil could then escape from the vacuum pump or the built in compressor could be damaged.

y

There are no additional safety systems for protecting the

ACX1280M against damage resulting from natural catastrophes.

y

Never remove any components from inside the ACX1280M except for maintenance or repair purposes.

y Follow the pertinent legal regulations or directives to ensure safe handling of pressurized devices.

y We recommend calibrating the scales at least once per year. Contact customer service for calibration of the scales.

y The ACX1280M must be subjected to regular maintenance by service personnel or authorized agents to ensure the safety of the unit.

y Disconnect power before performing any maintenance or service to unit.

y Never perform any maintenance work which is not expressly recommended in this manual. Contact customer service if components have to be replaced other than in the course of maintenance work.

y

ACX1280M must be connected to a properly grounded electrical connection.

y If there is damage to the ACX1280M, terminate usage immediately and contact customer service.

y The service hoses and service quick-release couplings must be regularly checked for wear and replaced if damaged.

y The ACX1280M must be operated in an environment that will provide at least four air changes per hour.

y Observe local laws or directives as to ensure the safety of the pressurized device.

y For safety reasons it is advisable to use a residual current operated circuit breaker (rccb) with the following specifications:

2.4.2 Refrigerant identification unit

y

Inspect the outside diameter of the white sample filter element before and after each use of this unit. As soon as red spots begin to appear on any portion of the white element outside diameter, the filter requires replacement. Failure to replace the filter when so indicated may result in damage to the identification unit (out of warranty).

y

This unit requires connection of the sample fitting to the

LP side port of the source vehicle or refrigerant cylinder.

Connection of the test hose to the high, or liquid, port of the source vehicle or refrigerant bottle will result in damage to the unit (out of warranty).

y

Inspect the test hose before and after each use of the unit. Immediately replace the hose if it appears cracked, obstructed, or fouled with oil.

y Never use a test hose other than those approved for use with the Identifier.

y

Never connect the Identifier to any refrigerant source that exceeds 300 psi pressure.

Parameters

Rated voltage

Rated frequency

Rated current

Rated tripping current

Tripping switch

Specification

120 VAC ± 10 %

50/60 Hz

10 A

30 mA

C

• Avoid using an extension cord with the unit. If necessary, use a good condition (three wire grounded, #14AWG or larger) extension cord of the shortest possible length. In addtion, the current drawn by all devices connected to the wall socket must not exceed 15A total.

© MAHLE

en 8 | ACX1280M | Product description

2.5 Safety devices

Description

Air flow sensor

Pressure switch

Safety valve

Circuit Breaker

Vents

Function

The ACX1280M contains an air flow sensor which detects whether or not there is a sufficient flow of air in the housing of the

ACX1280M.

Switches the compressor off if the normal operating pressure is exceeded.

The safety valve opens if the design pressure is exceeded.

Interrupts the power supply if overcurrent is applied to the ACX1280M.

The ACX1280M is provided with vents in the bottom of the housing to ensure the exchange of air even when switched off.

3. Product description

3.1 Application

ACX1280M is suitable for vehicles with a conventional engine as well as for hybrid and electric vehicles. ACX1280M features all the functions required for vehicle A/C service.

The following functions can be implemented: y Refrigerant recovery and recharging.

y

Vacuum generation.

y Flushing.

y Refrigerant identification.

m

The ACX1280M can only be operated with R1234yf. The

ACX1280M is not to be used for service work on vehicles with air conditioning systems employing refrigerants other than R1234yf, as this will cause damage. Prior to A/C service check the type of refrigerant used in the vehicle air conditioning system.

3.2 Scope of delivery

Description

Handle

Service hose (high pressure)

Service hose (low pressure)

Quick-release coupling (high pressure)

Quick-release coupling (low pressure)

Used oil bottle

Original instructions

Quick manual

Roll of paper for printer

Adapter (external bottle)

US Acme 1/2 LH

Calibration check ball

Inline filter set (2x)

Integrated refrigerant identification unit

USB operated scan tool

USB extension cable

1)

May be included in delivery, depending on the version ordered

© MAHLE

3.3 Description of unit

Product description | ACX1280M | 9 en

Fig. 1: Front view

1 Rear handle and grip

2 Tool tray and storage

3 Display and operating unit

4 Front handle

5 ACX1280M front housing

6 Locking caster

7 Rear wheel

8 Service door

9 Vacuum pump sight glass viewing window

10 USB port

Fig. 2: Rear view

1 Service door for used oil and vacuum pump oil

2 Power supply cable inlet, circuit breaker

3 Fan

4 Kick plate

5 Spare refrigerant bottle/Flush device storage shelf

Fig. 3: Left-rear view

1. Low-side parking/flush adapter

2. High-side parking/flush adapter

3. Service hose

4. Service hose connections

5. Main switch

6. Used oil load cell and bottle

7. Vacuum pump oil fill access port

8. Service door for oil bottles and vacuum pump

© MAHLE

en 10 | ACX1280M | Product description

Keys

O







or





or





i

C

3.3.1 Selection and function keys

Name Function

OK Confirm and store

Function depends on current menu

Back

Cancel

Back one menu level or cancel

Up or down control

Right or left control

Enter Confirm and store

Delete Deletes character to left of cursor

Information Show current data

Switching between number and letter input. Current mode is shown at bottom right of screen.

Fig. 4: Display and operating unit

1 Status and warning light

2 LCD

3 Selection and function keys

4 Refrigerant identifier

5 Printer

6 Low-pressure gauge

7 Input keys

8 High-pressure gauge

Various functions are assigned to the function keys in the

ACX1280M software. The functions of the keys are defined in the menu line of the ACX1280M software.

The pressure gauges (Fig. 4, Pos. 6, 8) of the display and operating unit are used to monitor the pressure during the individual vehicle A/C service phases. The status of the various service phases during maintenance is displayed on the multicolor LCD screen (Fig. 4, Pos. 2). The necessary entries are made by way of the input keys (Fig. 4, Pos. 7) on the keypad.

The selection and function keys (Fig. 4, Pos. 3) on the keypad are used to control the operator interface menu options.

3.3.2 Input keys

The input keys can be used to enter letters, numbers and special characters in the input boxes. If a key is pressed several times in succession in the input box, all the characters which can be used for this are displayed.

The status and warning light (Fig. 4, Pos. 1) indicates the service status:

Status and warning light display color

Red light

Flashing green

Green light

Maintenance status

Error/warning

Operation in progress

Operation completed/Attention Operator

MAHLE supplies a USB stick for updating the ACX1280M software. If required, the USB stick can be inserted in the

USB socket to perform updating of the firmware/software.

t

Refer to Section 8.9 for detailed information on the software updating procedure.

© MAHLE

Product description | ACX1280M | 11 en

3.3.3 Printer

t

Service reports can be printed out.

m

Protect thermal printer paper against direct sunlight, heat,oils, greases, tanning agents and materials containing plasticizers (e.g. PVC folders).

1

To open the service door on the cover, remove the two Phillips head screws and take out the service door.

45

9897_4Nk v

2

Fig. 5: Printer

1 Cover

Fig. 7: Removing service door

3.3.4 Service doors

t

There are two service doors: One on the left side and one on the rear of the housing.

m

Never attempt to operate the ACX1280M without service doors, as this would make the working area dangerous.

The housing of the ACX1280M was designed with a built-in ventilation fan to prevent the accumulation of potentially flammable R1234yf refrigerant vapors.

t

Tools can be placed on the upper cover.

t

The service door on the side provides access to the the internal refrigerant bottle, and the filter drier.

t

The service door on the rear permits access to the Vacuum pump oil fill/drain and used oil.

Fig. 6: Opening service door on back

© MAHLE

en 12 | ACX1280M | Product description

3.3.5 Scales for used oil and refrigerant

There are various scales for checking the quantities of refrigerant and used oil.

Used oil bottle

t

To remove the used oil bottle, pull the connection (Fig. 8) upwards slightly and detach the bottle downwards.

2

1

Fig. 8: Removing used oil bottle

1 Connection

Symbol Description

Used oil bottle

3.3.6 Service quick-release couplings

t

The service quick-release couplings are connected to the service connections of the vehicle air conditioning system during A/C service. When not in use, the service quickrelease couplings can be connected to the parking/flush couplers. t

To remove the service quick-release couplings from the parking/flush coupler, (Fig. 9, Pos. 2), press the coupling slightly towards the connection and carefully pull the knurled section back to unfasten it from the coupler.

459897_14Nkv

Fig. 9: Unfastening quick-release coupling

1 Parking couplers/Flush adapter

2 Service quick-release coupling

To connect the coupling, position the coupling on the parking coupler/Flush adapter, pull back the knurled section of the coupling element and press carefully onto the connection.

© MAHLE

Product description | ACX1280M | 13 en

3.3.7 Inline filters

The service hoses are connected to the ACX1280M by way of the inline filters. The inline filters prevent the ingress of fine particles into the internal hydraulic circuit of the ACX1280M.

3.4 Refrigerant identification unit

The refrigerant identification unit permits precise determination of the type of refrigerant as to prevent cross contamination by other refrigerants.

m

Only after successful identification of refrigerant, service hoses may be connected to the vehicle. t

The refrigerant identification unit is incorporated into the service procedure and thus always to be used for A/C service.

1 Adapter for connection

2 Filter element

3 Adapter for hoses

4 Sealing ring

3.4.1 Delivery

3.3.8 Locking caster brakes

Rolling of the ACX1280M can be prevented by locking the caster brakes (Fig. 1, Pos. 6) at the rear wheels.

3.3.9 Power supply cable and switch

The power supply cable is connected to the back of the unit.

When not in operation, the power supply cable can be coiled up and set on the spare tank storage area on the back of the

ACX1280M.

The ACX1280M is switched on by toggling the rocker switch to the On position.

Fig. 10: Refrigerant identification unit—delivery

1 Refrigerant identification unit

2 White sample filter

© MAHLE

en 14 | ACX1280M | Product description

3.5 Functional description

The refrigerant recovered from the air conditioning system passes through the combo filter to remove suspended particles and moisture.

The purpose of the vacuum pump is to generate a vacuum in the air conditioning system which removes excess moisture and to detect possible leaks in the vehicle air conditioning system.

Used oil separated from the vehicle refrigerant recovered drains into the used oil bottle.

Oil removed from the vehicle A/C system compressor during the recovery process should be manually injected into the A/C system prior to recharging the system.

The vehicle air conditioning system is partly filled with UV dye to facilitate the detection of leaks in the event of damage to the vehicle air conditioning system.

The refrigerant in the internal refrigerant bottle is used for filling the vehicle air conditioning system.

The purging unit for the non-condensable gases, consisting of a temperature sensor, pressure sensor, coil and orifice, always takes effect when the internal refrigerant bottle pressure is higher than the saturation pressure.

Refrigerant identification is a menu-driven process implemented by a refrigerant identification unit which is integrated into the ACX1280M.

© MAHLE

Commissioning | ACX1280M | 15 en

4. Commissioning

t

All the operations described in Section 4 must be performed prior to first A/C service.

4.1 Removing transportation packaging

t

When removing the packaging, use care to ensure there is no damage caused to the ACX1280M unit or any of the included accessories.

4.2 Attaching handles

1. Remove plastic bubble wrap from handle.

2. Remove bolt from rear handle mounting hole (both sides of ACX1280M unit).

3. Rotate handle upwards and over top of the handle mounting spacers.

1. Remove the cardboard box.

2. Remove screw from metal strap at front of unit.

3. Remove screws from straps at rear of unit.

4. Remove the straps from the slots at rear of unit.

5. Using a wrench, remove the nut from the bolt at front of unit to remove metal strap.

6. Remove cardboard blocks from under ACX1280M unit.

7. Remove ACX1280M from pallet.

Fig. 11: Setting up handle

t

Do not unplug any electrical connections and only have internal components opened and repaired by trained customer service personnel.

4. Insert the bolt on each side through handle and the spacer and tighten.

t

Contact customer service in the event of any transportation damage (e.g. oil leakage).

Fig. 12: Insert bolt and tighten

5. Tighten the bolt at the front side of the handle to ensure it does not come loose at a later time.

© MAHLE

en 16 | ACX1280M | Commissioning

4.3 ACX1280M

m

The ACX1280M is designed for 120 VAC ± 10 %, 50/60

Hz. Follow the information on the ACX1280M rating plate.

4.3.3 Setting workshop data

1. Select "Settings >> General settings >> Workshop

data".

t

A maximum of 30 characters can be entered.

1. Set the ACX1280M on a flat, vibration-proof surface.

2. Actuate the caster brake to stop the ACX1280M from rolling.

3. Connect the power supply cable to the power supply.

4. Switch on the main switch.

@

The self-test starts automatically. The menu appears following successful completion of the self-test.

@

The fan is switched on.

t

The fan runs while the ACX1280M is switched on.

t

Delete values previously entered with <C>.

2. Alter values with input keys.

3. Store entries and return with O.

4.3.4 Activating / deactivating printer, workshop info, buzzer, operator list

1. Select "Settings >> General settings >> System

settings".

2. Select the menu item printer, workshop info, buzzer or operator list with .

3. Activate/deactivate with .

4. Store entries and return with O.

Activation

Operator list

Workshop info

Buzzer

Printer

Description

An operator must be selected or a new operator entered prior to each A/C service.

Workshop data are printed out together with the service print-out

An audible alarm additionally sounds in the event of error messages.

Printer ready for operation.

4.3.5 Maximum service data records

t

The ACX1280M stores the service data sets. The factory limit value setting for the maximum number of data sets is 400.

4.3.1 Setting language

1. Select "Settings >> General settings >> Language".

2. Select language with .

3. Store entries with O.

4.3.2 Setting date and time

1. Select "Settings >> General settings >> Date and

time".

2. Alter values with input keys.

3. Move to next value with   .

4. Store entries and return with O.

t

If the number of stored data sets exceeds the limit, service can no longer be performed. Further service work is only possible after transferring the data sets to a USB stick. Password to resetting the data records is

"7123493".

1. Select "Settings >> General settings >>

Maximum service data records".

2. Alter values with input keys.

3. Store entries and return with O.

© MAHLE

Commissioning | ACX1280M | 17 en

4.4 Checking type of connection of external refrigerant bottle

4.5 Filling internal refrigerant bottle

t m

Follow the instructions below for filling the internal refrigerant bottle.

—

Refrigerant bottle with one valve:

Always turn the external refrigerant bottle upside down when filling the internal refrigerant bottle.

—

Refrigerant bottle with two valves:

Use the adapter set to connect the service hose (LP) to the external refrigerant bottle. In doing so, turn the external refrigerant bottle such that the connections are facing upwards.

The internal refrigerant bottle should only be replaced if it is severely damaged. The internal refrigerant bottle must always be filled using an external refrigerant bottle.

Warning – Risk of frostbite from escaping refrigerant

Refrigerant causes severe frostbite on the skin.

h Check the service hoses for damage.

h

Firmly connect the service quick-release couplings to the service hoses.

h Wear protective goggles.

h

Wear protective gloves.

t

Before the ACX1280M can be used, the internal refrigerant bottle must be filled with liquid refrigerant. Use only R1234yf refrigerant.

t

A menu-driven refrigerant check is performed before filling the internal refrigerant bottle.

m

During filling, the external refrigerant bottle must be firmly positioned and the operator must ensure that the service hoses are safely routed to avoid the danger of the external refrigerant bottle falling over.

t

The refrigerant can be obtained from your gas supplier. It can be stored normally and transported in bottles with connection fittings.

t

To ensure a reliable procedure, it is advisable to use the optimum quantity of refrigerant. The optimum quantity of refrigerant for the ACX1280M is 4 kg – 9.5 kg.

t

An inadequate quantity may make efficient filling of the vehicle air conditioning system impossible. Also, if there is an insufficient quantity, the ACX1280M may not be able to operate efficiently. In the event of an excessive quantity, there may not be sufficient space for the refrigerant recovered from the vehicle air conditioning system. m

Generally speaking, the actual quantity of refrigerant added exceeds the set quantity by approx. 200g as there is no refrigerant in the internal refrigerant circuit. Add 200g to the set quantity when filling with refrigerant for the first time.

1. Select "Maintenance >> Internal bottle fill".

2. Follow the menu prompting.

t

The current pressure inside the external refrigerant bottle is indicated on the low-pressure gauge.

t

Any amount of refrigerant between 100g and 10500g can be added.

m

Do not interrupt the automatic filling process prior to automatic termination by the ACX1280M.

t

Press the i key to check the quantity of refrigerant in the internal refrigerant bottle upon completion of the filling operation.

© MAHLE

en 18 | ACX1280M | A/C service preparation

5. A/C service preparation

t

Follow the vehicle manufacturer's recommendations for

A/C service on vehicles with a low-pressure connection only.

Warning – Risk of burns from hot engine components

Contact with hot engine components will cause severe burns.

h Allow the engine to cool down.

h

Wear protective goggles.

h

Wear protective gloves.

Warning – Risk of frostbite from escaping refrigerant

Refrigerant causes severe frostbite on the skin.

h Check the service hoses for damage.

h

Firmly connect the service quick-release couplings to the service hoses.

h

Wear protective goggles.

h

Wear protective gloves.

m

Service hoses must be contructed of the proper materials and have the lengths as supplied with the unit. Hoses must have shutoff devices (quick-release couplers) at the connection point to the A/C to minimize the introduction of air into the ACX1280M and to minimize the amount of refrigerant released while disconnecting the hoses.

t

Follow the manufacturer's instructions for the corresponding vehicle before performing A/C service.

m

The ACX1280M is only to be operated with R1234yf refrigerant. Check which refrigerant is used for the vehicle before performing A/C service.

m

The ACX1280M cannot be used for air conditioning systems repaired using a chemical sealant. These sealants may cause serious damage to the ACX1280M if they are present. Detection devices are available to check for chemical sealants. Non compliance will void the warranty.

Perform the following preparatory work prior to vehicle A/C service: m

Never attempt to close the valves of the internal refrigerant bottle while the ACX1280M is in operation.

m

Only new lubricant, as specified by the system manufacturer, shall be installed in the MAC system. Lubricant removed from the system and/or equipment shall be disposed of in accordance with the applicable federal, state, and local procedures and regulations.

m

Inspect hoses for signs of damage prior to performing A/C service. Use of damaged hoses will result in the loss of refrigerant and the possibility of refrigerant contamination.

1. Set the ACX1280M on a flat, vibration-proof surface.

2. Actuate the caster brake to stop the unit from rolling.

3. Connect the power supply cable to the power supply.

4. Switch on the main switch.

© MAHLE

Operation | ACX1280M | 19 en

6. Operation

6.3 Refrigerant identification unit

m

Before connecting service hoses proceed as follows:

1. Connect OBDII scanner (and extension cable if needed) to the right side of the ACX1280M. Then connect to OBD

Diagnostic Link Connector (DLC) of vehicle. Follow on screen instructions.

2. Perform refrigerant identification (see chapter 6.3).

6.3.1 Refrigerant analysis

m

Oil contamination will damage the refrigerant identification unit! If the refrigerant sample is supplied to the unit from the recycling equipment directly, it must be protected from oil that comes from vehicles or accumulate in service hoses!

6.1 Service phases

y Recovery phase: Refrigerant is extracted from the vehicle, cleaned and routed into the internal refrigerant bottle.

y

Vacuum phase: A vacuum is generated in the vehicle air conditioning system and the system is checked for leaks.

y

Recharge phase:

—

Refrigerant: The vehicle air conditioning system is filled with a specified amount of R1234yf refrigerant.

m

The operator must periodically examine the test hose and white sample filter for oil contamination and stop immediately if any oil is observed!

t

The gas pressure should be between 1.7 –16 bar. Accurate gas analysis can be achieved with less than 1.7 bar but additional time must be provided. In this case start the flow of gas and then wait for 20 seconds before instructing the refrigerant identification unit to test the gas.

6.2 My database

t

Perform the following steps to add a new vehicle to the operator-defined (direct parameter input) database or to make changes or deletions.

1. Switch on the ACX1280M.

2. Select "Vehicle A/C service >> Refrigerant identi-

fication".

3. Follow the menu prompting of ACX1280M.

1. Select "Settings >> My database".

2. Select vehicle with .

3. Press  .

4. Alter values with input keys.

5. Store entries and return with O.

t

Getting message "Sample not OK", check for contamination of the test hose, then repeat the procedure up to 2 times. t

Getting message "Sample not OK" for three times, a refrigerant verification must be performed.

© MAHLE

en 20 | ACX1280M | Operation

6.3.2 Decontamination

t

Perform the following steps to remove contaminated refrigerant from the service hoses and couplers.

1. Select “Maintenance >> Maintenance >> Decon-

tamination” or process continues automatically after

3 failed identifications.

2. Switch off the ACX1280M unit.

3. Disconnect power cord from outlet.

4. Move unit outside.

5. Connect High and Low side couplers to the Parking/

Flush adapter and open valves to equalize pressure.

6. Close Low side coupler and remove from Parking/

Flush adapter.

7. Connect Low side tank adapter to low side coupler.

8. Pointing adapter away from unit and person, slowly open valve until low pressure gauge shows 0 bar(g).

9. Close low side coupler and remove Low side tank adapter.

10. Connect low side coupler to the Parking/Flush adapter and open valve. Pressure on HP gauge should go down.

11. Close low side coupler and disconnect from parking/ flush adapter

12. Repeat steps 5-11 until both gauges read 0 bar(g).

t

This process may need to be repeated a number of times depending on the amount of pressure inside the hoses.

13. After all pressure has been released, connect low side coupler to Parking/flush adapter and open valve.

14. Connect power to the unit.

15. Switch on the ACX1280M unit.

16. Follow the menu prompting.

t If getting message "High Pressure in System" which appears after decontamination process begins, pressure has not been relieved from hoses properly. Repeat above steps starting at 5 to remove error above.

t Following the Decontamination routine, a Refrigerant verification should be performed.

Fig. 13: High low flushing adapter / Parking coupler

6.3.3 Refrigerant verification

t

Connect refrigerant identification unit to an external

R1234yf bottle with pure R1234yf.

1. Select "Vehicle A/C Service >> Refrigerant Identifica-

tion.".

2. Follow the menu prompting.

t

Contact customer service after not passed analysis for 3 times.

© MAHLE

Operation | ACX1280M | 21 en

6.4 Automatic A/C service 6.5 Manual A/C service

m

Before connecting service hoses proceed as follows:

1. Connect OBDII scanner (and extension cable if needed) to the right side of the ACX1280M. Then connect to OBD

Diagnostic Link Connector (DLC) of vehicle. Follow on screen instructions.

2. Follow on screen instructions to complete refrigerant identification (see chapter 6.3).

m

Before connecting service hoses proceed as follows:

1. Connect OBDII scanner (and extension cable if needed) to the right side of the ACX1280M. Then connect to OBD

Diagnostic Link Connector (DLC) of vehicle. Follow on screen instructions.

2. Follow on screen instructions to complete refrigerant identification (see chapter 6.3).

m

Only after successful identification of refrigerant, service hoses may begin on the vehicle.

m

Only after successful identification of refrigerant, service hoses may be connected to the vehicle. t

The contamination of the service hoses on the ACX1280M unit can only be removed by following the decontamination process (see Chapter 6.3.2).

t

The contamination of the service hoses on the ACX1280M unit can only be removed by following the decontamination process (see Chapter 6.3.2).

t

The contamination of the ACX1280M internal bottle can only be removed by a service provider at additional cost.

m

The contamination of the ACX1280M internal bottle can only be removed by a service provider at additional cost.

t

The service parameters (recharge quantity) can be found in the owner's manual or the vehicle repair manual.

t

The service parameters (recharge quantity) can be found in the owner's manual or the vehicle repair manual.

t

The refrigerant identification unit is incorporated into the service procedure and required to be used for A/C service.

t

The refrigerant identification unit is incorporated into the service procedure and required to be used for A/C service.

1. Select "Vehicle A/C service >> Automatic A/C serv-

ice".

2. Select

—

Direct parameter input (alteration of service parameters) or

—

Select last 10 vehicles or

—

My database.

3. Follow the menu prompting.

1. Select "Vehicle A/C service >> Manual A/C service".

2. Follow the menu prompting.

t

All service phases can be implemented manually with the

ACX1280M.

t

R1234yf can only be added to an air conditioning system in which there is a vacuum. The vacuum phase must therefore be implemented before filling with R1234yf.

© MAHLE

en 22 | ACX1280M | Operation

6.6

Phases

Automatic/manual vehicle A/C service overview

Automatic mode

Manual mode

6.7 Flushing after changing type of oil

m

When servicing a vehicle, the type of oil in the vehicle's A/C system should be noted to prevent a cross-contamination inside the ACX1280M. If a PAG system is serviced and another vehicle with a POE system is to be serviced next, a flush routine must be performed to prevent a crosscontamination of the oils.

Checking of air conditioner pressure x

Extraction of refrigerant

Separation of oil from refrigerant

Formation of vacuum

Maintenance of vacuum x

Addition of refrigerant

(test quantity 15% of total recharge quantity)

Extraction of refrigerant

(test quantity 15% of total recharge quantity)

Implementation of leak test x x x

Pressure increase test

Drainage of oil into used oil bottle

Pressure build-up x

Recharging refrigerant x

Tab. 1: Automatic/manual mode overview x = is implemented

x x x x x x x x x x

–

–

– x x

–

–

–

–

–

–

–

– x

–

– x x x x

–

– x x

– x x

–

– x x m

If the ACX1280M is not flushed, the internal hydraulic system and the vehicle air conditioning system could be damaged as a result of cross-contamination. MAHLE cannot accept liability for any such damage.

t

Enter the parameters for vacuum time and refrigerant quantity.

1. Select "Vehicle A/C service >> A/C system flushing

>> Short flushing".

2. Follow the menu prompting.

t

The Short Flushing procedure is used to clear out the

ACX1280M hoses when changing oil types. The Extended

Flushing procedure is used to perform liquid refrigerant flushing on A/C system components.

6.6.1 Recovery

6.8 Draining service hoses

1. Select "Maintenance >> Hose drain".

2. Follow the menu prompting.

t

The pressure in the vehicle air conditioning system is checked prior to the recovery phase. The vacuum phase commences automatically if the air conditioning system is depressurized (empty).

6.6.2 Vacuum

6.9 Setting service parameters

1. Select "Settings >> A/C service parameters".

2. Alter the parameters with the input keys.

t

The parameters can be pre-set at the start of the corresponding service phase in manual and automatic

A/C service.

t

A vacuum is generated and maintained for at least

5 minutes.

Service parameters

t

Make sure recovery has been performed before generating the vacuum.

Automatic vehicle

A/C service

Manual vehicle A/C service

6.6.3 Charging with refrigerant

t

Service phases: Vacuum, Vacuum hold, 15% of total charge test fill, leak test, extraction of test fill, pressure increase test, and final charging.

t

If pressure is detected in the vehicle air conditioning system during charging, recovery must be performed in order to continue.

Vacuum time

Vacuum hold time

R1234yf refrigerant

Tab. 2: Setting parameters

x x x

–

–

– x

–

–

–

– x m

Used oil must be disposed of in accordance with local regulations!

© MAHLE

6.10 Non-condensable gases

t

Purging takes place automatically in the ACX1280M on the basis of a pressure and temperature algorithm. The purged non-condensable gases are routed to the built-in ventilation fan and removed from the ACX1280M.

6.11 System leak test

t

The ACX1280M performs a system leak test to check that none of the components carrying refrigerant are leaking.

After 68kg (150lbs) of refrigerant has been processed, after combo filter replacement or after 60 hours of vacuum time, the operator is requested to perform a "system leak test".

The operator can conduct a "system leak test" at any time on completion of a process phase.

t

The system leak test takes roughly 30 minutes.

h Select "Maintenance >> System leak test".

”

The leak test process is started.

The following action must be taken if the system leak test is unsuccessful:

1. Check the service hoses and filter connections for leaks.

2. The valves of the service quick-release couplings must be closed.

3. Repeat the system leak test.

t

Contact customer service if the system leak test is again unsuccessful.

A/C service preparation | ACX1280M | 23 en

© MAHLE

en 24 | ACX1280M | Troubleshooting

7. Troubleshooting

t

Please contact customer service if any of the actions suggested in this Section cannot be implemented.

7.1 ACX1280M

Error code Messages

100A

1001

1002

1003

1004

RECOVERY:

Leak detected.

RECOVERY:

Service timeout.

RECOVERY:

High pressure shutdown.

RECOVERY:

Used oil bottle full.

RECOVERY:

Internal refrigerant cylinder full.

1005

1009

2001

2002

2003

5001

5002

5003

RECOVERY:

Used oil bottle not found.

RECOVERY:

Low pressure detected in vehicle.

VACUUM CREATION:

High pressure detected in vehicle.

VACUUM CREATION:

Leak detected

VACUUM CREATION:

Service timeout

RECHARGE:

Service timeout.

RECHARGE:

Insufficient refrigerant quantity.

RECHARGE:

Charging unsuccessful.

5004

5005

5006

Action

• Check A/C system and unit for leaks.

• Check inline filters.

• Contact customer service.

• Empty used oil bottle.

• Reset scales.

• Weight limit reached. Reduce quantity of refrigerant in internal refrigerant cylinder.

• Check scales.

• Check used oil bottle connection.

• Vacuum creation.

• Perform recovery process.

• Use a UV lamp to search for leaks in the vehicle air conditioning system.

• Check for clogging of service hoses.

• Check scales.

• Check for clogging of ACX1280M.

• Check whether the valves of the quick-release couplings are open.

• Perform Internal Cylinder Fill process.

• Optimum quantity of R1234yf is 4 kg – 9.5 kg.

• Check whether the valves of the service quick-release couplings are open.

• Check for clogging of service hoses.

• Charge the internal refrigerant cylinder.

• Check whether the valves on the internal refrigerant cylinder are open.

• Check for clogging of service hoses.

• Weight limit reached. Reduce quantity of refrigerant in internal refrigerant cylinder.

• Check scales.

• Perform recovery process.

9102

9201

9300

9600

A101

A103

A104

A105

RECHARGE:

High pressure shutdown.

RECHARGE:

Refrigerant cylinder full.

RECHARGE:

High pressure in vehicle. Perform recovery.

FACTORY SETTING:

Not completed.

SYSTEM ERROR:

No USB detected.

SELF-TEST UNSUCCESSFUL:

View detail.

PRINTER:

No paper in printer.

INTERNAL BOTTLE FILL:

Time elapsed.

INTERNAL BOTTLE FILL:

Refrigerant cylinder full.

INTERNAL BOTTLE FILL:

High pressure shutdown.

INTERNAL BOTTLE FILL:

Low pressure.

• Complete all vehicle information.

• Check whether USB stick is connected to USB connection.

• View details.

• Take corrective action to rectify error.

• Check for paper in printer.

• Check for clogging of ACX1280M.

• Weight limit reached. Reduce quantity of refrigerant in internal refrigerant cylinder.

• Check scales.

• Check whether the valves on the internal refrigerant cylinder are open.

• Check for clogging of service hoses.

• Check whether the valves on the external refrigerant cylinder are open.

• Check for clogging of service hoses.

© MAHLE

Error code Messages

A202

A203

A204

A205

SHORT FLUSHING:

Service timeout.

SHORT FLUSHING:

Insufficient refrigerant quantity.

SHORT FLUSHING:

Leak detected.

SHORT FLUSHING:

High pressure shutdown.

A206

A208

SHORT FLUSHING:

High pressure in vehicle.

SHORT FLUSHING:

Refrigerant cylinder full.

A209

A302

A303

A304

A305

A306

A307

A308

SHORT FLUSHING:

Charging unsuccessful.

EXTENDED FLUSHING:

Service timeout.

EXTENDED FLUSHING:

Insufficient refrigerant quantity.

EXTENDED FLUSHING:

Leak detected.

EXTENDED FLUSHING:

Deactivate high pressure.

EXTENDED FLUSHING:

High pressure in vehicle.

EXTENDED FLUSHING:

Used oil bottle full.

EXTENDED FLUSHING:

Refrigerant cylinder full.

A309

A701

A702

EXTENDED FLUSHING:

Charging unsuccessful.

CALIBRATION CHECK:

Weight not attached.

CALIBRATION CHECK:

Failed.

Troubleshooting | ACX1280M | 25 en

Action

• Check for clogging of ACX1280M.

• Charge the internal refrigerant cylinder.

• Repair vehicle air conditioning system or part being flushed.

• Check low-pressure valve at internal refrigerant cylinder.

• Check for clogging of service hoses.

• Perform recovery if pressure is above 0.6 bar.

• Generate vacuum if pressure is 0.6 bar.

• Weight limit reached.

• Reduce quantity of refrigerant in internal refrigerant cylinder.

• Check scales

• Check for clogging of service hoses.

• Check for clogging of ACX1280M.

• Charge the internal refrigerant cylinder.

• Check for leak at part just being flushed.

• Check for clogging of ACX1280M.

• Pressure is above 0.6 bar during extraction.

• Perform recovery.

• Empty used oil bottle.

• Reset scales.

• Weight limit reached. Reduce quantity of refrigerant in internal refrigerant cylinder.

• Check scales.

• Replace scales.

• Check for clogging of service hoses.

• Attach calibrating weight.

• Perform calibration again.

© MAHLE

D003

D004

D005

D006

D007

D008

en 26 | ACX1280M | Troubleshooting

7.2 Refrigerant identification unit

Error code Messages

D000 Sample NOK

D001

D002

Air or gas reading was unstable

Air or gas reading was excessively high

Air calibration resulted in low output

Unit is beyond temperature range

Excessive air or little or no sample flow

Internal error

User abort

Communication error

Action

• Move the unit away from sources of EMF or RFI such as radio transmitters and arc welders

• Repeat refrigerant analysis

• Move the unit away from sources of EMF or RFI such as radio transmitters and arc welders

• Repeat refrigerant analysis

• Prevent refrigerant from flowing into the unit through the sample inlet during air calibration

• Allow any refrigerant in the atmosphere to dissipate before performing air calibration

• Repeat refrigerant analysis

• Move the unit to an area where the ambient temperature is within the specified operating range

• Repeat refrigerant analysis

• Repeat refrigerant analysis

• Verify the coupler valve is open

• Repeat refrigerant analysis

• Verify the sample filter is not plugged with debris or oil.

• Replace brass sample filter

• Retry Operation. Contact tech-support if problem persists

• Repeat refrigerant analysis

• Check USB connection

© MAHLE

Maintenance | ACX1280M | 27 en

8. Maintenance

8.1 Maintenance interval

Description

Calibration of scales

Vacuum pump oil replacement and system leak test

Inline filter replacement

Combo filter replacement and system leak test

System leak test

White sample filter of refrigerant identification unit

Period

1 x per year

After 60 hours of service

Refer to filter drier

After 68kg (150lbs) of refrigerant processed

As required

As soon as red spots begin to appear on any portion of the white element

8.3.2 Calibrating used oil bottle scale

1. Select "Maintenance >> Maintenance >> Calibration

>> Scale Calibration".

2. Enter the password "227".

3. Select the used oil scale.

4. Remove the bottle.

5. Select O.

6. Attach the calibrating weight to the scales selected.

7. Enter the weight.

8. Select O.

”

Calibration completed.

8.4 Calibration check

t

Only internal refrigerant bottle.

m

Never perform any maintenance work which is not exm pressly recommended in this Section.

Contact customer service if components have to be replaced other than in the course of maintenance work.

8.2 Maintenance protocol

t

The ACX1280M stores various protocols which can be printed out.

—

Last 3 system service reports.

—

Self-test report

—

Refrigerant report

—

Error report

—

Operating hour meter t

Getting message "calibration check failed", calibration check should be performed again and if it still fails a second time, a calibration of the internal refrigerant bottle scale should be performed.

8.5 Taring of Scales

t

Only applies to used oil bottle scale.

1. Select "Maintenance >> Service report".

2. Select protocol with  and .

3. Print protocol.

8.3 Calibration of scales

8.3.1 Calibrating internal refrigerant bottle

1. Select "Maintenance >> Maintenance >> Calibration

>> Tare reset".

2. Select the scale.

3. Attach an empty bottle.

4. Select O.

”

Tare reset completed.

t

The internal refrigerant bottle is calibrated at the factory.

1. Select "Maintenance >> Maintenance >> Calibration

>> Calibration check".

2. Select the scale.

3. Attach the calibration check ball.

4. Select O.

”

Calibration check completed.

1. Select "Maintenance >> Maintenance >> Calibration

>> Scale calibration".

2. Enter the password "227".

3. Select the scale.

4. Select O.

5. Enter the weight.

6. Attach the calibrating weight.

7. Select O.

”

Calibration completed.

8. Select O.

9. Remove the calibrating weight.

© MAHLE

en 28 | ACX1280M | Maintenance

8.6 Replacing inline filters 8.7 Vacuum pump

t

The inline filters must always be changed when replacing the filter drier.

8.7.1 Changing vacuum pump oil

The inline filters consist of a filter element fitted in the hose adapter.

Attention – Risk of burns from hot surfaces

Contact with the hot surface of the vacuum pump will cause severe burns.

h

Allow the vacuum pump to cool down.

h Wear protective gloves.

1 Adapter for connection

2 Filter element

3 Adapter for hoses

4 Sealing ring t

The vacuum pump oil must be changed after 60 hours of operation. The message "Change vacuum pump oil" appears on the screen when the vacuum pump oil needs changing.

1. Drain the service hoses.

2. Disconnect the service hoses from the inline filters.

t

Use the vacuum pump oil specified by MAHLE

(part number 360 82946 00).

   

4598

97_45

Nkv

Fig. 14: Removing adapter

3. Remove the filter element.

4. Install the new filter element.

1. Place a container under the drain on back side of unit.

2. Open rear service door and pull plug to expose oil fill port.

3. Open the drain plug and filler plug of the vacuum pump.

4. Drain all the oil.

5. Close the drain plug.

6. Pour vacuum pump oil into oil fill port until oil level is somewhere between the min and max lines.

7. Turn on unit and start a vacuum process.

8. Check oil level .

t

Oil level is accurate when level is midway between full and empty.

”

Oil change completed.

8.7.2 Resetting oil change interval

1. Select "Maintenance >> Service Report >> Statistics

>> Vac. pump oil life".

t

The time since the last oil change is displayed.

2. Enter the password "227".

3. Store entries and return with O.

”

Oil change interval reset.

          

Fig. 15: Installing filter element

t

Make sure the sealing ring is correctly positioned at the adapter and not damaged. Replace the sealing ring if it is damaged.

5. Screw the inline filter onto the adapter.

6. Attach the service hoses to the adapter.

© MAHLE

Maintenance | ACX1280M | 29 en

8.8 Combo filter

8.8.1 Changing Combo-Filter

Warning – Risk of frostbite from escaping refrigerant

Refrigerant causes severe frostbite on the skin.

h

Check the service hoses for damage.

h Firmly connect the service quick-release couplings to the service hoses.

h

Wear protective goggles.

h

Wear protective gloves.

R-1234yf only

1 t

Unit operation is disabled at the end of the filter service life. Each filter is marked with a unique code. This code must be entered when replacing the filter. It is not possible to operate the ACX1280M if the same code is re-used. It is advisable to keep a supply of filters in stock to avoid downtimes due to the unit being disabled.

t

The ACX1280M is disabled once 68kg (150lbs) of R1234yf refrigerant have passed through the filter. A new filter must be installed and its unique code entered in the ACX1280M before vehicle A/C service can be performed.

Fig. 18: Location of PIN number on filter

1 Code

1. Drain the service hoses.

2. Remove the right service door.

3. Loosen the filter, using a 1-3/8" (35 mm) wrench.

4. Remove the filter.

t

Make sure the old sealing rings are removed before securing the new filter.

t

The message "Filter replacement due" appears once 57kg

(125lbs) of refrigerant have passed through the filter. As soon as this warning message is displayed, contact customer service to order a new filter. The contact data can be found on the rating plate.

5. Insert a new filter.

6. Tighten the filter to 74 ft-lbs (100 N-m).

7. Secure the service door.

m

Take care not to damage any hoses or electrical connections when changing the filter.

m

Pay attention to correct positioning of the two O-rings when fitting a new filter!

m

Never re-use an old filter.

8.8.2 Resetting filter replacement interval

1. Select "Maintenance >> Service Report >>

Statistics >> Filter Drier Life".

2. Enter the 16-position PIN number of the new filter.

3. Store entries and return with O.

”

The leak test process is started.

Fig. 16: O-Rings

Fig. 17: Replacing filter

1. Combo filter

© MAHLE

en 30 | ACX1280M | Maintenance

8.9

t

The firmware (software) can be updated by way of a USB stick.

t

Software update

The scales must be recalibrated after a firmware update.

8.11 Replacing white sample filter

(Refrigerant identification unit)

m

The need to replace the white sample filter may indicate oil contamination in the test hose. Replace the test hose if oil entrapment is found.

1. While powering on the ACX1280M unit, press and hold the

"8" key. Release key when the display shows "Firmware

Update" in the lower left corner.

2. When the Firmware update screen loads, it will ask the user to "Please insert Update Disk."

3. Insert USB disk into lower right hand corner of the control panel. After a few moments, the screen will change and instruct the user to press the "" key to update the unit.

4. Once user presses the "" key, the screen will have a status bar that appears at the bottom as the software loads.

This process can take serveral minutes.

5. After completion the unit will confirm the update has completed. At this time, remove the USB drive and turn off power to the unit.

6. The next time the unit is turned on, it should display the new software version in the lower left corner of the screen.

1. Switch off the ACX1280M unit.

2. Remove existing filter by pulling it straight out of the retaining clip.

3. Discard the used filter.

t

Align the arrow on the filter with the arrow on the unit.

8.10 Replacing printer paper

m

Avoid excessive force as not to damage the lever.

Fig. 19: Installing printer paper

1. Pull the printer lever until the cover is released.

2. Change the roll of paper.

3. Close the cover.

4. Position the filter into its retaining clip on the unit case.

5. Remove the 4 screws that attach the plastic tool tray.

6. Remove the 2 screws that attach the front display unit.

7. Carefully open the front display. NOTE: This step may require operator to loosen the 2 locking-nuts at the pivot point to be able to open the display.

8. Once unit is open, inspect clear hose coming from back side of identifier down to solenoid assembly mounted on the center panel.

9. Replace if necessary.

10. Fold display down and install 2 screws to front plastic.

11. Tighten locknuts at pivot point if they were loosened.

12. Reinstall tool tray and the 4 screws.

8.12 Resetting the circuit breaker.

1. Switch off the ACX1280M and unplug from receptacle.

2. Allow unit to sit for a minute.

3. Look above fan on back of unit for the white button

4. Press white circuit breaker button back in to reset.

5. Plug in unit and turn back on.

© MAHLE

Disposal | ACX1280M | 31 en

8.13 System information

9. Disposal

t

The following items of system information can be displayed when pressing the i key.

Display

PSA

PSV

PST

Refrigerant

Used oil

Tank-Temp.

Amb.-Temp.

Description

Pressure sensor/accumulator

Pressure sensor/vacuum (service hoses)

Pressure sensor/internal refrigerant bottle

Quantity in internal refrigerant bottle

Quantity in used oil bottle

Temperature/internal refrigerant bottle

Ambient temperature

8.14 Service Report

9.1 Disposal of electronic parts

This product is subject to the European directive 2002/96/EC (WEEE).

Old electrical and electronic devices, including cables, accessories and batteries, must be disposed of separately from household refuse.

h

Please make use of the return and collection systems operating in your region.

h

Proper disposal of old devices can help to avoid environmental pollution and health risks.

t

The ACX1280M unit tracks the quantity of refrigerant processed and requests a reset after January 1 of each calendar year. To perform this reset, the password required is "73738".

8.15 Spare and wearing parts

9.2 Disposal of LCD screen

Please dispose of the LCD screen in accordance with the local regulations governing the disposal of hazardous waste.

8.15.1 ACX1280M

9.3 Disposal of refrigerants, UV dye, lubricants and oils

Refrigerants which can no longer be used must be returned to the gas supplier for disposal.

The lubricants and oils removed from air conditioning systems must be returned to official collection points. The

UV dye must always be disposed of in accordance with the local regulations governing the disposal of hazardous waste.

Description Order number

Replacement combo filter

Vacuum pump oil

Roll of paper for printer

Service hose (HP)

Service hose (LP)

Quick-release coupling (HP)

Quick-release coupling (LP)

Used oil bottle

Service Kit (vacuum pump oil, o-rings, inline filter, ID-filter)

360 82739 00

360 82946 00

360 82947 00

360 82948 00

360 82949 00

360 82950 00

360 82951 00

360 82741 00

360 82740 00

Operation manual

Quick reference guide

035 82254 00

560 80755 00

Adapter (external bottle)

US ACME 0,5" 360 82953 00

1 kg calibrating weight for used oil calibration 360 82735 00

4 kg calibrating weight for internal ref. bottle 360 82734 00

Calibration check ball

Inline filter set (10 x)

360 82744 00

360 82605 00

Dust cover (accessory item)

Leak detector R1234yf (accessory item)

Safety goggles (accessory item)

026 80687 00

026 80635 00

360 82956 00

Protective gloves (accessory item)

Sealant Detection Kit (accessory item)

360 82957 00

360 81733 00

9.4 Disposal of combo filter

Dispose of the filter via official collection points or in accordance with the local regulations.

8.15.2 Refrigerant identification unit

Description

Refrigerant identification unit

White sample filter

Order number

360 82944 00

360 82958 00

© MAHLE

en 32 | ACX1280M | Glossary

10. Technical data

10.1 ACX1280M

Feature

Dimensions H x W x D

Weight

Operating voltage

Frequency

Workplace emission sound pressure level (as per EN ISO 11204)

Refrigerant

Pressure sensor

Pressure sensor

Pressure sensor

Low-pressure gauge

High-pressure gauge

Capacity of internal refrigerant bottle

Maximum system pressure PS

Pspec

Power

Operating temperature

Optimum R1234yf filling weight for operation

Value/Range

1016 x 580 x 840 mm

110 kg

120 VAC ± 10 %

50/60 Hz

< 70 dB(A)

R1234yf

0 bar

0 bar – 34.5 bar

0 bar – 10.3 bar

-1 bar – 16 bar

± 1 % of final value

-1 bar – 40 bar

±1 % of final value

10.5 kg

20 bar

18 bar

900 W

10°C – 50°C

4 kg – 9.5 kg t

The ACX1280M conforms to the low voltage directive (LVD).

10.2 Refrigerant identification unit

Feature

Refrigerant

Measurement accuracy

Sensor

Operating temperature

Value/Range

R1234yf

98.5 % ± 0.5 %

Optical (infrared)

10°C – 50°C

10.3 Electromagnetic compatibility

This product complies with the standards EN 61000-6-2 and EN 61000-6-4.

11. Glossary

y

Recovery phase: The refrigerant is extracted from the vehicle air conditioning system, cleaned and routed into the internal bottle of the ACX1280M. The refrigerant oil collected in the process is drained into the used oil bottle at the ACX1280M.

y

Vacuum phase: A vacuum is generated in the vehicle air conditioning system. Measurement of the drop in pressure begins as soon as the vacuum has been generated.

y Charging phase: A certain quantity of refrigerant is added to the vehicle air conditioning system.

© MAHLE

12. Notes

Notes | ACX1280M | 33 en

© MAHLE

en 34 | ACX1280M | Notes

© MAHLE

Notes | ACX1280M | 35 en

© MAHLE

MAHLE Aftermarket Inc.

10 Innovation Drive

York, PA 17402

USA

717-840-0678

www.servicesolutions.mahle.com