MAHLE ACX150, ACX250 User Manual
EN | 1 | ACX150/250 | CONTENTS
1 CONTENTS
1 CONTENTS 1
2 General instructions 3
2.1 General notes 3
2.2 General instructions 3
2.3 Manufacturer identification 3
3 Safety conditions 3
3.1 Personal safety information 3
3.1.1 Definitions 3
3.1.2 Personal safety
information 4
3.2 Important information on
service equipment safety 7
3.3 Safety devices 7
4 Layout of the manual 7
4.1 Use of the manual 7
4.2 Symbols 8
4.2.1 Safety 8
4.3 Glossary 8
4.4 Guidelines for the handling of
refrigerant 9
4.4.1 Precautions for
refrigerant storage 9
4.4.2 Conditions of refrigerant
and system 10
4.4.3 Recycling capacity 10
5 Product description 10
5.1 Application 10
5.2 Scope of delivery 10
5.3 Description of the unit 10
5.4 User interface 11
5.4.1 Main menu 12
5.5 E³ connect quick couplers 13
6 Technical features 14
7 Installation 15
7.1 Equipment installation 15
7.1.1 Unpacking ACX150/250
15
REFRIGERANT SCALE SCREW
RELEASE 16
8 Commissioning 16
8.1 Connections 16
8.1.1 Positioning and
connection 17
8.2 Initial verification 17
8.3 New oil bottle filling 18
8.4 UV dye bottle filling 19
9 Setup 19
10 A/C system charge 20
10.1 Preliminary operations 20
10.2 Non-condensable gas
discharge 21
10.3 Quick mode and zero
tolerance charge mode 22
11 Automatic cycle 22
11.1 Automatic cycle data loading
22
11.2 Automatic cycle data setting 23
12 Manual cycle 24
12.1 Recovery 24
12.2 Vacuum 24
12.3 Charge 24
12.4 Flushing (with optional
accessories) 25
12.5 Hoses drain 25
13 Special test 25
13.1 AC performance test 25
13.2 Refrigerant clean 26
14 Maintenance 26
14.1 Report exporting 26
14.2 Internal cylinder fill 26
14.3 Self leak test 27
14.4 Cylinder refrigerant view 27
14.5 Air purge 27
14.6 Pressures zero 27
14.7 Counters 28
14.8 E³ pump - pump oil change 28
14.9 Dryer filter replacement 29
14.10 System info 30
14.11 System update 30
11.1.1 Database 22
11.1.2 Last cycle 22
11.1.3 My database 23
11.1.4 Direct input 23
11.2.1 Electric Compressor
Function 23
14.8.1 Oil pump visual check 29
© MAHLE
14.12
Maintenance of printer
31
14.13 Periodic checks 31
14.14 Refrigerant type
replacement 32
15 Disposal 32
15.1 A/c service unit disposal 32
15.2 Recycled materials disposal 32
15.3 Packaging disposal 32
16 Spare parts 32
EN | 2 | ACX150/250 | CONTENTS
© MAHLE
EN | 3 | ACX150/250 | General instructions
2 General
instructions
2.1 General notes
All rights reserved.
This manual may not be reproduced, in
part or entirely, either in printed or digital
form.
It may be printed out solely for use by the
user and operators of the equipment to
which it refers.
MAHLE and resources used for the
drawing up of this manual will not be held
responsible for the incorrect use of the
manual while they guarantee that
information in the manual have been duly
checked.
The product can be subject to changes
and improvements. MAHLE reserves the
right to change without notice the
information contained in the manual.
Authorised MAHLE Centre, in
accordance with the practice described
in Chapter 12 of this manual.
This equipment is intended solely for use
by professionally trained operators
familiar with the basics of refrigeration,
refrigeration systems, refrigerants and the
hazards associated with pressurised
equipment.
Careful reading of the present manual by
the owners, the users and the operators
is required for a correct and safe use of
the tool.
The user shall not be entitled to open the
product since maintenance operations
are reserved to the authorised service
centre.
2.3 Manufacturer
2.2 General instructions
Pressure equipment undergoes checks
before commissioning and periodical
checks during operation, in compliance
with rules and law provisions in force in
the country where the tool is used.
The operator is responsible for operating
the equipment in conformity with local
legislation.
The equipment is designed for
recovering and recycling
R1234yf/R134a refrigerant fluid from
automotive A/C plant.
The equipment is intended to be used
by automotive and similar repair and
service workshops.
The switch between the two refrigerant
types, from R134a to R1234yf, can only
be performed by a technician of an
3 Safety conditions
3.1 Personal safety
3.1.1 Definitions
DANGEROUS AREAS:
Any area within or close to the equipment
implying risk for the safety and health of
exposed persons.
EXPOSED PERSON:
Any person completely or partially
standing in a dangerous area.
identification
The ACX equipment is manufactured by:
MAHLE Aftermarket GmbH
Service Solutions Europe
Pragstr. 26 - 46, 70376 Stuttgart,
Germany
Phone: +49 711 501-14003
information
© MAHLE
EN | 4 | ACX150/250 | Safety conditions
OPERATOR:
The person/s charged with operating the
machine for its intended purpose.
CLASSIFICATION OF OPERATORS
The operator can be classified according
to two main categories, which, in some
cases, refer to one single person:
The operator charged with the
equipment operation has the duty to:
o Start up and monitor the
machine's automatic cycle;
o Carry out simple setting
operations;
o Remove the causes of
equipment stop not implying
breakings of members but
simple operating anomalies.
Maintenance technician a technician
trained by an authorised MAHLE
centre, capable of working on the
machine’s mechanical and electrical
components with its guards open to
make adjustments and to service and
repair it.
USER
Body or person legally responsible for the
equipment.
3.1.2 Personal safety information
The MAHLE ACX 150/250 A/C service
station is particularly simple and reliable
due to its adjustments and functions.
When used correctly it presents no
hazard for the operator, provided he
observes the following general safety
instructions and that the service station is
regularly serviced (incorrect
maintenance/use compromise the
equipment's safety). Before operating the
service station for the first time, read
these instructions carefully. If any part of
the instructions is unclear, contact your
reseller or MAHLE.
This service station may be used by only
one equipment operator, familiar with A/C
and refrigeration systems and the hazards
associated with refrigerants and high
pressure equipment.
WORKPLACE: The station can work with
both R134a and R1234yf (the two
refrigerants cannot be stored within the
station at the same time).
Refrigerant R1234yf is defined as
flammable refrigerant.
Nonetheless, although refrigerant R134a
is not defined as flammable, mixtures of
air or oxygen with R134a may become
flammable under very particular
conditions.
The equipment must be operated
outdoor or in a well-ventilated location
(at least 1 air change per hour). The
workshop has to be equipped with
ventilation systems able to ensure air
change in every environment area or
carry out periodical ventilation by
opening the areas.
Use the equipment away from heat
sources or hot surfaces. The equipment
must not be used in explosion risk
environments (potentially explosive
atmospheres). Before using it, put the
equipment on a levelled plane and secure
position, blocking it with suitable wheel
stops.
Do not expose the tool to direct sunrays,
heat sources, rain and jets of water. Do
not smoke near the equipment and during
operations (keep at a distance of at least
1 m).
© MAHLE
EN | 5 | ACX150/250 | Safety conditions
The work area must be monitored by the
operator while the equipment is operating.
ATTENTION: R134a and/or R1234yf
refrigerant fumes/gases are heavier than
air and can gather on the floor or inside
cavities/holes and cause choke by
reducing the oxygen available for
breathing.
At high temperatures, the refrigerant
breaks down releasing toxic and
aggressive substances, harmful for the
operator and the environment.) Avoid
inhaling the system coolants and oils.
Exposure can irritate eyes and the
respiratory tract.
ELECTRICAL CONNECTION: Connect
the power cord solely to a mains supply
which conforms to the ratings on the
machine's nameplate (mounted on its
side). Make sure the mains socket is
grounded.
Maximum impedance allowed in the point
of connection to the mains shall comply
with standard EN 61000-3-11. Starting
currents can cause short voltage drops,
which may affect other equipments under
unfavourable conditions. If impedance in
the point of connection to the mains is
not compliant, this may lead to
interference so please consult the
electrical power network operator before
connecting the equipment.
Never use the service station with a
defective power cord or a different one
from that supplied with the machine. If
damaged, immediately have it replaced
with 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 bypass the safety
equipment and settings.
Do not leave the machine powered up
when not in use; shut off the power
supply before leaving the equipment
unused for a long time. Do not forget that
the tool (pressure tool) must always be
protected.
REFRIGERANTS AND LUBRICANTS PERSONAL SAFETY EQUIPMENT AND
PRECAUTIONS: The refrigerants and the
pressure cylinders have to be handled
with care, otherwise there will be possible
health risks.
The operator must wear safety glasses,
gloves and protective clothing suitable to
the work. Contact with the refrigerant can
cause blindness (eyes) and other physical
damages (freezing) to the operator. Avoid
contact with the skin; the refrigerant's low
boiling point (approx. –26 °C for R134a
and approx. -30 °C for R1234yf) can
cause freezing burns.
Further information about safety can be
obtained from the safety sheets of
lubricant and refrigerant producers.
Do not inhale refrigerant or oil vapour.
Keep away from the vent valves and
ventilation coupling, especially when noncondensable gas is being vented.
Never direct the quick couplings (taps)
towards your face or other persons or
animals.
© MAHLE
EN | 6 | ACX150/250 | Safety conditions
OTHER PROHIBITIONS AND USE
LIMITATIONS: Only use pure R134a or
R1234yf refrigerants, refrain from using
on vehicles containing other types of
refrigerants or mixtures of the two
refrigerants or other refrigerants.
Mixture with other types of refrigerant
produces serious damage to the
conditioning and cooling systems. Mixed
refrigerants have to be disposed of
according to the current regulations.
Never use ACX equipment with systems
containing compressed air; mixtures of
R134a or R1234yf with air or oxygen may
be potentially flammable.
Do not modify calibration of safety
devices. Do not remove seals of safety
valves and of control systems. Do not use
external tanks or other storage containers
that are not type-approved or without
safety valves.
Make sure the equipment's aeration and
ventilation ports are not obstructed or
covered while the equipment is operating.
HOSE CONNECTIONS: Hoses may
contain pressurised refrigerant. Before
changing the service couplers, check the
respective pressures in the hoses
(pressure gauge).
Before connection to a car A/C system, to
an external tank/cylinder, check that the
quick couplers are closed (unscrewed HP
and LP valves).
Scrupulously follow the instructions on
the equipment's display.
QUICK COUPLERS
CLOSING/OPENING:
Opening (connect to
the vehicle):
clockwise
Closing (detach from
the vehicle):
counter clockwise
MAINTENANCE/GENERAL CLEANING:
The equipment has to be serviced at the
intervals indicated by the equipment itself.
The service station maintenance has to
be performed according to the
procedures described in this manual and
to the current safety regulations.
Use only MAHLE original parts.
When the equipment requires the drier
filter and the vacuum pump oil to be
changed, you have to be careful in the
replacement.
A/C service station maintenance can be
carried out exclusively by a trained
operator or by a service man of a MAHLE
certified seller.
Do not use chemical agents for the
service station cleaning as they could
attack the material or the surface.
STOP FOR LONG PERIOD: Store the
equipment in a safe place, disconnected
from the mains, away from excessive
temperatures, humidity and the risk of
damaging impact.
Contact the Technical Service to run a
safety shutdown of the equipment, and if
© MAHLE
EN | 7 | ACX150/250 | Layout of the manual
scrapping the unit, to drain and recycle
the R134a or R1234yf refrigerant as
required by local legislation.
To resume operation, repeat the
installation (there is no need to register
the unit anew on the website) and run the
commissioning trials and regular
operational checks as required by local
legislation.
3.2 Important information
on service equipment
safety
When using the equipment, the following
operations are not allowed as they might
cause, under certain circumstances,
danger for persons and cause permanent
damage to the equipment itself.
- Do not remove or make
unreadable labels, signs
and/or dangers signs placed
on the equipment and in the
area nearby.
- Do not disable the unit's
safety equipment.
- The electrical system to
which the service equipment
is connected must be
configured as provided by
local legislation.
- Only operators or qualified
staff instructed or certified for
the equipment maintenance
can open the equipment. The
equipment contains parts
which can cause
electrocution: shut off power
to the equipment before
servicing/repairing it.
3.3 Safety devices
ACX 150/250 is equipped with the
following safety devices:
SAFETY PRESSURE SWITCH:
It stops the compressor in case
of excessive pressure.
SAFETY VALVE: The safety
valve opens when the pressure
inside the system reaches a
level higher than the fixed limits.
MAIN SWITCH: Switches the
equipment off by interrupting
the power supply. It is advisable
to pull the power cord plug out
of the mains socket in any case
before starting maintenance
work.
ANY TAMPERING WITH THE
ABOVE-MENTIONED SAFETY
DEVICES IS PROHIBITED.
Failure to observe any of the above
safety instructions voids the
equipment's warranty.
4 Layout of the
manual
4.1 Use of the manual
This manual is an integral part
of the equipment and must be
kept in the equipment's
immediate vicinity by the
purchaser
This manual shall accompany
the equipment in case this is
passed on to a new user.
© MAHLE
The content of this manual has
been drawn up in compliance
with the guide lines of the UNI
standard 10893:2000.
Diffusion, modification or use of
this manual for own aims is
forbidden.
The manual uses symbols which
call the reader's attention to
specific points to facilitate its
use.
It includes all technical,
operating, shutdown,
maintenance, spare parts and
safety information.
In case of doubts on the correct
interpretation of the instructions,
please contact our technical
service to obtain the required
clarifications.
Operations which are
potentially hazardous for the
operator are highlighted with
this symbol.
Such operations can cause
serious injury.
Operations requiring special
attention are highlighted with
this symbol.
Such operations shall be
carried out correctly to avoid
causing damage to objects or
to the surrounding
environment. This symbol also
highlights information to which
special attention must be paid.
Operations which require
careful reading of the manual's
instructions are highlighted
with this symbol.
EN | 8 | ACX150/250 | Layout of the manual
4.2 Symbols
This paragraph describes the safety
symbols which may be posted on the
service equipment.
4.2.1 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
4.3 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-
© MAHLE
EN | 9 | ACX150/250 | Layout of the manual
Tetrafluoroethane
A/C system: air conditioning system.
Equipment:
ACX 150/250
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.
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.
4.4 Guidelines for the
4.4.1 Precautions for refrigerant
Phase: Performance of a single function.
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
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.
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.
handling of refrigerant
storage
ATTENTION: when handling,
using and storing R-134a or R1234yf 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.
© MAHLE
4.4.2 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).
4.4.3 Recycling capacity
The service equipment's filtering systems
must be replaced regularly (see
maintenance messages) to ensure
effective recycling.
EN | 10 | ACX150/250 | Product description
5 Product
description
5.1 Application
ACX150/250 is suitable for vehicles with a
conventional engine. ACX150/250
features all the functions required for
vehicle A/C service.
The following functions can be
implemented:
Refrigerant recovery and
recharging.
Vacuum generation.
Flushing.
5.2 Scope of delivery
Description
Service hose (high pressure)
Service hose (low pressure)
Quick-release coupling (high pressure)
Quick-release coupling (low pressure)
New oil bottle (2pcs)
UV dye bottle
Used oil bottle
Original instructions
Adapter for external bottle
connection
Hose Flushing Adapter
(built-in)
Safety goggles
Safety gloves
Dust cover
5.3 Description of the unit
Fig.1: Left-Front view
1
Rear handle and grip
2
Tool tray and storage
3
Display and operating unit
4
ACX150/250 front housing
5
Locking caster
6
Rear wheel
7
New oil bottle
8
UV dye bottle
9
Used oil bottle
10
Low-side parking
11
High-side parking
12
Service hose
© MAHLE
EN | 11 | ACX150/250 | Product description
DO NOT USE THE UNIT
UNLESS THE CHARGING
HOSES (HP – LP) ARE
CORRECTLY CONNECTED
1
2
Fig. 2: Rear view (detail)
1
Fan
2
Vents
1
2
3
Fig. 3: Right-front view (detail)
1
Power cord connector and
Power switch
2
USB type B (Device port to PC)
3
USB type A (Host port to USB
Memory Stick)
The USB type-A connector
can only be used with USB
2.0 portable memory devices
with Mass storage service for
reports export and station
update, or for connection to
MAHLE refrigerant identifier.
Do not connect other types
of devices, such as USB
keyboards or other units.
Fig. 4: Display and operating unit
1
High-pressure gauge
2
Low-pressure gauge
3
LCD Display with Touch screen
4
Printer
The pressure gauges (Fig. 4, Pos. 1, 2)
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. 3).
The menu selection and the necessary
entries are made by way of the touch
screen (Fig. 4, Pos. 3) integrated in the
LCD display. MAHLE supplies a USB
stick for updating the ACX150/250
software. If required, the USB stick can
be inserted in the USB type A socket
(Fig. 3, Pos. 4) to perform updating of
the firmware/software.
5.4 User interface
All settings, controls and service
functions are available on the touch
screen display. It also displays the service
equipment’s status, the progress of A/C
system service and any alarms and error
messages.
© MAHLE
The touch screen is the basic operator
interface and can be operated with the
fingers.
When a button is pressed, a beep sounds.
The following functions keys are available:
To move up in the
menu options
To move down in
the menu options
Scroll bar to
move in the menu
options
Arrows to
decrease or
increase the data
value
To enter in the
data changing or
switching the
data to next
option
To return to the
previous page
To save the
programmed
cycle in a
personal memory
To confirm and to
go head
To begin the
cycle
To answer NO to
the displayed
question
To answer YES to
the displayed
question
To interrupt the
operation in
progress
EN | 12 | ACX150/250 | Product description
To select a function in the menu press the
text name of the function, the selection
occurs when the finger is released, the
selected entry is pointed out with a
different colour (from grey to blue) and
the menu screen page changes.
If there are descriptions that need more
space on the screen page, for example
the manual cycle list (see the screen page
below), or in case of setup, it is possible
to display the different entries by moving
the scroll bar to the right side. For this
reason, it is necessary to touch the blue
point on the scroll bar and slide up or
down with the finger.
Lift the finger when you are on the
desired position.
By touching the arrows, the menu moves
one line up or down depending on
whether it is touched on the arrow up or
on arrow down.
If you need to enter free text or identify a
set of data, a keypad automatically
appears (for example, for entering
workshop data (if the printer is present) or
at the end of the service cycle).
If this key
switch to the symbols keyboard.
is active, it is possible to
5.4.1 Main menu
The Main menu of the graphical user
interface allow to select the following
functions:
Automatic cycle
Manual cycle
Special tests
Setup
Maintenance
Service
Each function will be described in the
next chapters.
© MAHLE
EN | 13 | ACX150/250 | Product description
5.5 E³ connect quick
couplers
E³ CONNECT is the INTELLIGENT
COUPLER, that with the suitable
automated procedure in the software
enables to:
reduce the non condensable gas
formation inside the cylinder ;
avoid the refrigerant dispersion
in the air during the
disconnection (puff effect);
check possible SCHRADER
valve leaks before disconnection.
To connect the coupling, position the
coupling on the parking coupler, pull
back the knurled section of the
coupling element and press carefully
onto the connection.
© MAHLE
6 Technical features
Cylinders for R134a or R1234yf
fluids
R134a or R1234yf
cylinder capacity
Maximum
operating
pressure (PS)
PED category
(Dir.97/23/EC)
Weight of
refrigerant content
Safety valve
Type AIRTEK -
Calibration
pressure
PED category
(Dir.97/23/EC)
Containers for oil and detection dye
Recovered PAG
oil container
New PAG oil
container
UV detection dye
container capacity
Pneumatic circuit
Vacuum pump
flow rate
Vacuum level 0.02 mbar
Vacuum pump oil
life
Refrigerant
recovery
compressor cubic
capacity
20 l
20 bar
III
Scale
VS14NPT20HN
BRPED4 20bar
R 1/4 NPT
20 bar
IV
250 ml
250 ml, with OIL
CARE valve
250 ml, with OIL
CARE valve
170 l/min double
stage
60h – extensible
to max 1000 h
with Pump
Monitoring
System
procedure
14 cc
EN | 14 | ACX150/250 | Technical features
Drier filter Every 150Kg of
refrigerant
recovered
Non condensable
gas discharge
Automatic, with
solenoid valve
HP and LP taps Automatic
Safety pressure switch
Type 13/18bar
1/4SAE
Trip pressure 18 bar
PED category
IV
(Dir.97/23/EC)
Pneumatic fittings
Net length of
4,5 m
external HP and
LP hoses
HP and LP
pressure gauges
Analog 80 mm,
pulse-free, 1.0
class
Display Graphic 4,3”
TFT WideScreen
480x272, 65536
colours
Keypad Touch screen
Software updating USB type-A with
USB 2.0 key
USB type-B with
direct
connection to
PC.
Printer (optional) Thermal, 24
columns
Functions and features
Recovered oil
measurement
Automatic
weighing, 1 g
res., 5 g acc.
New oil automatic
charge
With automatic
scale, 1 g res.,
5g acc.
UV dye automatic
Timed
charge
Electric
compressor
With integrated
flushing system
function
© MAHLE
EN | 15 | ACX150/250 | Installation
Flushing “Regular”
function
(standard)
High intensity
flushing
available with
external
accessory
(option)
Database Autodata,
complete
electronic (cars
and industrial
vehicles only)
AC Performance
Test
Recovered oil
measurement
Sound level < 70 dB (A)
Battery type for
internal Real time
clock
Overall dimensions
WxDxH 1050 x 655 x
Loadless weight about 87 kg
Power supply
Frequency 50 Hz
Voltage 230 V ~
Power 800 W
Protection Thermal
Installation
category
Environmental conditions
Operating
temperature
Humidity 10-90% R.H.
Ambient pressure 75 kPa until 106
Manual and
automatic
Automatic
weighing, 1 g
res., 5 g acc.
Lithium CR-
2032 3V
180mAh 3g.
850 mm
10-50°C
(non
condensing)
II
kPa
7 Installation
7.1 Equipment installation
7.1.1 Unpacking ACX150/250
The manufacturer disclaims all
responsibility for damage to objects
and/or persons resulting from the
equipment being wrongly removed from
the pallet, or from the operation being
made by unsuitable personnel, with
RISK OF OVERTURNING
© MAHLE
improper means/protections and
without complying with the existing
laws on manual handling of loads and
with the operations described in this
manual.
Cut the strap and remove the carton.
Cut the straps securing the unit to the
pallet.
Remove the equipment from the
pallet (2 operators required)
EN | 16 | ACX150/250 | Commissioning
REFRIGERANT SCALE SCREW
RELEASE
Lift both front
wheels by
levering with the
handle and on
rear wheels (this
way the operators
must not lift the
full weight of the
unit)
Keep the pallet, carton and scratch
protection film for use when returning the
unit. The unit rolls on wheels; the two
smaller wheels can be locked.
ACX150/250 is supplied with the
accumulation tank empty. This prevents
problems in shipping the unit.
Slowly lower
the unit from the
pallet by means
of the rear wheels
The tool is transported, with the scale
blocked by a locking screw to avoid the
load cell damage. The scales locking
screw is placed on the equipment
bottom/right side (see the box shown
above) and is formed by a bolt. For
commissioning, unscrew the screws.
8 Commissioning
8.1 Connections
The unit has to be positioned on a
horizontal surface to ensure the correct
operation.
The unit has to be connected to the
electric mains following instructions on
the identification plate of the unit applied
next to the main switch, mainly as to
applicable voltage and power.
© MAHLE
EN | 17 | ACX150/250 | Commissioning
8.1.1 Positioning and connection
HANDLING: During handling, the
minimum 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 good rate of
change of air. The unit must be
located at least 10 cm from any
potential obstacles to its internal
ventilation. Keep the unit away
from rain and excessive humidity
as they can irreparably damage it.
In addition, the equipment must
never be directly exposed to the
sunrays or to excessive dust.
INSTALLATION: the unit must be
installed by a specialised
technician in scrupulous
observance of in accordance with
electrical engineering principles.
The use of the equipment in
explosive atmosphere is
forbidden.
CONNECTIONS: since the unit is
connected to the main power
supply, it must be properly
grounded with its power plug
GND pin. Failure to ground the
unit can damage it and
constitutes a risk of fatal injury to
the operator. Position the unit so
that the power plug is easy for the
operator to access.
Power mains
connection
Vehicle A/C system
connections
ATTENTION: Leave the quick
coupling taps closed when the
unit is not in use and at the end of
vehicle service operations.
8.2 Initial verification
Execute the following actions in sequence
by following the display guided procedure
and the illustrations on the screen of the
equipment:
Refrigerant weight check
Oil weight check
First tank filling
It is possible to interrupt the initial check
and print a report with the equipment
printer in which the checking status is
reported. The equipment cannot operate
in automatic mode until all the steps of
the initial check have been completed.
CAREFULLY ABIDE BY
THE FOLLOWING
INSTRUCTIONS TO
AVOID DANGER TO
PERSONS, THE
DISCHARGE OF
REFRIGERANT IN THE
ATMOSPHERE
© MAHLE
Let us consider as first filling the one
carried out during the initial check with
internal tank of the equipment free of
refrigerant and containing air.
Set the quantity of refrigerant to fill (at
least 3 kg) and follow the guided
procedure shown on the display.
Check that the equipment hoses are not
connected and positioned in the hose
winder. Start the procedure that initially
implies the creation of vacuum in the
internal tank. This phase will take 15
minutes and will act on the whole
equipment.
Only when the message appears asking
to connect the charge tank, connect the
HP quick coupler (colour red) of the unit
to an external refrigerant tank using the
supplied adaptor.
When the message occurs open the
coupler by turning the knob clockwise.
Open the valve on the external tank.
Just right before reaching the planned
quantity of refrigerant, the unit will stop
and ask the user to close the external
refrigerant tank. Then, the device will
continue the recovery from the hoses and
ends when these are empty. Hence, it is
necessary to open the HP quick-coupler
and disconnect it from the external tank.
Thanks to the E³ CONNECT function, the
refrigerant - usually kept between the
cylinder fitting and the hose quick-coupler
until the end of the process - will not be
released in the environment.
There may be two types of source tanks:
with plunger and without plunger.
Tanks with 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
down to transfer the liquid refrigerant.
EN | 18 | ACX150/250 | Commissioning
The LP gauge indicates the pressure
inside the external tank.
After some minutes the unit will
automatically end the function.
At the end the weight of the charged
refrigerant will be displayed.
8.3 New oil bottle filling
To fill the new oil bottle (Fig.1 Pos. 7) 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.
Fill the bottle by paying special attention
to the “oil care” valve.
This valve is made of a silicon polymer
membrane; it compensates pressure
variations within the bottle and stops
humid air infeed inside thus preserving
the new oil inside.
After filling, close the bottle and place it
back in its seat.
© MAHLE
EN | 19 | ACX150/250 | Setup
8.4 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.
The UV dye can therefore be used to
detect leaks of a small entity inside the
auto vehicle A/C system.
To fill the UV dye bottle (Fig.1 Pos. 6) 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.
Fill the bottle by paying special attention
to the “oil care” valve.
This valve is made of a silicon polymer
membrane; it compensates pressure
variations within the bottle and stops
humid air infeed inside thus preserving
the new oil inside.
After filling, close the bottle and place it
back in its seat.
9 Setup
From the SETUP menu it is possible to
select parameters and activations before
starting cycle:
ELECTRIC COMPRESSOR FUNCTION
by selecting this entry, one may
change the type of Oil to inject into
the A/C system.
E³ CONNECT
by selecting this entry, you can
enable the E³ CONNECT function
(the E³ CONNECT quick coupler
must be present on the car).
CHARGE MODE
by selecting this entry, one may
decide whether to enable use of the
Quick Mode or Zero Tolerance
charge method
AC PERFORMANCE TEST
by selecting this entry, one can
enable or disable the AC
PERFORMANCE TEST.
REFRIGERANT CLEAN
by selecting this entry, one may
decide whether or not to enable the
refrigerant clean function, which
enables an additional recycling,
within the station itself, started in
automatic when it is switched on but
not in use. This function ensures a
higher level of purity of the recycled
refrigerant to the advantage of the
service quality.
RECOVERED GAS AND OIL PRINTING
selecting this entry, you can choose
whether you want to enable
displaying and printing of the
recovered gas quantity. Setting
available only with printer installed.
REPORTS SAVING MODE
by selecting this entry, you can save
the reports of the performed charges
(automatic cycle or Reg. 842/2006).
© MAHLE
REPORT DATA
select what data you would like to
include in the saved and printed
report: -license plate, -km, -client’s
name, -technician’s name
HOSES LENGTH
by selecting this entry, it will be
possible to change the length of the
charge hoses.
UNIT OF MEASURE
selecting this entry, you can modify
the pressure unit of measurement
(switching from Bar to PSI)
CLOCK ADJUSTMENT
by selecting this entry, date and time
of the station may be changed.
GARAGE DATA
by selecting this entry, one can enter
the garage data to be printed on the
end of cycle report.
LANGUAGE
by selecting this entry, any language
present in the database may be set.
In case you choose a language with
unintelligible characters. Switch off
the equipment , keep pressed the
touch screen and switch on the
equipment in the meanwhile, you will
be directed to the language setting
menu.
RIGHT / LEFT-HAND DRIVE
It allows setting the database for
operations on A/C systems of
vehicles with right-hand or left-hand
drive and return the exact value of
gas and oil to be injected.
EN | 20 | ACX150/250 | A/C system charge
STARTUP SCREEN
By selecting this entry, you can
decide whether the startup screen of
the unit will be the databank page or
the main menu page.
DATABASE ACTIVATION
by selecting this entry, you will
receive the “database activation
request code” to be provided to your
distributor in order to be able to buy
the database activation/update and
subsequently receive the “ACX
activation key”.
GAS TYPE:
by selecting this entry, you can learn
the type of gas the unit is set for, to
change the type of gas contact an
Authorised MAHLE Service Centre.
DEFAULT SETUP
By selecting this entry, you can
restore the unit default settings.
MAHLE reserves the right to add
new parameters to make the
equipment increasingly versatile
and adaptable to market’s needs.
10 A/C system charge
10.1 Preliminary operations
The recovery and charge operations have
be carried out after the car /AC system
has run for some time; however, an
excessively hot A/C system has to be
avoided since the next charge phase
could be adversely affected by high
pressures.
The vehicle must not be prepared in a
special way; connecting hoses have to be
© MAHLE
EN | 21 | ACX150/250 | A/C system charge
attached by identifying their position.
Vehicle details necessary for the
performance of the charge/recovery/
vacuum cycle are the amount of
refrigerant and the type and quantity of oil.
These data are often found on the engine
compartment plate or on the technical
manuals.
As to oil quantity technical manuals of
cars, systems as well as available details
in general indicate the total quantity of oil
in the system.
Indeed the amount of oil to be charged is
that extracted during the refrigerant
recovery phase which is very small. In the
car A/C system you have to add only the
oil amount necessary to restore the
amount set by the car manufacturer
FEATURES
Your new A/C service station is equipped
with new E³ CONNECT quick couplers.
These new couplers offer the following
functions:
1. Avoid dispersion of the refrigerant,
allowing the recovery by the tool
(thus protecting the environment and
saving refrigerant).
2. Automatic leak test of the car A/C
system valve at the end of the
service.
After connecting the quick couplers to the
(high pressure) HP and (high pressure) LP
connectors of the vehicle, screw the
valves only when required by the
messages on the tool display.
10.2 Non-condensable gas
discharge
The station is equipped with the AIR
PURGE SYSTEM function, which allows
automatically detecting and purging noncondensable gas (mainly air) accumulated
within the tank.
If the station detects non-condensable
gas in the tank, it will automatically run
the non-condensable gas discharge
procedure.
Running this procedure is very important
to ensure the ideal working parameters
for the station operation. The presence of
non-condensable gas in the tank will
increase the pressure inside the tank and,
therefore, will slow down and reduce the
efficiency of charge cycle on the vehicle.
The procedure will take a few minutes,
and its duration may vary according to
the amount of non-condensable gas
within the tank.
NON-CONDENSABLE
GAS VENT VALVE
WARNING: Leave the quick
coupling taps closed when the
unit is not in use and at the end of
vehicle service operations.
WARNING: For the Air Purge
System procedure to be executed
manually, the station must have
been off for at least one hour.
© MAHLE
10.3 Quick mode and zero
tolerance charge mode
ACX150/250 can apply two different
refrigerant charge modes; the first one is
called Quick mode and features the
opening of the charge valve by charging
refrigerant through the HP port. By the
Quick Mode part of the refrigerant
remains into the hoses and is
compensated by software calculation.
Whenever the charge is not completed
the UNIT shifts automatically to the Zero
Tolerance mode.
The Zero Tolerance function is the
second charge procedure, an alternative
to the Quick Mode.
It features a more accurate charge and
guarantees a successful charge (it
however requires a longer time and the
operator's intervention).
If the car A/C system is equipped with
both couplers or with LP coupler only,
there are two slightly different working
modes; in any case if only the HP coupler
is available the Zero Tolerance mode is
not applicable.
With both HP and LP couplers available
the Zero Tolerance features the charge of
the selected refrigerant amount into the
system through the HP hose; then
refrigerant remained into the HP hose is
sucked by the car system – engine and
compressor running – through LP (after
disconnecting and closing the HP
coupler).
In case the LP coupler only is available
the station charges the system with 50%
of the selected amount with car
compressor off and waits for 10 minutes
before recalling the operator. This wait
time – quite rare since most of cars are
equipped with HP coupler too – allows
the refrigerant charged near the
EN | 22 | ACX150/250 | Automatic cycle
compressor – that is LP side – to
evaporate to prevent any damage to the
compressor during the admission of liquid
phase refrigerant. Then, after car and A/C
system switch ON charge continues
through timed charge of refrigerant
through hose LP, such charges start
exclusively if the LP pressure is lower
than 3 bar (this threshold is adjustable).
11 Automatic cycle
The access to Automatic cycle can be
achieved selecting Database, Last Cycle
or My database (a 100 personal
automatic cycle) .
11.1 Automatic cycle data
loading
11.1.1 Database
MAHLE offers customers purchasing
ACX150/250 the possibility of enhancing
potentials of the UNIT through the
database.
This database contains all data related to
the A/C system of most vehicles. Hence,
it will be possible to speed up the charge
operations of the system with the aid of
the data provided by the database.
Make
Model
Version / engine capacity
Year
System
11.1.2 Last cycle
It loads the parameters of the last
automatic cycle.
© MAHLE
EN | 23 | ACX150/250 | Automatic cycle
11.1.3 My database
It allows loading the parameters of the
automatic cycle previously saved by the
user.
11.1.4 Direct input
It loads the default parameters of
automatic cycle.
11.2 Automatic cycle data
setting
After selecting the type of A/C system the
main page is shown with the following
preset values
Vacuum phase (recommended
values but changeable – they do
not depend by the car selected)
Vacuum duration
Leak test duration
Oil Charge mode and quantity of
oil that will be charged into the
system
o OIL: <value> g. It
charges the quantity of
oil that has been set.
o REC. + <value> g. It
charges the quantity of
recovered oil plus the
quantity of oil that has
been set
o NO OIL. No oil is
charged during the
charge cycle
Oil type: It sets the oil type being
used. PAG (ISO46/100/150) or
POE, it does depends by the
selected vehicle.
It is possible to select the charge
of the UV dye (a single shot of about
8 g.)
amount of refrigerant that will be
charged into the system and the
amount of refrigerant available in
the inner tank of the UNIT.
Charge type: It allows selecting
from which hose the service is
carried out, according to the
type of system.
o Charge from HP hose
(red)
o Charge from LP hose
(blue)
o Charge from HP hose
(red) and LP hose (blue)
o Charge from HP hose
(red) on the system low
pressure side. Specific
for some Renault
models.
At the end of the setup, press the
“START” button to start the automatic
cycle.
Or press Save if you want to save this
cycle with a name in a My Database
record.
11.2.1 Electric Compressor
Function
Before connecting the ACX150/250 hoses
to the A/C system of the vehicle, select
the Vehicle Compressor Type.
If the selected type is Electric (high
voltage), a special function named
“Electric Compressor Function” will be
executed to clean the hoses from any
previous oil residue.
When the following message appears:
Connect LP and HP quick coupler to their
support connectors on ACX150/250.
© MAHLE
After the connection, press “YES” to
proceed and follow the instructions
showed on the screen.
12 Manual cycle
The access to manual cycle can be
achieved selecting the functions in the
Manual Cycle menu.
12.1 Recovery
In the MANUAL CYCLE menu select
RECOVERY function.
Press and start the recovery function and
follow the tool instructions. If there is no
pressure inside the system, this function
cannot be started.
POSSIBLE ERROR INDICATION
Too high pressure in the A/C
service unit.
Valves or couplers closed or
system empty.
12.2 Vacuum
From the main menu select MANUAL
CYCLE and press VACUUM.
Connect the HP – LP couplers or the
single coupler to the vehicle system and
screw the couplers. Now set the time for
the vacuum and control phase, if different
EN | 24 | ACX150/250 | Manual cycle
from the default settings. The vacuum
phase is automatically followed by the
“vacuum test” phase.
Press START to start the vacuum phase.
POSSIBLE ERROR INDICATION
System pressurised
POSSIBLE ERROR INDICATION
System not tight
12.3 Charge
In the main menu select MANUAL CYCLE
and then CHARGE.
Set the following items :
Charge mode and quantity of oil
that will be charged into the
system
o OIL <value> g. It
charges the quantity of
oil that has been set.
o REC. + <value> g. It
charges the quantity of
recovered oil plus the
quantity of oil that has
been set
o NO OIL. No oil is
charged during the
charge cycle
Oil type: It sets the oil type being
used. PAG (ISO46/100/150) or
POE
UV: Option for the charge of UV
dye
Amount of refrigerant that will be
charged into the system and the
amount of refrigerant contained
in the inner tank of the UNIT.
Charge type: It allows selecting
from which hose the service is
carried out, according to the
type of system.
© MAHLE
EN | 25 | ACX150/250 | Special test
Connect the couplers to the vehicle
fittings and follow the instructions on the
screen page.
Press START to begin the refrigerant
filling phase.
o Charge from HP hose
(red)
o Charge from LP hose
(blue)
o Charge from HP hose
(red) and LP hose (blue)
o Charge from HP hose
(red) on the system low
pressure side. Specific
for some Renault
models.
POSSIBLE ERROR INDICATION:
The amount of refrigerant in the
A/C service units tank is less than
that required. Closed hoses, charge
impossible.
THIS PHASE HAS TO BE
CARRIED OUT EXCLUSIVELY
ON A/C SYSTEM UNDER
VACUUM (AFTER A VACUUM
PHASE HAS BEEN PULLED).
12.4 Flushing (with optional
accessories)
After performing a lot of charge cycle or
after replacing components or parts of
the /AC circuit on a vehicle it is advisable
to carry out a system flushing.
The system washing (Flushing) consists in
purifying the vehicle cooling system
through several R1234yf/R134a
refrigerant flushes, by recovering it each
time, so that the impurities can be filtered
little by little through the additional filter.
Thanks to its specific design,
ACX150/250 automatically manage the
flushing process so that the process
becomes fully automatic.
Once the (optional) flushing kit has been
installed, as described in the instructions
included in the kit, and after selecting the
specific function for the kit being used,
start the phase.
In case of problems or errors during this
phase, a message will be displayed,
identifying the type of error.
It is possible to interrupt the phase in
progress at any time.
12.5 Hoses drain
To empty the charge hoses completely
perform the HOSES DRAIN phase.
Select in the menu the HOSES DRAIN
function. Wait the end of the procedure.
13 Special test
13.1 AC performance test
To check the vehicle A/C system status –
for instance in case there is no flow of
cold air from flaps – pressure values can
be checked.
Connect the HP - LP couplers or the
single coupler to the vehicle system.
Under the sequence guided by the
software perform the following preliminary
operations on the vehicle:
1. Turn on the A/C system
2. Set temperature at
minimum level.
3. Set fan speed at maximum
level; close all the flaps
except the central one and
© MAHLE
In the MANUAL CYCLES menu, select
the AC PERFORMANCE TEST function.
Execute the AC PERFORMANCE TEST
following the instruction.
And at the end make sure that both
values on LP and HP gauges fall within
the values shown on the display.
It is possible to interrupt the phase in
progress at any time.
set air distribution to
central position.
4. Keep engine at accelerated
idle at constant speed for
at least 2 minutes.
5. Check the pressure values
within about 3 - 5 minutes.
PRESSURE VALUES CHANGE
CONSIDERABLY WHEN
AMBIENT TEMPERATURE
CHANGES. KEEP THIS IN MIND
WHEN CHECKING PRESSURE
VALUES
13.2 Refrigerant clean
By selecting this function, you can start
the refrigerant clean function, allowing for
a further recycle, which is internal to the
station itself. This mode guarantees a
higher level of the service quality.
14 Maintenance
ACX150/250 is a remarkably reliable unit,
manufactured using the highest quality
components, making use of the most
advanced production techniques.
Please contact an authorized technical
service centre for purchasing original
spare parts.
EN | 26 | ACX150/250 | Maintenance
The access to manual cycle can be
achieved selecting the functions in the
Maintenance menu.
INTERVENTIONS ON SERVICE
STATION COMPONENTS
WHICH ARE NOT MENTIONED
MAKE SURE THE TOOL IS
UNPLUGGED FROM THE
POWER MAINS BEFORE
IN THE FOLLOWING
PARAGRAPHS ARE
PROHIBITED.
OPENING.
14.1 Report exporting
In the main menu select MAINTENANCE
and press “REPORT EXPORTING”.
By selecting this function, is possible to
export the report on USB Key and
manage it on PC with ACX Manager.
14.2 Internal cylinder fill
In the main menu select MAINTENANCE
and press “INTERNAL CYLINDER FILL”.
Set the quantity of refrigerant to fill and
follow the guided procedure shown on
the display.
The set value is limited to avoid to fill too
much the internal cylinder.
Only when the message appears asking
to connect the charge tank, connect the
HP quick coupler (colour red) of the unit
to an external refrigerant tank using the
supplied adaptor.
When the message occurs open the
coupler by turning the knob clockwise.
Open the valve on the external tank.
Just right before reaching the planned
quantity of refrigerant, the unit will stop
and ask the user to close the external
© MAHLE
EN | 27 | ACX150/250 | Maintenance
refrigerant tank. Then, the device will
continue the recovery from the hoses and
ends when these are empty. Hence, it is
necessary to open the HP quick-coupler
and disconnect it from the external tank.
Thanks to the E³ CONNECT function, the
refrigerant - usually kept between the
cylinder fitting and the hose quick-coupler
until the end of the process - will not be
released in the environment.
There may be two types of source tanks:
with plunger and without plunger.
Tanks with 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
down to transfer the liquid refrigerant.
The LP gauge indicates the pressure
inside the external tank.
After some minutes the unit will
automatically end the function.
At the end the weight of the charged
refrigerant will be displayed.
14.3 Self leak test
In the main menu select MAINTENANCE
and press “SELF LEAK TEST”.
A leak test is carried out on the internal
components of ACX150/250.
This phase includes:
Hoses emptying
Vacuum test
This test allows to check the tightness of
the internal circuits of the equipment from
the solenoid valve, allowing the fluid
outflow from the internal cylinder, to the
manifold, (metallic component housing
the check solenoid valves) to the
compressor infeed, including the dryer
filter leak test.
In case of failed leak test, it is necessary
to check the charge hoses conditions
and the quick couplers leak, and make
the possible repair and then repeat the
test.
14.4 Cylinder refrigerant
view
In the main menu select MAINTENANCE
and press “CYLINDER REFRIGERANT
VIEW”.
The available refrigerant for next
recharging is 2 kg less than the total
contents of the cylinder.
Two kg is the minimum quantity that
should be always left in an operating
ACX150/250.
14.5 Air purge
In the main menu select MAINTENANCE
and press “AIR PURGE”.
By selecting this function, is possible to
check the non condensable gases
condition (high level red area, low level
green area ) and if necessary start
manually the discharge.
14.6 Pressures zero
In the main menu select MAINTENANCE
and press “PRESSURES ZERO”.
This function allows to determine and
store the atmospheric pressure value.
© MAHLE
We recommend running this procedure
every time the ACX150/250 will be moved
from a location to another with a different
altitude.
14.7 Counters
In the main menu select MAINTENANCE
and press “COUNTERS”.
In the COUNTERS page, at any time, the
vacuum pump and compressor hours of
life can be displayed; besides, remaining
time before replacement of vacuum pump
oil and dryer filter can also be displayed.
This is useful to understand if some
maintenance activity should be performed.
14.8 E³ pump - pump oil
change
The ACX150/250 is equipped with a
special function named E³ PUMP that
enables to optimize the vacuum pump oil
use by avoiding the replacement every 60
hours of operation.
E³ PUMP is a special function allowing to
extend even to 1000 hours the life of the
pump oil used in the station. E³ PUMP
function performance is suggested at the
end of 60-hour operation intervals of the
vacuum pump and can be manually
activated in the MAINTENANCE menu
pressing E³ PUMP.
E³ PUMP procedure has to be started
only after checking and, if necessary,
topping up the pump oil level and lasts 1
hour: during this time the tool cannot be
used.
During the procedure the oil is
automatically purified from the gaseous
polluting residues absorbed during the
emptying operations of vehicles air
conditioning systems.
EN | 28 | ACX150/250 | Maintenance
At the end of the procedure, the vacuum
pump performance check is carried out
and a result to the operator is signalled.
In case of negative result you have to
replace the vacuum pump oil.
After 1000 hours of vacuum pump
operation since the last oil change, the E³
PUMP procedure cannot be activated
anymore and you have to replace the oil
according to the following instructions.
Required tools:
1 Hex screwdriver (2.5 mm)
1 Medium-sized flathead
screwdriver
1 Hex key (10 mm)
For replacement, comply with the
instructions outlined below:
1. Disconnect the unit from the
mains.
2. Remove the six screws that fix
the front door of the unit and
remove it.
3. Place a bowl underneath the
machine, right under the pump
oil drain hole. Open the upper
plug and then the lower plug to
drain the used oil contained
within the vacuum pump.
© MAHLE
EN | 29 | ACX150/250 | Maintenance
Upper filling plug
Oil inspection
window
Lower
drain plug
4. Once the pump has been
emptied, screw the lower plug
again.
5. Fill the pump with new oil
through the upper opening,
using a funnel if needed. Bring
new oil level halfway through
the oil inspection window.
6. Once the pump has been filled,
close the upper plug.
7. Once oil has been replaced,
switch on the unit and from the
MAINTENANCE menu select
PUMP OIL REPLACEMENT:
press the “RESET” key to set
the counter.
14.8.1 Oil pump visual check
Without opening the equipment is always
possible to remove the rubber tap in the
following position to check level and the
clearness of the oil inside the pump.
14.9 Dryer filter
replacement
The dehydrator filter must be replaced
after having dehydrated 150 kg of
refrigerant fluid, since the filter capacity to
keep the humidity present in the
refrigerant will run out.
To replace the dryer filter, from the
MAINTENANCE menu select DRYER
FILTER REPLACEMENT: press “START”
to set the counter to zero and to start the
filter replacement procedure. Insert the
code of the new filter. Now you can
replace the filter.
Required tools:
1 Hex screwdriver (2.5 mm)
1 regular or torque Hex key (24
mm)
1 Hex key (17 mm)
For replacement, 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. confirm to have already
worn the personal protective
equipment (PPE) and follow
the safety regulations in
force.
© MAHLE
DANGER OF CONTACT WITH R134a
REFRIGERANT and motor vehicle A/C
system oil
4. Before opening the doors of
the equipment, switch off
the equipment and
disconnect the power
supply cord.
DANGEROUS VOLTAGE HAZARD
5. Remove the six screws that
fix the front door of the unit.
6. Unscrew the 2 connection
nuts of the filter by means of
the hex keys.
7. Remove the straps that
wind up the filter
DRYER FILTER
8. Install the new filter paying
attention to the position of
gaskets and to the direction
of the arrow indicating the
fluid flowing direction.
9. Screw the two connection
nuts of the filter.
10. Replace the front panel
11. Carry out the automatic leak
test requested by the
software when switched on
again after the filter
replacement.
NUTS
EN | 30 | ACX150/250 | Maintenance
14.10 System info
In the main menu select MAINTENANCE
and press “INFO”.
In the INFO page, at any time, the
software version and the serial number
can be displayed.
14.11 System update
The firmware (software) can be
updated by way of a USB stick.(where
the new version is stored).
1. Insert the USB stick in
USB port (fig.3 pos.4)
Power on ACX150/250.
2.
In the main menu select
3.
MAINTENANCE and
press “SYSTEM
UPDATE”.
A message will appear
4.
that the unit is loading
an update.
5.
The unit may load an
updated language file,
database file and
configuration file while
updating.
Once unit is updated,
6.
the software version
string on the
introduction screen
during power up will
change.
© MAHLE
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