MAHLE RTI AC860 User Manual

OPERATION

&

MAINTENANCE

MANUAL

AC860

Refrigerant Handling System

Manual P/N 035-80844-00

TABLE OF CONTENTS

Startup & Safe Operation.............. 1

Introduction to the AC860 ............. 2

Control Panel ....................... 3

Keypad Functions ................... 4

First Time Use of the AC860 ........... 5

Start-Up ........................... 6

Recover (Recycle) ................... 7

Purge Air - Drain Oil.................. 7

Vacuum ........................... 8

Charge............................ 8

Maintenance ....................... 9

Parts Lists .........................10

R134a Connection to Cylinder ..........11

CONGRATULATIONS

You have purchased one of the f inest Recovery, Recycling,
and Charging Machines available!

Your AC860 was proudly manufactured for MA TCO Tools by
RTI Technologies Inc., York, PA.

Fill out and return the Warranty Card within 90 days to
activate the warranty and free lifetime technical support.

TECHNICAL SUPPORT

800-468-2321 (Ext. 259)

[e-mail]

STARTUP & SAFE OPERATION

9 Do not use a damaged unit. Check for shipping damage and place a claim with carrier if damage

is discovered.

9 Return the Warranty Card to activate technical support service and warranty coverage.
9 The AC860 should not be operated or serviced by any person who has not read all the contents

of this manual.

9 This manual des cribes normal operation and maintenance for the AC860. Failure to read and

comply with these instructions or any one of the limitations noted herein can result in serious injury
and/or property damage. The instructions should not be interpreted to anticipate every possible
contingency.

9 It is the responsibility of the owner/ user to operate the AC860 in accordance with all laws and

specifications which may apply.

9 Recover (recycle) and charge only the refrigerant for which the AC860 is configured.
9 Avoid breathing refrigerant or lubricant vapor. Exposure may irritate eyes, nose and throat.

Ventilate work area if accidental system discharge occurs.

9 Wear safety glasses and protectiv e gloves. Refrigerant has a very low boiling point and can cause

frostbite.

9 Follow the AC860 operating pr ocedures sequentially to avoid prematurely disconnecting hoses or

opening valves which may release refrigerant to the atmosphere.

9 Do not expose the AC860 to moisture or operate in wet areas.
9 Use the AC860 in locations with ventilation that provides at least four air changes per hour.
9 Hoses must have shutoff devices within 12 inches of the connection point to the A/C to minimize

the introduction of air into the AC860 and the release of refrigerant when being disconnected.

9 Avoid using an extension cord with the AC860. If necessary use a good condition, three wire

grounded, #14 AWG or larger extension cord of the shortest possible length.

9 Disconnect power before performing any maintenance or service on the AC860.
9 Do not connect the red or blue hoses to the liquid port of a cylinder of refrigerant to fill the charge

cylinder. Doing so may cause the compressor to fail and void the warranty.

9 Do not connect the AC860 to the liquid side of any A/C with a capacity greater than 4 lbs.

Refrigerant in A/C Systems having larger capacities must be recovered from the vapor side only.

Special Considerations with R134a

R134a has been shown to be nonflammable at ambient temperature and atmospheric pressure.
However, tests under controll ed conditions hav e indi cated that at pressures abov e atmospheri c and
with air concentrations greater than 60 percent by volume, R134a can form combustible mixtures.

While it is recognized that an ignition source is also required for combustion to occur, the presence
of combustible mixtures is a potentially dangerous situation and should be avoided.

Under no circumstances should any equi pment be pressure tested or leak tested wi th air and R134a
mixtures. Do not use compressed air for leak detection in R134a systems.

Page 1

INTRODUCTION TO THE AC860

The AC860 is a complete refrigerant management center featuring state-of-the-art electroni c control
with digital weight scale measuring of refrigerant. Operation of the AC860 is intuitive and very easy
to master.

Following is an overview of the operation and features of the AC860:

RECOVER (RECYCLE)

Refrigerant is recover ed from the A/C, impurities ( particulates, oil , moisture and air ) are remov ed
and the refrigerant is stor ed in the internal cy linder. The recov ery pr ocess stops when the AC860
senses an 8 InHg vacuum at the A/C. Wait for at least two minutes and watch the pr essure gauges
to determine if there is an increasing pressur e. If pressure in the A/C rises duri ng this time per iod
due to vaporization of residual liquid refrigerant, the AC860 will restart to recover this refrigerant.
When the AC860 stays off continually for at least two minutes, the recovery procedure is complete.

VACUUM

A deep vacuum should be drawn on the A/C to remove air, moisture and refrigerant dissolved i n
the oil. A deep vacuum is especially important if the A/C was opened for replacement of
components.

PURGE AIR - DRAIN OIL

Excess air and recovered oil must be removed from the AC860 after all refrigerant has been
recovered from the A/C. Temperature and pressure readings are examined and air is released
using the purge valv e. Oil is dr ained i nto the oil dr ain cup for measuring to determi ne the need to
replenish the A/C.

CHARGE

Refrigerant is charged into the A/C by weight. The amount to be charged is entered and the AC 860
automatically charges the refrigerant into the A/C.

1 Keypad
2 Function Valve
3 Purge Chart
4 Gauge Manifold
5 Tool Tray
6 Purge Gauge
7Purge Valve

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