Caution! Warning! - Snap

Transcript

SECTION I AC POWER DISTRIBUTION _____________________________________________________________ CAUTION! ! THIS UNIT MUST BE PLUGGED IN TO A PROPER AC OUTLET FOR UNIT TO OPERATE CORRECTLY. REFER TO UNIT ID PLATE LOCATED ON BACK OF UNIT. EXTENSION CORDS ARE NOT RECOMMENDED, BUT IF AN EXTENSION CORD MUST BE USED, USE A CORD THAT IS LESS THAN 50 FEET WITH A 16 AWG, OR ABOVE 50 FEET AND LESS THAN 100 FEET WITH A 14 AWG. WARNING! ! USE STANDARD REFRIGERANT HANDLING SAFETY PROCEDURES WHEN PERFORMING INSTALLATION ALWAYS WEAR SAFETY GOGGLES, DON'T SPILL OR TOUCH LIQUID REFRIGERANT, AVOID FLAMES, & EXCESSIVE HEAT. USE ONLY IN WELL VENTILATED AREA. AC DISTRIBUTION (REFER TO FIGURE 1-1) Always use the "One Hand Rule"when working with AC voltages by keeping one hand in your pocket or behind your back. Before removing wires from the ACT-1500, always verify that the Tester is "OFF". Turn off the Main Power Switch on the front panel and unplug the AC power cord from the AC outlet. The hot side (black wire) of the 115VAC is wired directly to the 8 amp circuit breaker, from there it is routed to the "ON/OFF" front panel power switch. VACUUM SWITCH CHARGE SELECT OIL OFF CB1 HOT MASTER SWITCH ON R12 TIMER R-12 OIL TIMER GND NEUTRAL GND VACUUM PILOT R-12 PILOT VACUUM SOLENOID R-12 SOLENOID OIL PILOT NEUTRAL HOT OIL SOLENOID FIGURE 1-1 AC DISTRIBUTION Page 1 - 1 Page 1 - 2 SECTION II THEORY OF OPERATION ______________________________________________________________________________________ _ POWER ON MODE ELECTRICAL (REFER TO FIGURE 1-2) The Power On Mode is activated by turning the Master Switch on the Front Panel to the "ON" position. When turned on, the light in the ACT-1500's master switch will light. This routes power to the Vacuum Switch, as well as the Charge Selector Switch, if the Vacuum Switch is in the off position. VACUUM SWITCH CHARGE SELECT OIL OFF CB1 HOT MASTER SWITCH R12 TIMER R-12 ON OIL TIMER GND NEUTRAL GND VACUUM PILOT R-12 PILOT VACUUM SOLENOID R-12 SOLENOID OIL PILOT NEUTRAL HOT FIGURE 1-2 OIL SOLENOID POWER ON MODE NOTE:The symbols in the Flow Diagrams indicate flow, and no flow. The Solid Arrow means direction of flow. The Detail Marker shows active refrigerant, but no flow. Page 1 - 3 VACUUM MODE ELECTRICAL (REFER TO FIGURE 1-3) Power is routed from the Master Power Switch through the Vacuum Switch. Once the Vacuum Switch is turned "ON", the Vacuum Pilot will turn "ON" and the Vacuum Solenoid will energize. The AC Outlet is wired to the Vacuum Solenoid. Therefore, 115 volts AC is present at the outlet to run the Vacuum Pump and the Heater Blanket. VACUUM SWITCH CHARGE SELECT OIL OFF CB1 HOT MASTER SWITCH R12 TIMER R-12 ON OIL TIMER GND NEUTRAL GND VACUUM PILOT R-12 PILOT VACUUM SOLENOID R-12 SOLENOID OIL PILOT NEUTRAL HOT FIGURE 1-3 OIL SOLENOID VACUUM MODE (ELECTRICAL) PNEUMATICS (REFER TO FIGURE 1-4) In the Vacuum Mode the only pneumatic components involved are the Vacuum pump, Vacuum solenoid, In-line Filter, and Low Side Gauge. The Vacuum pump pulls a vacuum through S1 (Vacuum Solenoid), through the In-line filter, and finally to the low side port. The Low side gauge monitors and displays the amount of vacuum in Inches of Mercury (Hg). LEFT SIDE PANEL Manual Purge Valve HIGH GAUGE Check Valve High Side Port NC Back Panel Oil Port Flow Indicator Purge Port Low Side Port S3 LOW GAUGE In Line Filter Check Valve S2 NC S1 Refrigerant Port NC Flow Regulator Vacuum Port FIGURE 1-4 Page 1 - 4 VACUUM MODE (PNEUMATICS) OIL CHARGE MODE ELECTRICAL (REFER TO FIGURE 1-5) With the Vacuum Switch in the "Off" position, power is routed to the Charge Select Switch. With the Charge Select Switch set to "OIL", and the Oil Timer set for a charge amount, power is then routed to the Oil Pilot, Oil Solenoid, and Oil Timer itself. This starts the Oil Timer, opens the Oil Solenoid, and Lights the Oil Pilot light. VACUUM SWITCH CHARGE SELECT OIL OFF CB1 HOT MASTER SWITCH R12 TIMER R-12 ON OIL TIMER GND NEUTRAL GND VACUUM PILOT R-12 PILOT VACUUM SOLENOID R-12 SOLENOID OIL PILOT NEUTRAL HOT FIGURE 1-5 OIL SOLENOID OIL CHARGE MODE (ELECTRICAL) PNEUMATICS (REFER TO FIGURE 1-6) With the vehicle in a deep vacuum (from the Vacuum Mode) oil is drawn from the Oil Cylinder, and pushed out the Oil Cylinder (due to the 100 lb charge of Nitrogen in the Oil Cylinder), through S3 (Oil solenoid), Check Valve, Flow Indicator, Flow Regulator, through anIn-Line Filter and out to the vehicle. Oil continues to flow in this manner until the Oil Timer has expired. LEFT SIDE PANEL Manual Purge Valve HIGH GAUGE Check Valve High Side Port NC Back Panel Oil Port Flow Indicator Purge Port Low Side Port S3 LOW GAUGE In Line Filter Check Valve NC S1 Refrigerant Port NC Flow Regulator S2 Vacuum Port FIGURE 1-6 OIL CHARGEMODE (PNEUMATICS) R12 CHARGE MODE Page 1 - 5 ELECTRICAL R ( EFER TO FIGURE 1-7) With the Vacuum Switch in the "Off" position, power is routed to the Charge Select Switch. With the Charge Select Switch set for R-12, and the R-12 Timer set for a charge amount, power isrouted to the R-12 Pilot, R-12 Solenoid, and R-12 Timer itself. This starts the R12 Timer, opens the R-12 Solenoid, and Lights the R-12 Pilot. VACUUM SWITCH CHARGE SELECT OIL OFF CB1 HOT MASTER SWITCH R12 TIMER R-12 ON OIL TIMER GND NEUTRAL GND VACUUM PILOT R-12 PILOT VACUUM SOLENOID R-12 SOLENOID OIL PILOT NEUTRAL HOT FIGURE 1-7 OIL SOLENOID R-12 CHARGE MODE (ELECTRICAL) PNEUMATIC (REFER TO FIGURE 1-8) With the vehicle in a deep vacuum (from the Vacuum Mode) refrigerantis drawn from the Refrigerant Cylinder, and pushed out the Refrigerant Cylinder(due to the Heater Blanket raising the cylinder pressure), through the S2 (R-12 Solenoid), Check Valve, Flow Indicator, Flow Regulator, through an In-Line Filter and out to the vehicle. Refrigerant continues to flow in this manner until the R12 Timer has expired. LEFT SIDE PANEL Manual Purge Valve HIGH GAUGE Check Valve High Side Port NC Back Panel Oil Port Flow Indicator Purge Port Low Side Port S3 LOW GAUGE In Line Filter Check Valve NC S1 NC Flow Regulator Refrigerant Port S2 Vacuum Port FIGURE 1-8 Page 1 - 6 R-12 CHARGEMODE (PNEUMATICS) SECTION III TROUBLESHOOTING I. Unit will not power up. Check customer AC outlet. Check Circuit Breaker for 115 Volts AC on both terminals. If AC is not present, on the load side, reset or replace Circuit Breaker. Check Master Switch for 115 Volts AC on both sides with power on. Replace Master Switch. Master Power Switch will not light. Check for 115 Volts across the switch on both sides. Replace Master Switch. _______________________________ ______________________________________________________ II. Unit will not pull a vacuum. Check for 115 Volts on Vacuum Switch. (BLACK Lead) Refer to Complaint I. Check for 115 Volts on Vacuum Switch with switch turned on. (BLUE Lead) If not present, replace Vacuum Switch. Check for 115 Volts on the AC Outlet. If not present, replace AC Outlet. If present, replace vacuum pump. Check for 115 Volts on Vacuum Solenoid. If present, replace Vacuum Solenoid _______________________________ ______________________________________________________ III. One or more lamps will not Check for 115 Volts on lamps with the correct operating mode. Be sure that the Timers are on for OIL or R-12. light. Replace lamp if voltage is present. Refer to complaint I. _______________________________ ______________________________________________________ IV. Timer(s) will not run. With the Vacuum Switch in the off position, and the Charge Selector in the OIL/R-12 Mode, turn the timer clockwise. Check for 115 Volts on the three terminals closest to each other. Replace Timer Assy. Page 1 - 7 Refer to Complaint V. _______________________________ ______________________________________________________ V. Charge Selector Switch not With the Vacuum Switch in the off position, check for 115 Volts on the Red lead from the Vacuum Switch to the Charge Selector working correctly. Switch. Replace the Vacuum Switch. Refer to complaint II. Check for 115 Volts on the Charge Selector Switch set for OIL charge. (Orange lead right) Replace Charge Selector Switch. Check for 115 Volts on the Charge Selector Switch set for R-12 charge. (Orange lead left) Replace Charge Selector Switch. _______________________________ ______________________________________________________ VI. Unit will not charge Refrigerant. Ensure voltage is getting to R-12 Charge Timer. If present, check output of timer. If not present, and master switch light is lighted, check Vacuum switch and Charge select switch. Is R-12 pilot light is lighted? If yes, continue to next step. If No, replace vacuum timer. Does the R-12 solenoid have 110 volts across it? If yes, check pneumatics for restrictions. If no, replace solenoid. Page 1 - 8 SECTION IV PARTS ______________________________________________________________________________________ _ GENERAL This chapter describes assemblies/subassemblies/parts considered replaceable at on-site field installation. WARRANTY CONSIDERATIONS All ACT-1500 carried a 1 Year warranty. It has been over a year since any ACT-1500 has been built. Any ACT-1500 that SUN will service should be billed to the customer. Page 1 - 9 SUBSECTION A. PARTS BY PICTORIAL ACT-1500 FRONT VIEW ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER 1 Gauge, Low Side K15032 8 Knob, Bleed Valve K40801 2 Light, Pilot (Oil) K30505 9 Indicator, Flow & Tubing K40820 3 Timer, Oil K30420 10 Knob, Timer K90005 4 Light, Pilot (Vac) K30505 11 Switch, Charge Selector K30198 5 Timer, R-12 K30400 12 Knob, Timer K90005 6 Light, Pilot (R12) K30505 13 Switch, Vacuum K30198 7 Gauge, High Side K15022 14 Switch, Master K30011 Page 1 - 10 ACT-1500 BACK VIEW ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER 1 Handle Not Available 6 Solenoid, Oil K60060 2 Cable, AC K30151 7 Solenoid, R-12 K60060 3 Circuit Breaker K30051 8 Tubing, High Side K40801 4 Outlet, 115 Volt K30060 9 Tubing, Low Side K40813 5 Solenoid, Vacuum K60060 10 Tubing, High Side K40801 Page 1 - 11 ACT-1500 INSIDE VIEW ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER 1 Gauge, High Side K15022 12 Outlet, 115 Volt K30060 2 Light, Pilot (R12) K30505 13 Solenoid, Vacuum K60060 3 Timer, R-12 K30400 14 Solenoid, Oil K60060 4 Switch, Charge Selector K30198 15 Valve, Flow K60021 5 Light, Pilot (Vac) K30505 16 Solenoid, R-12 K60060 6 Timer, Oil K30420 17 Indicator, Flow & Tubing K40820 7 Light, Pilot (Oil) K30505 18 Tubing, High Side K40801 8 Switch, Vacuum K30198 19 Tubing, Low Side K40813 9 Gauge, Low Side K15032 20 Tubing, High Side K40801 10 Circuit Breaker K30051 21 Knob, Bleed Valve K40801 11 Switch, Master K30011 Page 1 - 12 ACT-1500 BACK OF UNIT ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER 1 Handle Not Available 5 Wheel, Rear K80002 2 Hose, 36" Yellow K25207146 6 Nut, Pal 5/8" K90001 3 Hose, 48" Blue K25007160 7 Caster, Front K80001 4 Axle K80003 8 Hose, 48" Red K25107161 Page 1 - 13 SUBSECTION B. PARTS IN ALPHABETICAL ORDER DESCRIPTION PART NUMBER Axle K80003 Cable, AC K30151 Caster, Front K80001 Circuit Breaker K30051 Gauge, Low Side K15032 Gauge, High Side K15022 Hose, 48" Blue K25007160 Hose, 48" Red K25107161 Hose, 36" Yellow K25207146 Indicator, Flow & TubingK40820 Knob, Bleed Valve K40801 Knob, Timer K90005 Light, Pilot K30505 Nut, Pal 5/8" K90001 Outlet 115 Volt K30060 Solenoid, Vacuum K60060 Solenoid, R-12 K60060 Solenoid, Oil K60060 Switch, Master K30011 Switch, Charge Selector K30198 Switch, Vacuum K30198 Timer, R-12 K30400 Timer, Oil K30420 Tubing, High Side K40801 Tubing, Low Side K40813 Valve, Flow K60021 Wheel, Rear K80002 Page 1 - 14 SUBSECTION C. PARTS IN NUMERICAL ORDER PART NUMBER DESCRIPTION K15022 K15032 K25007160 K25107161 K25207146 K30011 K30051 K30060 K30151 K30198 K30198 K30400 K30420 K30505 K40801 K40801 K40813 K40820 K60021 K60060 K60060 K60060 K80001 K80002 K80003 K90001 K90005 Gauge, High Side Gauge, Low Side Hose, 48" Blue Hose, 48" Red Hose, 36" Yellow Switch, Master Circuit Breaker Outlet 115 Volt Cable, AC Switch, Charge Selector Switch, Vacuum Timer, R-12 Timer, Oil Light, Pilot Tubing, High Side Knob, Bleed Valve Tubing, Low Side Indicator, Flow & Tubing Valve, Flow Solenoid, Vacuum Solenoid, Oil Solenoid, R-12 Caster, Front Wheel, Rear Axle Nut, Pal 5/8" Knob, Timer SECTION V OPERATORS MANUAL _____________________________________________________________ _ TABLE OF CONTENTS Page Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Tank Replacement and Air Purging Procedure . . . . . . . . . . Oil Tank Replacement and Air Purging Procedures . . . . . . . . . . . . . . . . . 1-16 1-17 1-17 1-18 Operating Instructions Testing Air Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use with Recovery Recycling Equipment . . . . . . . . . . . . . . . . . . . . . Evacuating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging with Unheated R-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging with Heated R-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 1-18 1-19 1-19 1-19 1-19 Maintenance Vacuum Pump Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purge Valve Ball Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubing and Solenoid Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flow Valve Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 1-20 1-20 1-20 1-21 1-21 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Page 1 - 15 WARRANTY This product is warranted to be free of defects in workmanship and materials for a period of one year from date of purchase by original purchaser. If the product fails within this period, it will be repaired or replaced at sellers option, provided (1) the product is submitted with proof of purchase date, (2) transportation charges are prepaid to the factory. Liability under this warranty is expressly limited to repairing or replacing the product or parts thereof. This warranty does not apply to product or parts broken from accident, overload, abuse or if they have been tampered with or altered. If this warranty does not apply, then the retail purchaser shall pay all costs for labor, material and transportation. Page 1 - 16 HOSE PLACEMENT On all 96" hoses listed below, make sure you attach the straight end (without valve core depressor) to ports on back of cabinet. 1. HIGH HOSE PLACEMENT- The 96" red hose is connected between the discharge port on the air conditioner system and the console port marked "HIGH". IMPORTANT Anti-Blow Back Valve is attached to the 45 degree end of the red hose. DO NOT REMOVE red hose at any time -- leave it installed. 2. 3. 4. 5. LOW HOSE PLACEMENT- The 96" blue hose is connected between the suction port on the air conditioner system and the console port marked "LOW". R-12 HOSE PLACEMENT- The 48" blue hose is connected between the port marked R-12 and the R-12 tank. After connection is made, open R-12 tank valve. Be CERTAIN tank valve is not leaking. OIL HOSE PLACEMENT- The 48" red hose is connected between the port marked oil and the oil tank. VACUUM HOSE PLACEMENT- The 36" yellow hose is connected between the port marked vacuum and the vacuum pump suction port. IMPORTANT Wear safety goggles when installing internal hoses. REFRIGERANT TANK REPLACEMENT AND AIR PURGING PROCEDURES IMPORTANT Wear safety goggles during this procedure. 1. 2. 3. 4. 5. 6. Turn master switch "OFF". Remove blue hose from empty tank and connect to replacement tank. Turn tank valve "ON". Check tank valve for leak. The R-12 tank must be positioned such that liquid is flowing from the port. Loosen blue hose at back of console to bleed air from hose. Turn master switch on. Resume charging process. Page 1 - 17 OIL TANK REPLACEMENT AND AIR PURGING PROCEDURES IMPORTANT Wear safety goggles during this procedure. 1. 2. 3. 4. Turn master switch "OFF". Remove red hose from empty tank. Connect red hose to new tank. Place tank on its handles and turn tank valve on. (a) If the tank is being replaced while the machine is not connected to an air conditioner system, purge air from the lines by turning the master switch and the oil timer "ON" for two to three seconds. (b) If the tank ran empty while charging oil into an evacuated system. purge air from the lines by turning the master switch "ON" and then the vacuum pump "ON" for approximately two minutes. OPERATING INSTRUCTIONS IMPORTANT Always wear safety goggles when servicing a system and operation service center. TESTING AIR CONDITIONERS : 1. 2. 3. 4. 5. 6. With engine off, attach hoses-red to high side, blue to low. On compressors with manual service valve, mid-seat both valves. Bleed air from hoses at right side of cabinet. Start engine and adjust speed to fast idle. Set air conditioner controls at "MAX" cooling and "HIGH" fan speed. Insert thermometer in air outlet nearest the evaporator. With windows and doors closed, allow system pressures to stabilize. Set blower fan speed on "LOW" and check ambient temperature, gauge readings, thermometer and sight glass. USE WITH RECOVERY RECYCLING EQUIPMENT: 1. 2. 3. Attach hose from recovery machine to the purge port. Open purge valve and start recovery machine. Close purge valve when recovery is complete. Page 1 - 18 EVACUATING: 1. 2. 3. Turn vacuum pump on for ten minutes. (Bubbles in flow indicator normal.) Turn pump off. Gauge readings should hold for two to three minutes. If there are no leaks in the system. Turn pump on for thirty minutes. If vacuum pump cycles on and off, change vacuum pump oil. OIL CHARGING: 1. 2. 3. Select the temperature scale nearest the ambient temperature. Set charge selector switch to "OIL". (Vacuum pump switch must be off). Set desired oil charge on proper scale. Flow indicator must be monitored. If foam appears while charging, turn master switch off immediately and refer to oil tank replacement. When oil charge shuts off, charge a minimum 1/8 pound of R-12 to clear oil from hoses. CHARGING WITH UNHEATED R-12: 1. 2. 3. 4. Bypass cycling clutch controls on cycling clutch system. Set charge selector switch to R-12 . (Vacuum pump switch must be off.) Set R-12 timer to desired charge on the Unheated Tank scale of the R-12 timer dial. (R-12 flow must be monitored in flow indicator. If R-12 supply is depleted and flow stops while charging, shut master switch off and refer to R-12 tank replacement. Start car after 1/2 lb. of refrigerant has been dispensed. CHARGING WITH HEATED R-12: 1. 2. Allow 5-15 minutes for pressure to build in the tank before beginning to charge R-12. (This can be accomplished while evacuating and/or oil charging.) Set desired charge on the "Heated Tank scale of the R-12 timer dial. (Only charge heated R-12 into an A/C system that is NOT operating. Unheated R-12 can be charged while the system is in operation.) R-12 flow must be monitored in the flow indicator. If R-12 supply is depleted and flow stops while charging, shut master switch off and refer to R-12 tank replacement. Page 1 - 19 MAINTENANCE VACUUM PUMP OIL CHANGE: The vacuum pump should have the oil changed after every 25 evacuations and must be changed after evacuating a contaminated system: i.e. compressor failure, dehydrator failure, or system left open. Most failures of the vacuum pump occur from contaminated pump oil. To change oil: 1. 2. 3. 4. 5. 6. Remove plug in bottom of pump. Allow oil to drain completely. Replace the plug making sure the O-ring seal is not damaged. Unscrew vacuum pump suction hose from solenoid valve. Place suction hose into 12 ounces of General Motors transmission fluid "type A" (Dextron). Turn the vacuum pump on and it will suck the oil into itself.DO NOT OVERFILL. THE PUMP HOLDS 12 OUNCES. PURGE VALVE BALL REPLACEMENT: The purge valve should require only a small amount of torque to shut off. If it is over-tightened the valve might begin to leak. If this happens, remove the purge valve stem and replace the steel ball with an oversize ball (3/16"). HOSE GASKET REPLACEMENT: The hose gaskets will eventually become crushed and might leak after many uses or if over-tightened. To remove the gaskets on the straight end, pry up on the gasket with an ice pick, then press in a new gasket. To remove the gaskets on bent end, use needle nose pliers to unscrew old gasket, then screw in new gasket. TUBING AND SOLENOID FLUSHING: 1. 2. 3. 4. 5. 6. 7. 8. Disconnect power cord and remove bottom cover. Remove flow valve. Lay a rag under the tubing port that points downward. To flush the R-12 solenoid valve: (a) Set charge selector to "R-12". (b) Turn R-12 timer on for 2-3 seconds. (c) Repeat 2 or 3 times to insure thorough flushing. To flush the oil solenoid valve: (a) Remove red hose from oil tank. (b) Shut R-12 tank valve off and remove R-12 hose from tank. (c) Connect red oil hose to R-12 tank and turn R-12 tank valve on. (d) Set charge selector to "OIL". (e) Turn oil timer on for 2-3 seconds. (f) Repeat 2 or 3 times to insure thorough flushing. (g) Return all hoses to original positions. Install flow valve. To flush the vacuum solenoid valve: (a) Cap the LOW port on the back of the console. (b) Set charge selector to R-12 and turn the R-12 timer on and allow pressure to stabilize. (c) Turn R-12 timer off and turn vacuum pump on. (d) Repeat 2 or 3 times to insure thorough flushing. If the solenoid valve still malfunctions, see Solenoid Cleaning section. Page 1 - 20 Note: Make sure there is no pressure on components before removing from system! SOLENOID CLEANING: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Disconnect power cord and remove bottom cover. Disconnect hose, tubing and fittings from solenoid to be cleaned. Remove retainer nut and ID plate from end of valve assembly. Slide brass valve assembly out of electrical coil and bracket. Place brass body in a vise. (Avoid crushing ports) Use right angle truarc pliers to unscrew collar from brass body. Disassemble and clean inside of valve thoroughly. Reassemble valve making certain that spring is in end of plunger with tapered end out and plunger is free in tube. Plunger seat material should be flush with the end of plunger and show a complete circular indentation where it mates on the brass seat in the body. Check for leaks by capping the LOW port on the side of the console, turning the R-12 timer on, and allowing the pressure to stabilize. Turn R-12 timer off and leak check. FLOW VALVE CLEANING: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove valve from machine. Remove knurled nut. Remove top, piston and spring. Clean in mineral spirits and blow dry. If piston cylinder, gasket, and O-ring come out of body while cleaning, place cylinder in body with small holes toward adjusting screw and place gasket into channel formed by body cylinder. Insert spring into cylinder to rest on adjusting screw. Insert piston into cylinder. (Be certain spring enters cavity in piston and small orifice is out.) Place the cap and knurled nut on body and tighten securely. Before replacing in machine, flush the tubing. Replace valve in machine. Page 1 - 21 STORAGE: When storing the machine for a prolonged period of over a month, a few simple precautions will insure proper performance when you are ready to use the machine again. 1. 2. 3. 4. Change the Vacuum Pump Oil. Make sure all hoses are sealed. Leave purge valve slightly open to relieve pressure. Pull a vacuum for 5 minutes on the low hose. (Handvalve must be closed.) Leave this vacuum on hose during storage. Page 1 - 22 CHAPTER 2 ACT-2000 / WHITE-01016 INTRODUCTION: GENERAL OVERVIEW This chapter provides service information for the Snap-on branded White Industries built ACT-2000, and the White Industries built 01016. It is very important to understand the difference between the two units. The ONLY difference is: • • White-01016 Does Not have a Beeper. White-01016 Does Not have a Beeper Relay. Since the two model machines are nearly identical, only the electrical and pneumatic diagrams for the ACT-2000 will be referenced with Section 2, (Theory of Operation) of this chapter. However, for your convenience a electrical and pneumatic diagram, for the White-01016, has been added to the end of Section 2. Whenever servicing a White-01016 machine please refer to the electrical and pneumatic drawings at the end of section 2, and refer to the theory of operation text for the mode you are troubleshooting. Again, please note that you should ignore any reference to the beeper or beeper relay in the theory of operation text. Effective 8/96 Page 2-1 CHAPTER 2 ACT-2000 / WHITE-01016 NOTE: Page 2-2 Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 AC POWER DISTRIBUTION ! THIS UNIT MUST BE PLUGGED INTO A PROPER AC OUTLET TO OPERATE CORRECTLY. REFER TO ID PLATE LOCATED ON BACK OF UNIT. EXTENSION CORDS ARE NOT RECOMMENDED, BUT IF AN EXTENSION CORD MUST BE USED, USE A CORD THAT IS LESS THAN 50 FEET WITH A 16 AWG, OR ABOVE 50 FEET AND LESS THAN 100 WITH A 14 AWG. ! USE STANDARD REFRIGERANT HANDLING SAFETY PROCEDURES WHEN PERFORMING INSTALLATION ALWAYS WEAR SAFETY GOGGLES, DON'T SPILL OR TOUCH LIQUID REFRIGERANT, AVOID FLAMES, AND EXCESSIVE HEAT. USE ONLY IN WELL VENTILATED AREA. AC DISTRIBUTION: (REFER TO DRAWING 2-1, PAGE 2-5) Always use the "One Hand Rule" when working with AC voltages by keeping one hand in your pocket or behind your back. Before removing wires from the ACT-2000, always verify that the Tester is "UNPLUGGED". The 115V AC input voltage from the wall outlet is routed to the master switch via the black (HOT) and white (NEUTRAL) input cord. With the master switch in the "OFF" position no power is distributed throughout the charging station. With the master switch in the "ON" position and assuming all of the timers are set to "OFF" the 115V AC (HOT) lead is routed to the 115V Heater Blanket Outlet, 115V Accessory Outlet, VACUUM Timer, OIL Timer, and R12 Timer. For specific charging station functions and the AC routing pertinent to that function, refer to SECTION II. Effective 8/96 Page 2-3 CHAPTER 2 ACT-2000 / WHITE-01016 NOTES: Page 2-4 Effective 8/96 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: TITLE: DWG: ACT-2000A T. PARSELL CHK BY: 0896 J. HINKLE ACT -2000A AC DISTRIBUTION 2-1 PAGE: 2-5 CHAPTER 2 ACT-2000 / WHITE-01016 NOTES: Page 2-6 Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 THEORY OF OPERATION POWER ON MODE: ELECTRICAL (REFER TO DRAWING 2-2, PAGE 2-9) The power on mode is activated by turning the Main Power Switch on the Side panel to the "ON" position. When turned on the light in the ACT-2000's main power switch will light. This routes power to the optional heater blanket outlet as well as the outlets on the side of the unit. Power is also routed through the Vacuum timer, through the Oil timer, and to the R12 Timer where it stops. NOTE: Power will only be routed through a timer if the timer is in the "OFF" position. VACUUM MODE: ELECTRICAL: (REFER TO DRAWING 2-3, PAGE 2-11) Power is routed from the main power switch through the AC outlets and to the Vacuum Timer. When the Vacuum Timer is set to the desired amount, the internal contacts of the Vacuum timer route power to the Vacuum Pilot Light, Vacuum Solenoid, Vacuum Pump, and the Vacuum timer (i.e.. It also routes power to itself). This causes the Vacuum Solenoid to be energized, the Vacuum Pump to run, the Vacuum Pilot light to light and the vacuum timer starts. PNEUMATICS: (REFER TO DRAWING 2-4, PAGE 2-13) In the Vacuum Mode the only pneumatic components involved are the Vacuum pump, S1 Vacuum solenoid, In-line Filter, Low Side Gauge, and the Low side port. The Vacuum pump pulls a vacuum through the S1 Vacuum solenoid, the In-line filter, and finally to the low side port. The Low side gauge monitors and displays the amount of vacuum in Inches of Mercury (Hg). Once the time on the vacuum timer has expired, the vacuum timer reverts back to its "OFF" state and AC voltage is then routed to the Oil Timer. OIL CHARGE MODE: ELECTRICAL: (REFER TO DRAWING 2-5, PAGE 2-15) With the Vacuum Timer in the Off position power is routed to the Oil timer. With the oil timer set for a charge amount, power is then routed to the Oil Pilot Light, Oil Solenoid, and the Oil Timer itself. This starts the Oil Timer, Opens the Oil Solenoid, and Lights the Oil Pilot light. PNEUMATICS: (REFER TO DRAWING 2-6, PAGE 2-17) With the vehicle in a deep vacuum (from the vacuum mode) Oil is drawn from the oil tank, and pushed out the Oil tank (due to the 100lb charge of Nitrogen in the Oil Tank), through the two In-line filters, S3 Oil solenoid, flow indicator and flow valve, through another In-line filter and out to the vehicle. Oil continues to flow in this manner until the Oil timer has expired. In that instance the Oil timer contacts open and power is routed to the R12 timer. Effective 8/96 Page 2-7 CHAPTER 2 ACT-2000 / WHITE-01016 R12 CHARGE MODE: ELECTRICAL: (REFER TO DRAWING 2-7, PAGE 2-19) With the vacuum timer and the Oil timer in the "OFF" position AC power is routed to the R12 timer. If the R12 timer has a charge amount selected power is then routed to the S2 R12 Solenoid, Flow Switch light, R12 Float relay, Beeper Relay, and the R12 Timer itself. This starts the R12 Timer, opens the R12 solenoid, lights the flow switch light, energizes the Beeper relay, and powers the R12 timer itself. PNEUMATIC: (REFER TO DRAWING 2-8, PAGE 2-21) Refrigerant from the Tank flows through the first In-line filter, flow switch, second In-line filter, and up to the Differential pressure switch. Then, through the S2 Refrigerant solenoid, through the check valve and flow indicator, through the flow valve, to the low side gauge, through the last In-line filter, and out the low side port to the vehicle. Page 2-8 Effective 8/96 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: ACT-2000A T. PARSELL CHK BY: 0896 J. HINKLE TITLE: DWG: POWER ON MODE 2-2 2-9 PAGE: CHAPTER 2 ACT-2000 / WHITE-01016 Page 2-10 Effective 8/96 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: ATC-2000A T. PARSELL CHK BY: 0896 J. HINKLE TITLE: DWG: VACUUM MODE 2-3 2-11 PAGE: CHAPTER 2 ACT-2000 / WHITE-01016 Page 2-12 Effective 8/96 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. ACT-2000 J. HINKLE 0896 VACUUM MODE 2-4 2-13 CHAPTER 2 ACT-2000 / WHITE-01016 Page 2-14 Effective 8/96 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: ACT-2000A T. PARSELL CHK BY: 0896 J. HINKLE TITLE: OIL CHARGE MODE 2-5 2-15 DWG: PAGE: CHAPTER 2 ACT-2000 / WHITE-01016 Page 2-16 Effective 8/96 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. ACT-2000 J. HINKLE 0896 OIL CHARGE MODE 2-6 2-17 CHAPTER 2 ACT-2000 / WHITE-01016 Page 2-18 Effective 8/96 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: ACT-2000A T. PARSELL CHK BY: 0896 J. HINKLE TITLE: R-12 CHARGE MODE DWG: 2-7 PAGE: 2-19 CHAPTER 2 ACT-2000 / WHITE-01016 Page 2-20 Effective 8/96 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. ACT-2000 J. HINKLE 0896 R-12 CHARGE MODE 2-8 2-21 CHAPTER 2 ACT-2000 / WHITE-01016 Page 2-22 Effective 8/96 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: White-01016 J. HINKLE 0896 CHK BY: TITLE: ELECTRICAL DWG: 2-9 PAGE: 2-23 CHAPTER 2 ACT-2000 / WHITE-01016 Page 2-24 Effective 8/96 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: WHITE-01016 J. HINKLE 0896 CHK BY: TITLE: PNEUMATIC DWG: 2-10 PAGE: 2-25 CHAPTER 2 ACT-2000 / WHITE-01016 Page 2-26 Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 TROUBLESHOOTING COMPLAINT I. LOW TANK LIGHT illuminates while charging refrigerant. CORRECTIVE ACTION Empty or nearly empty tank. Insufficient Flow. • Replace empty tank with a full tank. Flow Switch is sticking Down. II. CHARGING DIFFERENTIAL PRESSURE light illuminates while charging refrigerant. • Press Float Reset Switch on front panel. • Clean Oil Soaked switch Empty or near empty tank. Insufficient pressure. • Replace empty tank with a full tank. • Use Heater blanket to heat tank. • Start Up vehicle A/C system III. ACT-2000, Beeper will not shut off even though all indications are the machine is functioning properly. Beeper relay is sticking in the Normally Closed position. IV. Differential Pressure light comes on too soon. Differential pressure switch is out of calibration. V. Vacuum Pump Will not run. • • Replace Beeper relay. Replace Differential Pressure Switch. Dirty Oil in Pump. • Change Oil in Pump every 25 evacuations. Pump Low on Oil. • Vacuum timer is being turned on with pressure on low side gauge. Pump Overfilled with Oil. • VI. Insufficient Low Tank Light stays ON. Effective 8/96 Oil timer is being turned on out of sequence, then turning on the vacuum timer. Float Switch is Sticking. • Oil in the float switch is sticking causing bobber to stick in the down position. Page 2-27 CHAPTER 2 ACT-2000 / WHITE-01016 TROUBLESHOOTING CONT... COMPLAINT VII. Inaccurately charges Oil CORRECTIVE ACTION Out of Oil. • Replace empty oil tank. Pneumatics Dirty. • Clean Pneumatics. (In-line Filters...) Timer not moving. • VIII. Inaccurately Charges Refrigerant. Change Timer Empty or nearly empty tank. • Replace tank with new tank. Flow valve Dirty. • Take apart and Clean. It cannot be calibrated. Pneumatics Dirty. • Clean Pneumatics, including In-line filters. Charge Timer not moving. • Page 2-28 Replace Timer. Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 PARTS GENERAL This chapter describes assemblies/subassemblies/parts considered replaceable at on-site field installation. All ACT-2000's come standard with a one year warranty. I. How to read SERIAL NUMBERS: NOTE: Serial # Location - Left hand side. A. In 1970's a FOUR digit serial number was used. The First digit dictates the Year Built. 1. B. EXAMPLE: 811032 = Built in 1981 In 1992 to present a 10 digit number was used. 1. 2. 3. 4. 1st digit = Year 2nd digit = Month 3rd digit = Make 4th & 5th digit = Model 5. 6th thru 10th = Lot # 6. Effective 8/96 2341 = Built in 1972 In 1980 to 1991 a SIX digit serial number was used. The first two digits dictate the Year Built. 1. C. EXAMPLE: EXAMPLE: B=1992, C=1993, ... A=January, B=February, ... W=White, S=Snap-On 2A=ACT-2000, 62=ACT-3000 80=ACT-3300, 85=ACT-3400 Number of unit coming off production line. BAS621301=Built in 1992, January, Snap-On, ACT-3000, 1301 lot# Page 2-29 CHAPTER 2 ACT-2000 / WHITE-01016 PARTS BY PICTORIAL ACT-2000 UPPER CONSOLE VIEW ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 DESCRIPTION Gauge, High Light, Pilot Timer, R-12 Beeper Timer, Vacuum Switch, Float Reset Gauge, Low Timer, Oil Tubing, Flow Indicator Receptacle, Heater Solenoid, Oil, w/o fittings Valve, Check, Duck Bill Filter, Oil Tubing, High Circuit Valve, Flow Page 2-30 PART NUMBER K15022 K30505 K30400 K30555 K30410 K30042 K15032 K30420 K40820 K30061 K60060 K60025 K90423 K40801 K60021 ITEM 16 17 18 19 20 21 22 23 NS NS NS NS NS NS NS DESCRIPTION Solenoid, Vac. w/o fittings Relay, Beeper Relay, Float Switch Solenoid, R-12 w/o fittings Switch, Diff. Pressure Switch, ON/OFF Outlet, 115V Breaker, Circuit 8 amp Knob, Timers Thermometer Cord, Power Tubing, Low Circuit Tubing, Accessory Tubing, Purge Port Low Gauge adapter fitting PART NUMBER K60060 K30041 K30041 K60060 K30023 K30011 K30060 K30051 K90005 K99008 K30151 K40813 K40828 K40840 K10681 Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 ACT-2000 LOWER CABINET VIEW ITEM 1 2 3 4 5 DESCRIPTION Filter, Oil Filter, R-12 Hose, 3' Red Hose, 2' Blue Cylinder, Oil Charge 1G. Effective 8/96 PART NUMBER K90423 K90423 K25107221 K25207222 K90800 ITEM 6 7 8 NS NS DESCRIPTION Tube, R-12 Supply Strap, Tank Hose, 3' Blue Float Switch Float Switch Box PART NUMBER K40580 K90080 K25007220 K30040 K35150 Page 2-31 CHAPTER 2 ACT-2000 / WHITE-01016 ACT-2000 VACUUM PUMP ASSEMBLY ITEM 1 2 3 3a DESCRIPTION Vacuum Pump Tube, Drain Cap, relay, Breaker assy. Breaker, Compressor Page 2-32 PART NUMBER K16019 Not Available K30314 K30314 ITEM 3b 6 7 DESCRIPTION Relay, Compressor Mounts, Shock Case, Relay PART NUMBER K30314 Not Available K30314 Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 PARTS IN ALPHABETICAL ORDER DESCRIPTION Adapter, Fitting Beeper Box, Float Switch Breaker, 8 Amp Circuit Cabinet, Complete Cap, 1/4 Flair Caster Catches, Magnetic Door Chrome Strip kit (left & right) Cord, Float Switch Power Cord, Power Depressors, Screw in Door, Left Door, Right Drawer Filter, Screen Filter, Inline Particle Gasket, Hose Gauge, High Gauge, Low Grommet (Heyco Bushing) Handle, Drawer Hanger, Hose Harness, Complete Wiring Hose, 96" Blue Hose, 96" Red Hose, 96" Yellow Hose, 36" Blue Hose, 24" Yellow Hose, 36" Red Hose, 24" Yellow Knob, Timers Label, Snap-On Logo Light, Pilot Lock and Key, Drawer Mats, Rubber O-Ring, Neoprene Oil, R-12 Refrigerant Outlet, Single 115V Outlet, Dual 115V Panel, Back Panel, Front Relay Relay, Overload, Cap, and Case Slides, Drawer Solenoid Strap, Tank Switch, Float Reset Switch, Float Switch, ON/OFF Switch, Differential Pressure Thermometer Timer, Vacuum Timer, Oil Effective 8/96 PART NUMBER K10681 K30555 K35150 K30051 K35006 K90312 K80001 K35120 K35402 K30152 K30151 K45321 K35035 K35036 K35051 K90420 K90423 K45331 K15022 K15032 K90041 K35091 K35100 K31018 K25007160 K25107161 K25207162 K25007220 K25207223 K25107221 K25207222 K90005 K35403 K30505 K35070 K35145 K45030 K90800 K30061 K30060 K35029 K35401 K30041 K30314 K35110 K60060 K90080 K30042 K30040 K30011 K30023 K99008 K30410 K30420 COMMENTS Back Side of Low Side Gauge 110 Volt Sheet Metal Sheet Metal To Cover Outside Bulkhead Ports Package Of 10 Screen Filters Brass Assy. Oil or R-12 Liquid Filled Gauges No longer Available Liquid Filled Gauges No longer Available Power Cord, Float Cord, Pump Cord With Screws Vehicle Hose Without Hand Valve Vehicle Hose Without Hand Valve Auxiliary Vacuum Hose From Virgin Tank To Float Switch Assy From Oil Tank To Oil Charge Solenoid Vacuum Pump To Vacuum Solenoid Logo on Front Drawer All Front Panel Indicators Contains Both Black Rubber Mats Package of 25 1 Gallon Beeper and Float Switch For Old Style Vacuum Pump R-12, Oil, and Vacuum W/out fittings Includes Photocell, Light, and Bobber Page 2-33 CHAPTER 2 ACT-2000 / WHITE-01016 DESCRIPTION Timer, R-12 Tube, Differential Pressure Switch Tube, Drain Tube, R-12 Supply Tubing, Flow Indicator Tubing, Purge Tubing, Low Circuit Tubing, Flow Indicator Tubing, High Circuit Tubing, Accessory Vacuum Pump Valve, Antiblow-back Valve, Flow Valve, Schrader Valve, Antiblow-back Valve, Check (Duck Bill) Valve, Check (Non-Duck Bill) Page 2-34 PART NUMBER K30400 K40512 K40750 K40580 K40823 K40840 K40813 K40820 K40801 K40828 K16019 K60072 K60021 K99011 K60070 K60025 K60119 COMMENTS From Dif. Press. Switch To Brass Tee From Float Switch Assy. To Solenoid Old Style Contains Flow Indicator To Low side gauge New Style Contains Purge Valve, To High side gauge To R-12 Charge solenoid Female End Used In Bulkhead Ports on Side of Unit Male End Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 PARTS IN NUMERICAL ORDER PART NUMBER K10681 K15022 K15032 K16019 K25007160 K25007220 K25107161 K25107221 K25207162 K25207222 K25207223 K30011 K30023 K30040 K30041 K30042 K30051 K30060 K30061 K30151 K30152 K30314 K30400 K30410 K30420 K30505 K30555 K31018 K35006 K35029 K35035 K35036 K35051 K35070 K35091 K35100 K35110 K35120 K35145 K35150 K35401 K35402 K35403 K40512 K40580 K40750 K40801 K40813 K40820 K40823 K40828 K40840 K45030 Effective 8/96 DESCRIPTION Adapter Fitting Gauge, High Gauge, Low Vacuum Pump Hose, 96" Blue Hose, 36" Blue Hose, 96" Red Hose, 36" Red Hose, 96" Yellow Hose, 24" Yellow Hose, 24" Yellow Switch, ON/OFF Switch, Differential Pressure Switch, Float Relay Switch, Float Reset Breaker, 8 Amp Circuit Outlet, Dual 115V Outlet, Single 115V Cord, Power Cord, Float Switch Power Relay, Overload, Cap, and Case Timer, R-12 Timer, Vacuum Timer, Oil Light, Pilot Beeper Harness, Complete Wiring Cabinet, Complete Panel, Back Door, Left Door, Right Drawer Lock and Key, Drawer Handle, Drawer Hanger, Hose Slides, Drawer Catches, Magnetic Door Mats, Rubber Box, Float Switch Panel, Front Chrome Strip kit (left & right) Label, Snap-On Logo Tube, Differential Pressure Switch Tube, R-12 Supply Tube, Drain Tubing, High Circuit Tubing, Low Circuit Tubing, Flow Indicator Tubing, Flow Indicator Tubing, Accessory Tubing, Purge O-Ring, Neoprene COMMENTS Back Side of Low Side Gauge Liquid Filled Gauges No longer Available Liquid Filled Gauges No longer Available Vehicle Hose Without Hand Valve From Virgin Tank To Float Switch Assy Vehicle Hose Without Hand Valve From Oil Tank To Oil Charge Solenoid Auxiliary Vacuum Hose Vacuum Pump To Vacuum Solenoid Includes Photocell, Light, and Bobber Beeper and Float Switch For Old Style Vacuum Pump All Front Panel Indicators 110 Volt Sheet Metal With Screws Contains Both Black Rubber Mats Sheet Metal Logo on Front Drawer From Dif. Press. Switch To Brass Tee From Float Switch Assy. To Solenoid Contains Purge Valve, To High side gauge To Low side gauge New Style Old Style To R-12 Charge solenoid Contains Flow Indicator Package of 25 Page 2-35 CHAPTER 2 ACT-2000 / WHITE-01016 PART NUMBER K45321 K45331 K60021 K60025 K60060 K60070 K60072 K60119 K80001 K90005 K90041 K90080 K90312 K90420 K90423 K90800 K99008 K99011 Page 2-36 DESCRIPTION Depressors, Screw in Gasket, Hose Valve, Flow Valve, Check (Duck Bill) Solenoid Valve, Antiblow-back Valve, Antiblow-back Valve, Check (Non-Duck Bill) Caster Knob, Timers Grommet (Heyco Bushing) Strap, Tank Cap, 1/4 Flair Filter, Screen Filter, Inline Particle Oil, R-12 Refrigerant Thermometer Valve, Schrader COMMENTS R-12, Oil, and Vacuum W/out fittings Male End Female End Power Cord, Float Cord, Pump Cord To Cover Outside Bulkhead Ports Package Of 10 Screen Filters Brass Assy. Oil or R-12 1 Gallon Used In Bulkhead Ports on Side of Unit Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 ACT-2000 OPERATORS MANUAL TABLE OF CONTENTS Warranty................................................................................................................................................. 2-34 Assembly Instructions .......................................................................................................................... 2-35 Hose Placement..................................................................................................................................... 2-35 Refrigerant Tank Replacement and Air Purging Procedures.............................................................. 2-36 Oil Tank Replacement and Air Purging Procedures............................................................................ 2-36 Operating Instructions .......................................................................................................................... 2-37 Testing Air Conditioner ............................................................................................................ 2-37 Discharging Air Conditioner..................................................................................................... 2-37 Use with Recovery Recycling Equipment............................................................................... 2-37 Evacuating................................................................................................................................. 2-37 Oil Charging .............................................................................................................................. 2-37 Charging with Unheated R-12 .................................................................................................. 2-38 Charging with Heated R-12...................................................................................................... 2-38 Charging through Accessory Port ........................................................................................... 2-38 Maintenance........................................................................................................................................... 2-39 Vacuum Pump Oil Change ....................................................................................................... 2-39 Purge Valve Ball Replacement ................................................................................................. 2-39 Hose Gasket Replacement........................................................................................................ 2-39 Tubing and Solenoid Flushing ................................................................................................ 2-40 Solenoid Cleaning..................................................................................................................... 2-40 Flow Valve Cleaning ................................................................................................................. 2-41 Storage................................................................................................................................................... 2-41 Effective 8/96 Page 2-37 CHAPTER 2 ACT-2000 / WHITE-01016 WARRANTY This product is warranted to be free of defects in workmanship and materials for a period of one year from the date of purchase by original manufacturer. If the product fails within this period, it will be repaired or replaced at sellers option, provided (1) the product is submitted with proof of purchase date, (2) transportation charges are prepaid to the factory. Liability under this warranty is expressly limited to repairing or replacing the product or parts thereof. This warranty does not apply to product or parts broken from accident, overload, abuse or if they have been tampered with or altered. If this warranty does not apply, then the retail purchaser shall pay all costs for labor, material and transportation. Page 2-38 Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 ASSEMBLY INSTRUCTIONS 1. 2. 3. INSTALL WHEELS USING BOLTS PROVIDE. Install WITH NUTS "UP" TO PROVIDE WHEEL CLEARANCE. Install handles on drawer and front doors using screws provided. Remove shipping caps from vacuum pump discharge tube. Install the rubber vent tube on discharge tube and route through hole provided in bottom of cabinet. HOSE REPLACEMENT On all 96" hoses listed below, make sure you attach the straight end (without core depressor) to ports on the side of the cabinet. 1. EXTERNAL HOSE PLACEMENT a. The 96" red hose is connected between the discharge port on the air conditioner system and the console port marked "HIGH". b. The 96" blue hose is connected between the suction port on the air conditioner system and the console port marked "LOW". c. (OPTIONAL) The 24" hose is connected to the console port marked "ACCESSORY" with the valve core depressor end of the hose on the port. (See the "ACCESSORY CHARGING" section of this manual for instructions on its use.) IMPORTANT Anti-blow back valve is attached to 45 end of red hose. DO NOT REMOVE from red hose at any time. 2. INTERNAL HOSE PLACEMENT IMPORTANT Wear safety goggles when installing internal hoses. a. The 18" blue hose is connected between the R-12 float assembly and the R-12 tank. After connection is made, open R-12 tank valve. Be certain that the tank valve is not leaking. b. The 36" red hose is connected between the oil solenoid filter and the oil tank. c. The 36" yellow hose is connected between the vacuum solenoid valve and the vacuum pump suction port. Effective 8/96 Page 2-39 CHAPTER 2 ACT-2000 / WHITE-01016 REFRIGERANT TANK REPLACEMENT AND AIR PURGING PROCEDURES IMPORTANT Wear safety goggles during this procedure. 1. 2. 3. 4. 5. 6. 7. 8. Turn master switch "OFF". Remove blue hose from empty tank and connect to the replacement tank. Turn tank valve "ON". Check tank valve for leak. The R-12 tank must be positioned such that liquid is flowing from the port. Turn master switch "ON". Turn R-12 timer "ON". (If R-12 tank became empty while charging an air conditioner the R-12 timer will already be on.) Momentarily depress the float reset switch until float switch light goes out. Refrigerant charging system is now ready for use. OIL TANK REPLACEMENT AND AIR PURGING PROCEDURES. IMPORTANT Wear safety goggles during this procedure. 1. 2. 3. 4. Turn master switch "OFF". Remove red hose from empty tank. Connect red hose to new tank. Place tank on its handles and turn tank valve on. a. If the tank is being replaced while the machine is not connected to an air conditioner system, purge air from the lines by turning the master switch and the oil timer "ON" for two to three seconds. b. If the tank ran empty while charging oil into an evacuated system. Purge air fro ht e lines by turning the master switch "ON" and then the vacuum pump "ON" for approximately two minutes. Page 2-40 Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 OPERATING INSTRUCTIONS IMPORTANT Always wear safety goggles when servicing a system and operating service center. Testing Air Conditioner: 1. 2. 3. 4. 5. 6. With engine off, attach hoses-red to high side and blue to low side. On compressors with manual service valve, mid-seat both valves. Bleed air from hoses at right side of cabinet. Start engine and adjust speed to fast idle. Set air conditioner controls at "MAX" cooling and "HIGH" fan speed. Insert thermometer in air outlet nearest the evaporator. With windows and doors closed, allow system pressures to stabilize. Set blower fan speed on "LOW" and check ambient temperature, gauge readings , thermometer and sight glass. Discharging Air Conditioner: IMPORTANT Consult local laws governing discharge of R-12 to the atmosphere. 1. 2. 3. With the engine off, open purge valve. When low side pressure drops below 10 PSI, vacuum pump can be turned "ON". Close purge valve and turn off vacuum pump when low side pressure drops below 0 PSI. Use with Recovery Recycling Equipment: 1. 2. 3. Attach hose from the recovery machine to the purge port. Open purge valve and start recovery machine. Close purge valve when recovery is complete. Evacuating: 1. 2. 3. Set vacuum timer for ten minutes. (Bubbles in flow indicator normal.) When timer shuts off, gauge readings should hold for two to three minutes if there are no leaks in the system. Reset timer for thirty minutes. If vacuum pump cycles on and off, change vacuum pump oil. Oil Charging: IMPORTANT Charge oil only into an evacuated system. 1. Select the temperature scale nearest the ambient temperature. 2. Set desired oil charge on proper scale. Flow indicator must be monitored. If flow appears while charging, turn master switch off immediately and refer to oil tank replacement. 3. When oil charge shuts off, charge a minimum 1/8 pound of R-12 to clear oil from hoses. Effective 8/96 Page 2-41 . CHAPTER 2 ACT-2000 / WHITE-01016 W h eCharging with Unheated R-12: n n1. o2. t i n3. Bypass cycling clutch controls on cycling clutch system. Set R-12 timer to desired charge on the "Unheated Tank" scale of the R-12 timer dial. (R-12 flow must be monitored in flow indicator. If R-12 supply is depleted and flow stops while charging , shut master switch off and refer tot R-12 tank replacement. Start car after 1/2 lb. of refrigerant has been dispensed. uCharging with Heated R-12: s e1. Allow 5-15 minutes for pressure to build in the tank before beginning to charge R-12. (This can be , accomplished while evacuating and/or oil charging.) 2. Set desired charge on the "Heated Tank" scale of the R_12 timer dial. (Only charge heated R-12 A L into an A/C system that is NOT operating. Unheated R-12 can be charged while the system is in W operation.) A Y Charging through Accessory Port: S 1. R E 2. M O 3. V E 4. 5. H O S E Connect safety dispensing valve to can. Connect 24" hose to safety dispensing valve, then connect other end of hose (with core depressor) to accessory fitting. Open dispensing valve and charge in liquid position. Monitor sight glass until it clears. Shut engine off, remove and plug hoses. Replace system service cap and turn service center master switch "OFF". F R O M A C C E S S O R Y P O R T A N D C A Page P 2-42 T Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 MAINTENANCE Vacuum Pump Oil Change: The vacuum pump should have the oil changed after every 25 evacuations and must be changed after evacuating a contaminated system, i.e., compressor failure, dehydrator failure, or system left open. Most failures of the vacuum pump occur from contaminated pump oil. To change the oil: 1. 2. 3. 4. 5. 6. Remove plug in bottom of pump. Allow oil to drain completely. Replace the plug making sure the O-ring seal is not damaged. Unscrew vacuum pump suction hose from the solenoid valve. Place suction hose into 12 ounces of General Motors' transmission fluid "type A" (DEXTRON). Turn the vacuum pump on and it will suck the oil into itself. DO NOT OVERFILL. THE PUMP HOLDS 12 OUNCES. Purge Valve Ball Replacement: The purge valve should require only a small amount of torque to shut off. If it is over-tightened the valve might begin to leak. If this happens, remove the purge valve stem and replace the steel ball with an oversized ball (3/16"). Hose Gasket Replacement: The hose gaskets will eventually become crushed and might leak after many uses or if over-tightened. To remove the gaskets on the straight end, pry the gasket out with an ice pick. Then press in a new gasket. To remove the gaskets on the bent end, use needle nose pliers to unscrew old gasket, then screw in new gasket. Effective 8/96 Page 2-43 CHAPTER 2 ACT-2000 / WHITE-01016 Tubing and Solenoid Flushing: 1. 2. 3. 4. 5. 6. 7. 8. Disconnect power cord and remove bottom cover. Remove the flow valve. Lay a rag under the tubing port that points downward. To flush the R-12 solenoid valve: a. Turn R-12 timer on for 2-3 seconds. b. Repeat 2 or 3 time to insure thorough flushing. To flush the oil solenoid valve: a. Remove red hose from oil tank. b. Shut R-12 tank valve off and remove R-12 hose from tank. c. Connect red oil hose to R-12 tank and turn R-12 tank valve on. d. Turn oil timer on for 2-3 seconds. e. Repeat 2 or 3 times to insure thorough flushing. f. Return all hoses to original position. Install flow valve. To flush the vacuum solenoid valve: a. Cap the LOW port on the back of the console. b. Turn the R-12 timer on and allow the pressure to stabilize. c. Turn R-12 timer off and turn vacuum pump on. d. Repeat 2 or 3 times to insure thorough flushing. If the solenoid valve still malfunctions, see Solenoid Cleaning section. Solenoid Cleaning: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Disconnect power cord and remove bottom cover. Disconnect hose, tubing and fittings from solenoid to be cleaned. Remove retainer nut and ID plate from end of valve assembly. Slide brass valve assembly out of electrical coil and bracket. Place brass body in a vise. (Avoid crushing ports) Use right angle truarc pliers to unscrew collar from brass body. Disassemble and clean inside of valve thoroughly. Reassemble valve making certain that spring is in end of plunger with tapered end out and plunger is free in tube. Plunger seat material should be flush with the end of plunger and show a complete circular indentation where it mates on the brass seat in the body. Check for leaks by capping the LOW port on the side of the console, turning the R-12 timer on, and allowing the pressure to stabilize. Turn r-12 timer off and leak check Page 2-44 Effective 8/96 CHAPTER 2 ACT-2000 / WHITE-01016 .Flow Valve Cleaning: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove valve from machine. Remove knurled nut. Remove top, piston, and spring. Clean in mineral spirits and blow dry. If piston cylinder, gasket, and O-ring come out of body while cleaning, place cylinder in body with small holes toward adjusting screw and place gasket into channel formed by cylinder body. Insert spring into cylinder to rest on adjusting screw. Insert piston into cylinder. (Be certain spring enters cavity in piston and small orifice is out.) Place the cap and knurled nut on body and tighten securely. Before replacing in machine, flush the tubing. Replace valve in machine. STORAGE When storing the machine for a prolonged period of over a month, a few simple precautions will insure proper performance when you are ready to use the machine again. 1. Change the vacuum pump oil. 2. 3. Make sure all hoses are sealed. Leave purge valve slightly open to relieve pressure. 4. Pull vacuum for 5 minutes on the low hose. (Hose must be plugged.) Leave this vacuum on hose during storage. Effective 8/96 Page 2-45 SECTION I AC POWER DISTRIBUTION _____________________________________________________________ THIS UNIT MUST BE PLUGGED IN TO A PROPER AC OUTLET FOR UNIT TO OPERATE CORRECTLY. REFER TO UNIT ID PLATE LOCATED ON BACK OF UNIT. EXTENSION CORDS ARE NOT RECOMMENDED, BUT IF AN EXTENSION CORD MUST BE USED, USE A CORD THAT IS LESS THAN 50 FEET WITH A 16 AWG, OR ABOVE 50 FEET AND LESS THAN 100 FEET WITH A 14 AWG. USE STANDARD REFRIGERANT HANDLING SAFETY PROCEDURES WHEN PERFORMING INSTALLATION ALWAYS WEAR SAFETY GOGGLES, DON'T SPILL OR TOUCH LIQUID REFRIGERANT, AVOID FLAMES, & EXCESSIVE HEAT. USE ONLY IN WELL VENTILATED AREA. AC DISTRIBUTION (Refer to Drawing 3-1, Page 3-3) Always use the "One Hand Rule" when working with AC voltages by keeping one hand in your pocket or behind your back. Before removing wires from the ACT-2500, always verify that the Tester is "UNPLUGGED". The hot side (black wire) of the 115VAC is wired directly to the (NC) High Pressure Switch. From there it is routed to the 9-Pin Connector Pin 2 which supplies the AC volts to the Cycle Start Switch. The AC is also routed from the High Pressure Switch through the (NC) Vacuum Switch. From there it is routed to the 9-Pin Connector on Pin 3 which supplies AC volts to the Master Relay Pin 6. AC is located on the Master Relay Pins 1, 2, and 5 via Pin 6. The Neutral line is routed to the Compressor, Solenoids, 9-Pin Connector Pin 1, Fan, Lamps, and the Master Relay Pin 7. Page 3 - 1 NOTES _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ Page 3 - 2 Page 3 - 4 SECTION II THEORY OF OPERATION _______________________________________________________________________ POWER ON MODE ELECTRICAL: (Refer to Drawing 3-2, Page 3-7) Power is routed from the AC power cord through the (NC) High Pressure Switch. AC is then routed to the 9-Pin Connector pin-2 and also through the (NC) Vacuum Switch. AC from the Vacuum Switch is routed to the 9-Pin Connector Via pin-3. AC is routed from pin-3 to the Master Relay pin-6, and routed from pin-2 to the Cycle Start Switch. CYCLE START MODE ELECTRICAL: (Refer to Drawing 3-3, Page 3-9) With the Cycle Start Switch depressed AC is routed from the Cycle Start Switch to the System Operating Lamp, Selector Switch, Fan, Compressor, and the Master Relay pin-8. Once the Cycle start switch is released the Master Relay will energize and supply AC to pin-3 from pin-6 on the Master Relay. This, in turn supplies AC to pin-8 on the Master Relay, Fan, Compressor, System Operating Lamp, and Selector Switch. The unit will continue to recover until the vacuum switch opens, due to a 5 to 10 inch vacuum draw on the vehicle. If the Vacuum Switch is open, AC will not be present at the 9-Pin Connector pin-3. Therefore, the Cycle Start Switch will not energize the Master Relay when released. RECOVERY MODE: ELECTRICAL (Refer to Drawing 3-4, Page 3-11) The Recovery Mode will be activated only if the System Operating Lamp is "ON" (Refer to Cycle Start Mode). Selecting RECOVER, using the Selector Switch, will route AC to the 9-Pin Connector pin-5, to the Common pin on the Tank Full Switch. If the tank is full, power is routed through the NO pin on the Tank Full switch and goes through the 9-Pin Connector pin-6 to turn "ON" the Tank Full Lamp. If the tank is not full, power is routed through the NC pin on the Tank Full switch to energize the (NC) Recovery Solenoid thus opening the Solenoid. All commons are tapped together and are routed through the 9-Pin Connector pin-1, back to the AC power cord. PNEUMATIC (Refer to Drawing 3-5, Page 3-13) In the Recovery Mode, the refrigerant enters the system through the In-Line Filter to remove any debris that may contaminate the system. The refrigerant then travels through the System Pressure Gauge so the operator can monitor the system pressure. The refrigerant then travels through the Recovery Solenoid, which is OPEN in this mode, then past the Vacuum Switch into the Oil Separator. The Vacuum Switch stops the cycle at a vacuum of 5 to 10 HG at the end of the cycle. The Oil Separator is located internally in the Reclaim Tank, and the purpose of the Oil Separator is to collect any oil that may come from the automobile AC system during Recovery. The Oil Separator requires manual purging after every recovery. The oil free refrigerant then travels into the Filter Dryer that removes any moisture, then through a one way Check Valve that prevents back flow. The refrigerant then enters the suction (LOW) side of the compressor where it is converted from a low pressure vapor to a high pressure vapor that exits the discharge (HIGH) side of the compressor. Next the refrigerant enters the Temprite Oil Reservoir INLET port. Page 3 - 5 RECOVERY MODE (PNEUMATIC) continued... The Temprite collects any Compressor oil that escapes the discharge side of the pump, and it collects in the bottom. At any point above 2.5 inches from the bottom, a ball float inside the Temprite will rise and open a needle valve which will let some oil return to the pump through the RETURN port, thus keeping the pump at the correct oil level. The refrigerant leaves the Temprite via the OUTLET port as a high pressure vapor. The high pressure vapor travels through a coil that works as a condenser and converts the high pressure vapor into a high pressure liquid. The high pressure liquid refrigerant empties into the Reclaim Tank via a one way Check Valve to prevent back flow. RECYCLE MODE: ELECTRICAL (Refer to Drawing 3-6, Page 3-15) The Recycle Mode will be activated only if the System Operating Lamp is "ON" (Refer to Cycle Start Mode). Selecting RECYCLE using the Selector Switch, will route AC to the 9-Pin Connector pin-7, to the (NC) Recycle Solenoid thus opening the Solenoid. PNEUMATIC (Refer to Drawing 3-7, Page 3-17) In the Recycle Mode, the liquid refrigerant is drawn from the Reclaim Tank, through the Recycle Solenoid, Moisture Indicator, and Liquid Capillary Tube to Re-enter the system. The refrigerant then travels into the Oil Separator. The Oil Separator is located internally in the Reclaim Tank, and the purpose of the Oil Separator is to collect any oil that may come from the refrigerant leaving the Reclaim Tank. The Oil Separator requires manual purging after every recycle. The oil free refrigerant then travels into the Filter Dryer, that removes any moisture, then through a one way Check Valve that prevents back flow. The refrigerant then enters the suction (LOW) side of the compressor where it is converted from a low pressure vapor to a high pressure vapor that exits the discharge (HIGH) side of the compressor. Next the refrigerant enters the Temprite Oil Reservoir INLET port. The Temprite collects any Compressor oil that escapes the discharge side of the pump, and it collects in the bottom. At any point above 2.5 inches from the bottom, a ball float inside the Temprite will rise and open a needle valve which will let some oil return to the pump through the RETURN port, thus keeping the pump at the correct oil level. The refrigerant leaves the Temprite via the OUTLET port as a high pressure vapor. The high pressure vapor travels through a coil that works as a condenser and converts the high pressure vapor into a high pressure liquid. The high pressure liquid "Cleaned" refrigerant empties into the Reclaim Tank via a one way Check Valve that prevents back flow. This process must run until the Moisture Indicator indicates that the refrigerant is free of moisture. Page 3 - 6 . Page 3 - 8 Page 3 - 10 Page 3 - 12 Page 3 - 14 Page 3 - 16 Page 3 - 18 SECTION III TESTING PROCEDURES _______________________________________________________________________ RECOVERY CHECK 1. Open the cabinet door. 2. Remove the Reclaim Tank from unit. 3. Connect the Testing Bypass Hose to both black hoses that were connected to the Reclaim Tank. 4. Connect the Pressure Relief Valve to the Compression Discharge Hose. 5. Remove any hose or cap from the Recovery Port on the side of the unit. 6. Attach the Air Purge Gauge to the Schrader Valve on top of the filter housing and purge any air that is present. Close the gauge. 7. Put the Rocker Switch in the Recovery position. 8. Press the Cycle Start Switch. 9. With the System Operating Light ON, feel the Recovery Port for suction with your right hand. Feel the Pressure Relief Valve with your left hand. a. b. c. If you do not feel suction at the Recovery Port, see Troubleshooting (Page 22). If you do not feel suction at the Recovery Port, but the Air Purge Gauge on the Filter Shell draws into a vacuum, see Troubleshooting Page 22). If both System Operating and Tank Full Lights come on, see Scale Calibration (Page 20). TANK FULL LIGHT CHECK 1. With your finger near the Recovery Port, place your left foot on the Scale Plate. 2. As you depress the Scale Plate enough to trigger the Tank Full Light, suction at the Recovery Port should stop. As you lift your foot off the Scale Plate, the Tank Full Light should go out and you should feel suction again on the Recovery Port. a. b. If the Tank Full Light Remains ON, see Scale Calibration. (Page 20). If the Tank Full Light does not illuminate, see Scale Calibration (Page 20). 3. Repeat step 2 several times. 4. Hold your finger over the Recovery Port (or cap it off) and watch the Air Purge Gauge on the Filter shell. The gauge should go down into a vacuum of 10-20 inches of mercury and the System Operating Light should go out as the unit automatically turns itself OFF. If the Air Purge Gauge goes down to 10-20 inches of mercury, but the machine does not turn OFF, then: a. b. The Vacuum Switch (K30030-A) needs to be replaced or, There is an internal leak. HIGH PRESSURE SWITCH CHECK 1. Remove the Pressure Relief Valve from the red compression discharge hose. Page 3 - 19 HIGH PRESSURE SWITCH CHECK continued... 2. Attach adapted High Pressure Gauge to the red Compression Discharge hose. 3. With the Rocker Switch in Recovery Mode, press the Cycle Start Switch. (Watch Gauge PSI build). a. b. Old style switch should cut off at 250-275 PSI. New style switch should cut off at 315-325 PSI. 4. If unit cuts off within + 10 PSI of the upper and lower specified range, the switch needs to be replaced. 5. Remove adapted High Pressure Gauge and attach Pressure Relief Valve. 6. Bleed all air from red Compression Discharge hose. (Point hose towards floor). RECYCLE TEST: 1. Open both the Liquid and Vapor Valves on the Reclaim Tank. 2. Press the Selector switch in the Recycle position. 3. Press the Cycle Start Switch until you see liquid in the Moisture Indicator. Release the Cycle Start Switch. 4. After the Indicator has turned green or has changed noticeably, the refrigerant is dry. Press the Selector Switch to the End Cycle position. 5. Upon reaching a vacuum of 10-20 inches of mercury, the unit will shut down. After the unit is OFF, close both the Liquid and Vapor Valves on the Reclaim Tank. 6. Disconnect the hoses from the Reclaim Tank and remove the Tank from the unit. 7. Before installing an empty Reclaim Tank on the unit, bleed the pressure off of the red Compression Discharge hose using the Pressure Relief Valve. SCALE CALIBRATION: 1. With the Selector Switch in the Recovery Mode and the Cycle Start Switch activated, lift the Reclaim Tank from the Scale Plate thereby decreasing the amount of weight on the Scale Plate. Does the Tank Full Light turn OFF? If so, proceed to step 2. If not proceed to troubleshooting. 2. With the Reclaim tank removed, locate the Scale Calibration Bolt on the Scale Plate. 3. Remove the 1/2" Locknut on the Calibration Bolt and turn the threaded portion of the Calibration Bolt counterclockwise as far as it will go. 4. Center 80Lbs. of weight on the Scale Plate. 5. With the Selector Switch in the Recovery Mode, turn the Calibration Bolt clockwise 1/4 revolution at a time until you hear the Microswitch beneath the Scale Plate click and see the Tank Full Light illuminate. 6. Reinstall 1/2" Locknut while holding Calibration Bolt securely from underneath the Scale Plate. Holding the Calibration Bolt ensures that it does not move while tightening the 1/2" Locknut. 7. Reinstall the Reclaim Tank ensuring that the hose connections are tight. Page 3 - 20 TROUBLESHOOTING I. System Operating Lamp will not light when Cycle Start Switch is depressed. The System Operating Lamp is burned out. While holding down the Cycle Start Switch, Check for 115 Volts AC across System Operating Lamp. If voltage is present, replace lamp. The Cycle Start Switch is open. Check for 115 Volts AC on both sides of the switch while it is being depressed. If voltage is not present on one side, replace switch. The High Pressure Switch is open. Check for 115 Volts AC on both sides of the Switch. If voltage is not present on one side, check the pressure in the reclaim tank. If < 320psi in tank replace pressure switch. Open wire between High Pressure Switch and Cycle Start Switch. Check resistance between pin 2 of the 9-Pin Connector to the Cycle Start Switch and the High Pressure Switch. II. System Operating Lamp will not stay lit after Cycle Start Switch was released. Master Relay will not energize. Hold down the Cycle Start Switch, and check for 115 Volts AC on pin 8 of the Master Relay. If voltage is not present, refer to drawing 3-3. Hold down the Cycle Start Switch, and check for 115 Volts AC on pin 6 of the Master Relay. Replace Master Relay Vacuum Switch is open. Release the vacuum via the Filter Dryer. Check for 115 Volts AC on both sides of the Vacuum Switch. If voltage is present on both sides, END TROUBLESHOOTING. If voltage is not present on one side, and there is not a vacuum at the Filter Dryer, replace Vacuum Switch. Page 3 - 21 TROUBLESHOOTING Cont... III. Compressor will not start running when the System Operating Lamp is lit. Voltage not present at Compressor. Check for 115 volts AC on 9-Pin Connector on pin 4. If voltage is present, check Klixon. IV. Tank Full Lamp on, but the Reclaim Tank is not full or empty. NOTE: The System Operating Lamp must be on to perform this test. Tank Switch stuck open. Place the Selector Switch in the RECOVER mode and check the voltage on the 9-Pin Connector pin 6. If voltage is present, check for 115 Volts on the Recovery Solenoid. If voltage is not present, replace Tank Switch. If voltage is present, Tank Switch is shorted internal to both connectors, replace Tank Switch. V. Recovery unit will not pull from A/C system. Hose connections not opening valve cores on A/C system. Check valve cores and depressors Recovery Tank has excessive air. Refer to Operator Manual for procedure on purging excess air from tank. Tank inlet hose not connected. Connect hose to tank correctly. Tank is full. Check Tank Full Lamp. Pneumatics are dirty. Clean pneumatics. VI. Recovery unit will not continue running after starting in RECYCLE mode. Liquid valve on tank is not open. Open liquid valve on tank. Ambient temperature below 50 degrees F. Move machine to warmer ambient. System not stabilized when button released Hold down Cycle Start Switch longer. Refer to complaint II. Page 3 - 22 TROUBLESHOOTING Cont... VII. Recovery unit shuts off after running a short time in RECYCLE mode. Excessive air in tank. VIII. Moisture Indicator will not turn green. Insufficient process time. Refer to Operator Manual for procedure on purging excess air from tank. Run in RECYCLE mode longer. Filter/Dryer contaminated. Change Filter. Indicator fouled. Change indicator element. IX. Recovery unit will not shut off automatically in END CYCLE mode. Recovery tank has excessive air. Refer to Operator Manual for procedure on purging excess air from tank. Defective Vacuum Switch. Replace switch. The two large quick connects are not fully engaged to the tank. Check connections. Page 3 - 23 NOTES _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ Page 3 - 24 SECTION IV PARTS _______________________________________________________________________________________ GENERAL This chapter describes assemblies/subassemblies/parts considered replaceable at on-site field installation. NOTE: The following is a breakdown description for Serial Numbers: I. How to read SERIAL NUMBERS: NOTE: Serial # Location - Left hand side. A. In 1970's a FOUR digit serial number was used. The First digit dictates the Year Built. 1. B. 2341 = Built in 1972 In 1980 to 1991 a SIX digit serial number was used. The first two digits dictate the Year Built. 1. C. EXAMPLE: EXAMPLE: 811032 = Built in 1981 In 1992 to present a 10 digit number was used. 1. 2. 3. 4. 1st digit = Year 2nd digit = Month 3rd digit = Make 4th & 5th digit = Model 5. 6th thru 10th = Lot # 6. EXAMPLE: B=1992, C=1993, ... A=January, B=February, ... W=White, S=Snap-On 2A=ACT-2000, 62=ACT-3000 80=ACT-3300, 85=ACT-3400 Number of unit coming off production line. BAS621301 = Built in 1992, January, Snap-On, ACT-3000, 1301 lot # Page 3 - 25 SUBSECTION A. PARTS BY PICTORIAL ACT-2500 FRONT VIEW Page 3 - 26 ACT-2500 FRONT VIEW ITEMS ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER 1 Core, Filter K16200 12 Spring, Scale K90660 2 a Gauge Gauge Lens K15041 K15005 a Switch, Tank Full K30015 3 Dry Dot, Green K91050 13 Tube, Scale Pivot K42016134 a Dry Dot, Yellow K91050 a Tube Cap, Scale Pivot K42016134 4 Switch, Rocker K30198 14 Wheel, 10" Rear K80002 5 Hose, 14" Black Separator K25312202 a Axle K80003 a Connector, Quick 1/4" K50006 b Cap, Axle K90001 6 Hose, 18" Red Discharge K25107200 15 Manual, Operator's K99304 a Connector, Quick 1/8" K50015 16 Hose, 96" Red K25107161 7 Hose, 22" Black Filter K25312201 17 Hose, 36" Yellow K25207122 a Connector, Quick 1/4" K50006 18 Hose, 96" Blue K25007160 8 Hose, Liquid 3988-0246-01 19 Tee, Hose K50501 a Valve, Anti Blow Back 4719-0055-01 20 Filter, Particle Inlet K90423 9 Door K14004 21 Cord, AC Power K30194 a Thermometer K99013 22 Light, Pilot K30505 10 Scale, Plate K35017 23 Switch, Cycle Start K30042 11 Caster, Front K35252 24 Handle K35537 Page 3 - 27 ACT-2500 INSIDE CABINET VIEW ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER 1 Relay, Main Power K30041 7 Solenoid, Recycle K60060 2 Hose, Compressor K25312201 8 Separator, Oil K16602 3 Compressor K16011 9 Fan K32511 4 Switch, High Pressure K30031 a Grill K32531 5 Solenoid, Recovery K60060 10 Indicator, Moisture K40838 6 Switch, Vacuum K30030-A Page 3 - 28 ACT-2500 TANK ASSEMBLY ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER 1 Gauge, Air Purge K60003 8 Label, Clean/Dirty K91050SN 2 Valve, Air Purge K60003 9 Gasket, Separator Lid K61050 3 Connector, Quick 1/8" K50015 10 Cup, Measuring K90301 4 Valve, Air Pressure K50503 11 Valve, Liquid K60000 5 Nipple, 1/4" K50006 12 Valve, Oil Discharge K60001 6 Nipple, 1/8" K50015 13 Hose, Oil Discharge K25207-123 7 Tank Assembly Not Available 14 Connector, Quick 1/4" K50006 Page 3 - 29 SUBSECTION B. PARTS IN ALPHABETICAL ORDER DESCRIPTION PART NUMBER Axle K80003 Cabinet, Complete K35025 Cap, Axle K90001 Caster, Front K35252 Chrome Strip K35024 Left Side Chrome Strip K35024 Right Side Compressor K16011 Includes all Compressor Fittings Connector Kit, Quick 1/8" K50015 Comes with Male 1/8" Nipple Connector Kit, Quick 1/4" K50006 Comes with Male 1/4" Nipple Cord, AC Power K30194 Cord, Fan Power K6030004 Cup, Measuring K90301 Depressors, Screw In K45321 Door K14004 Element Kit, Moisture Indicator K16601 Contains Spring, Seals, Glass, and Element Fan K32511 Can Use 0587-0504 Fan, Panel K35016 Filter, Inline Particle K90423 Brass Assy. Filter, Inline Particle Screen K90420 Package of 10 Filter, Shell K16202 Filter, Core (Desiccant) K16200 Package of 2, With O-rings Fitting Kit, Brass K51050 All Brass Fittings for this Unit, No Ferrules Gasket, Hose K45331 Package of 25 Gauge K15041 Grill, Fan Grommet COMMENTS Sheet Metal Only Package of 25 K32531 (Heyco Bushing) K90041 For AC Power Cord and Tank Full Cord Handle Harness, Wiring Complete K33170 Hose, 18" Yellow K25207102 From Tank Liquid Port to Recycle Solenoid Hose, 18" Red K25107200 From Discharge Coil Tube to Reclaim Tank Hose, 12" Yellow Oil Discharge K25207123 For Discharging Oil from Oil Separator Hose, 13 " Black Compressor K25312200 From Filter Dryer to Compressor Hose, 22" Black Filter K25312201 From Oil Separator to Filter Dryer Hose, 14" Black Separator K25312202 From Oil Separator to Brass Input Manifold Hose, 96" Red K25107161 Vehicle Hose w/o Hand Valves to Brass Tee Hose, 36" Yellow K25207122 From Side Port of Tester to Brass Tee Hose, 96" Blue K25007160 Vehicle Hose W/o Hand Valves to Brass Tee Indicator, Moisture K40838 With Capillary Tube Label Kit K91050SN Green and Yellow Dots, Clean/Dirty Label Page 3 - 30 Label, Snap-On Logo K35403 On front panel of unit Latch, Door K90801 Lens, Gauge K15005 Light, Pilot K30505 O-ring Seal K45030 Package of 25 Overload Kit, Compressor K30301 Comes with Scale Plate Stops and Hardware Panel, Front K35026 Top Sheet Metal Plate, Scale K35017 Sheet Metal, Plate Tank Sits On Plate, Spring K90011 Used In Filter Dryer Relay Kit, Compressor K30301 Contains Comp. Relay, Overload, and Case Relay, Main Power K30041 Separator, Compressor Oil K16602 Solenoid K60060 Recover or Recycle Without Fittings Spring, Scale K90660 Comes with Scale Plate Stops and Hardware Switch, High Pressure K30031 Opens at 435 psi Switch, Tank Full K30015 Switch, Rocker K30198 Recover, End Cycle, Recycle Switch, Vacuum K30030-A Opens at 15" Hg Switch, Cycle Start K30042 Tank, Rebuild Kit K61050 Gasket, Oil Discharge Valve, Schrader Valve Tee, Brass Hose K50501 On 96" Hoses going to Vehicle Thermometer K99013 Tube Cap, Scale Pivot K42016134 Tube, Compressor Discharge K40502 Tube, Discharge Coil K40837 Tube, Liquid Capillary K40832A From Moisture Indicator To Bulkhead Port Tube, Moisture Indicator K4000811001 From Moisture Indicator to Recycle Solenoid Tube, Oil Return K40833A From Compressor to Oil Separator Return Tube, Scale Pivot K42016134 Valve, Check K60022 Valve, Pressure Access K50503 Valve On Top of Filter Dryer Valve, Air Purge K60003 Manual Air Purge, For Purging Reclaim Tank Valve, Check K60022 Valve, Liquid K60000 Liquid Valve on Top of Reclaim Tank Valve, Anti Blow Back K60070 Male End Wheel, 10" Rear K80002 Plastic cover for Front Panel Gauge From Compressor To Oil Separator Inlet Page 3 - 31 SUBSECTION C. PARTS IN NUMERICAL ORDER PART NUMBER DESCRIPTION COMMENTS K14004 Door K15005 Lens, Gauge K15041 Gauge K16011 Compressor Includes all Compressor Fittings K16200 Filter, Core (Desiccant) Package of 2, With O-rings Plastic cover for Front Panel Gauge K16202 Filter, Shell K16601 Element Kit, Moisture Indicator K16602 Separator, Compressor Oil K25007160 Hose, 96" Blue Vehicle Hose w/o Hand Valves to Brass Tee K25107161 Hose, 96" Red Vehicle Hose w/o Hand Valves to Brass Tee K25107200 Hose, 18" Red From Discharge Coil Tube to Reclaim Tank K25207102 Hose, 18" Yellow From Tank Liquid Port to Recycle Solenoid K25207122 Hose, 36" Yellow From Side Port of Tester to Brass Tee K25207123 Hose, 12" Yellow Oil Discharge For Discharging Oil from Oil Separator K25312200 Hose, 13 " Black Compressor From Filter Dryer to Compressor K25312201 Hose, 22" Black Filter From Oil Separator to Filter Dryer K25312202 Hose, 14" Black Separator From Oil Separator to Brass Input Manifold K30015 Switch, Tank Full K30030-A Switch, Vacuum Opens at 15" Hg K30031 Switch, High Pressure Opens at 435 psi K30041 Relay, Main Power K30042 Switch, Cycle Start K30194 Cord, AC Power K30198 Switch, Rocker Recover, End Cycle, Recycle K30301 Overload Kit, Compressor Comes with Scale Plate Stops and Hardware K30301 Relay Kit, Compressor Contains Comp. Relay, Overload, and Case K30505 Light, Pilot K32511 Fan K32531 Grill, Fan K33170 Harness, Wiring Complete K35016 Fan, Panel K35017 Plate, Scale Sheet Metal, Plate Tank Sits On K35024 Chrome Strip Left Side K35024 Chrome Strip Right Side K35025 Cabinet, Complete Sheet Metal Only K35026 Panel, Front Top Sheet Metal K35252 Caster, Front K35403 Label, Snap-On Logo Handle Page 3 - 32 Contains Spring, Seals, Glass, and Element Can Use 0587-0504 On front panel of unit K4000811001 Tube, Moisture Indicator From Moisture Indicator to Recycle Solenoid K40502 Tube, Compressor Discharge From Compressor To Oil Separator Inlet K40832A Tube, Liquid Capillary From Moisture Indicator To Bulkhead Port K40833A Tube, Oil Return From Compressor to Oil Separator Return K40837 Tube, Discharge Coil K40838 Indicator, Moisture K42016134 Tube, Scale Pivot K42016134 Tube Cap, Scale Pivot K45030 O-ring Seal Package of 25 K45321 Depressors, Screw In Package of 25 K45331 Gasket, Hose Package of 25 K50006 Connector Kit, Quick 1/4" Comes with Male 1/4" Nipple K50015 Connector Kit, Quick 1/8" Comes with Male 1/8" Nipple K50501 Tee, Brass Hose On 96" Hoses going to Vehicle K50503 Valve, Pressure Access Valve On Top of Filter Dryer K51050 Fitting Kit, Brass All Brass Fittings for this Unit, No Ferrules K60000 Valve, Liquid Liquid Valve on Top of Reclaim Tank K60003 Valve, Air Purge Manual Air Purge, For Purging Reclaim Tank K60022 Valve, Check K60022 Valve, Check K60060 Solenoid Recover or Recycle w/o Fittings K60070 Valve, Anti Blow Back Male End K6030004 Cord, Fan Power K61050 Tank, Rebuild Kit K80002 Wheel, 10" Rear K80003 Axle K90001 Cap, Axle K90011 Plate, Spring Used In Filter Dryer K90041 Grommet For AC Power Cord and Tank Full Cord K90301 Cup, Measuring K90420 Filter, Inline Particle Screen Package of 10 K90423 Filter, Inline Particle Brass Assy. K90660 Spring, Scale Comes with Scale Plate Stops and Hardware K90801 Latch, Door K91050SN Label Kit K99013 Thermometer Page 3 - 33 (Heyco Bushing) With Capillary Tube Gasket, Oil Discharg Valve, Schrader Valve Green and Yellow Dots, Clean/Dirty Label NOTES _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ Page 3 - 34 SECTION V OPERATORS MANUAL ______________________________________________________________ TABLE OF CONTENTS Page Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Up the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recovering Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge Manifold Hook Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Station Hook Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recycling Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Excess Air Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moisture and Oil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the Filter Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scale Plate Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 3-37 3-37 3-38 3-38 3-38 3-39 3-39 3-39 3-40 3-40 3-41 Page 3 - 35 WARRANTY This product is warranted to be free of defects in workmanship and materials for a period of one year from the date of purchase by original manufacturer. If the product fails within this period, it will be repaired or replaced at sellers option, provided (1) the product is submitted with proof of purchase date, (2) transportation charges are prepaid to the factory. Liability under this warranty is expressly limited to repairing or replacing the product or parts thereof. This warranty does not apply to product or parts broken from accident, overload, abuse or if they have been tampered with or altered. If this warranty does not apply, then the retail purchaser shall pay all costs for labor, material and transportation. Page 3 - 36 SAFETY PRECAUTIONS NOTE: This equipment should only be used by qualified personnel. A working knowledge of refrigeration systems and refrigerant properties is necessary for safe and efficient operation. Improper use could cause serious injury or damage to the A/C System or the Recovery Recycling Center. WARNING Always wear eye protection when working with refrigerants. To avoid possible loss of refrigerant to the atmosphere, always use the quick disconnect fittings and anti-blow back valves supplied with this unit and replace hoses as needed to maintain optimum performance of the Recovery Recycling Center. If using extension cords with this unit, make sure they are of sufficient current capacity to avoid overloading. Only use the tanks that are designed for use with this unit. SETTING UP THE UNIT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove the unit and recovery tanks from the shipping carton. Install the handle on the unit using (4) #10-32x1 screws. Remove filter canister lid (located on top of machine), spring plate, and shipping material from inside canister. Remove the filter core from the vacuum sealed can. Do not expose filter core to the atmosphere for more than 2 minutes; doing so will shorten its service life. Immediately install filter into canister (metal plate facing up). Replace spring plate (spring facing up). Replace filter canister lid and tighten nuts evenly in a crossing pattern to 10-15 ft.-lb torque. Vent the shipping charge of pressure from one of the recovery tanks by opening the liquid valve. Open access door located on the lower front of the unit. Install tank making sure the foot ring centers in the flanges of the scale plate. Connect the two large "Quick Disconnects" onto the two large male ports located in the center of the tank. These connections are reversible. Connect the small "Quick Disconnect" to the small male port located on the top of the tank. NOTE: Make sure all quick disconnects are fully engaged and locked in place. 12. Connect a vacuum pump to the liquid valve, open the valve and evacuate tank for a minimum of thirty minutes to remove the air. NOTE: Evacuating the tank for 2 to 4 hours will further dry the system and reduce the first tank recycle time. 13. 14. After evacuating the tank close the liquid valve and disconnect the vacuum pump. Connect the yellow hose with the anti-blow back valve to the liquid valve port. NOTE: Make sure that this fitting is fully screwed on so that the valve in the anti-blow back is opened. 15. Connect the oil purge hose to the oil purge valve port. 16. The unit is now ready to recover from a vehicle. Page 3 - 37 RECOVERING REFRIGERANT CAUTION Always wear eye protection when working with refrigerants The magnetic label should be applied to the tank at this time with the "CONTAMINATED" side showing to indicate that the refrigerant being recovered must be recycled before being dispensed. 1. 2. 3. 4. 5. 6. 7. 8. 9. Connect the unit to the air conditioning system using a gauge manifold or a charging station. a. GAUGE MANIFOLD HOOK UP: Using the hoses supplied, connect straight end of the blue hose to the low side (blue) of the manifold. Connect the other end with the anti-blow back valve to the low side port of the air conditioner. Connect the straight end of the red hose to the high side (red) of the manifold. Connect the other end with the anti-blow back valve to the high side port of the air conditioner. Connect the yellow hose on the center port of the manifold and the recovery port located on the side of the unit. b. CHARGING STATION HOOK UP: Using the Charging/Recovery Parallel Kit (Part Number 02503) connect the valves and hoses as outlined in the kit instructions. Close the liquid valve on the tank during recovery. Verify that there is refrigerant in the A/C system to serviced by testing to see if there is a positive pressure in the system. Do not try to recover if there is not pressure in the system. The pressure should be at least 40 PSI if there is refrigerant present. After all connections have been made push the rocker switch (located on face plate) to the RECOVER position. Momentarily depress the CYCLE START button (2-3 seconds). The SYSTEM OPERATING light will come on as the unit begins the recovery process. The unit will operate until all of the refrigerant has been recovered leaving the A/C system in a slight vacuum. It is normal for the machine to vibrate as it works in a vacuum just before shutting off. The unit shuts off automatically. With the unit off, disconnect it from the vehicles A/C system. You are now ready to perform normal A/C service. To measure oil removed from the vehicles A/C system, open the oil purge valve when the system pressure drops to the 15 psig to 20 psig range. Use the measuring cup supplied with the unit. By measuring oil removed from the vehicles A/C system the technician can properly reinstall the amount of refrigerant oil upon recharging. When the recovery tank has reached its capacity the TANK FULL light will go on and the machine will shut off automatically. At this time, recycle the recovered refrigerant and install the second tank. Page 3 - 38 RECYCLING REFRIGERANT CAUTION Recovered refrigerant must be recycled before use. this process will remove the non-condensable gases (air), the excess moisture and the excess oil from the refrigerant that has been recovered. Excess Air Purge: 1. 2. 3. 4. 5. 6. 7. 8. Let the tank stabilize for 2 hours minimum to insure the refrigerant is at room temperature. Install the air purge valve assembly to the air purge port on top of the tank. Read the tank pressure on the gauge of the air purge valve and refer to the "Excess Air Purge Chart." Find temperature of the room that you are currently in, in the table inside the front door of the unit. If the pressure reading of the gauge is above the pressure given in the table, excess air must be removed from the tank. If air must be removed, open the air purge valve and slowly bleed off the pressure. Continue to purge until the gauge reading drops below the value given in the table for the temperature you are currently in. Remove the air purge valve from the air purge port after purging air. Proceed to the moisture and oil removal. Moisture and Oil Removal: NOTE: For optimum performance wait until the tank is full or nearly full before recycling the refrigerant. 1. The liquid valve on the tank should be fully opened at this time. Make sure hose is properly connected to port. 2. Push rocker switch to the RECYCLE position. 3. Momentarily push the CYCLE START button (2-3 seconds). The SYSTEM OPERATING light will come on as the unit begins its recycling process. Liquid refrigerant can be seen flowing through the moisture indicator glass at this time. NOTE: In order for the unit to recycle, there must be at least a minimum of 5 pounds of refrigerant stored inside the tank. 4. Leave the unit in the recycle mode until the moisture indicator turns from yellow to green. This process will take from 1 to 6 hours depending on the amount of moisture contamination in the refrigerant. NOTE: The unit in the recycle mode may be left unattended overnight if desired. 5. 6. 7. 8. Recycling beyond the point of purity will have no adverse affect to the unit or refrigerant. The moisture indicator will only indicate dryness while the liquid refrigerant is flowing. Icing of the oil separator inlet is normal. The color sample dot indicates the minimum level of dryness. When the moisture indicator is darker green than in the sample, put the rocker switch from the RECYCLE position to the END CYCLE position. The unit will then shut off completely after a few seconds. It is normal for the machine to vibrate as it works in a vacuum just before shutting off. Close the liquid valve on the tank, disconnect all of the hoses on the tank and remove tank from the unit. Apply the magnetic label to the tank to indicate that it has been recycled and is ready for use. The second tank may be installed at this time. Page 3 - 39 REPLACING THE TANK CAUTION Always wear eye protection when working with refrigerant. IMPORTANT Use only the refrigerant recovery tank designed for this unit. 1. 2. Evacuate the replacement tank at the liquid valve. This must be done each time prior to placing the tank in the unit after using the recycled refrigerant. To install the tank, open the door on the front of the unit and place the tank on the scale plate. IMPORTANT Place the tank within the flanges of the scale plate so that the unit will shut off when the tank is full. 3. 4. 5. Connect the quick disconnect hoses from the unit to the appropriate fittings on the tank (larger hoses to larger fittings and smaller red hose to smaller fitting). Make sure all quick disconnects are fully engaged and locked in place. Connect the yellow hose from the unit to the liquid valve on the tank. Make sure that this fitting is fully screwed on so that the valve in the anti-blow back valve is opened. The system is now ready to begin recovering. CHANGING THE FILTER CORE CAUTION Always wear eye protection when working with refrigerants. 1. 2. 3. Place the rocker switch in the END CYCLE position and depress the CYCLE START button. Allow the unit to run until the SYSTEM OPERATING light goes out and machine shuts off. This will pump out any residual refrigerant left in the filter canister. Remove the cap from the access port located on top of the filter canister and depress the valve core to vent the vacuum that has been pulled on the canister. 4. 5. Remove the six flange bolts and remove the canister lid. Remove the spring plate. 6. Remove the filter core from the canister. (A magnet can be applied to the top of the core to lift it out.) Clean the inside of the shell if necessary. DO NOT REMOVE THE STRAINER IN THE BOTTOM OF THE SHELL. 7. 8. Remove the new core from its canister. IMPORTANT DO NOT EXPOSE FILTER TO THE OPEN ATMOSPHERE FOR MORE THAT TWO MINUTES. DOING SO CAN DEPLETE MOISTURE CAPACITY. 9. 10. Install the filter core into the shell with the metal end plate up. Install the spring plate on top of the core with the spring up. Page 3 - 40 CHANGING THE FILTER CORE continued 11. NOTE: 12. 13. 14. Replace gasket in the canister lid if it is damaged. Lubricate the new gasket with refrigerant oil. Replace the lid and flange nuts and tighten evenly in a cross pattern to 10-15 ft.-lb torque. Connect a vacuum pump to the port on the lid and evacuate for 30 minutes to remove any air in the shell. The unit is now ready for use. SCALE PLATE CALIBRATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the tank from the unit. Remove NUT #1 on top of the calibration unit. Turn the calibration bolt counter-clockwise (upward) until it stops. In order to properly calibrate the scale, 80 pounds of equally distributed weight must be used. (This can be achieved by filling the recovery tank with refrigerant or placing weights on the plate, leaving access to the calibration bolts.) With the 80 pound tank inverted or 80 pounds of weight on the scale plate, turn the calibration bolt clockwise (downward) until it touches the roller on the microswitch. Continue turning the bolt slowly until you hear a light "click" from the microswitch. Carefully remove the tank or weights. With a 1/2" wrench, tighten down NUT #1 while holding NUT#2 with a 3/8" wrench. The scale is now calibrated for the 50 pound tank. Page 3 - 41 NOTES _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ Page 3 - 42 CHAPTER 4 ACT-3000 / WHITE-01060 INTRODUCTION GENERAL OVERVIEW: This chapter provides service information for the Snap-on branded White Industries Built ACT-3000, and the White Industries built 01060. There are currently two version of these units in the field. The early version uses a timer, relays and a Tank Full Board to control pneumatic components; the newer version has a Smart Board that replaces these components. It is very important to understand the difference between the two units (3000 and 01060). The ONLY difference is: • White-01060 Does Not have the pressure test capability. That means it does not have the Pressure Test Front Panel Switch or the Pressure Test Solenoid. Since the two model machines are nearly identical, only the electrical and pneumatic diagrams for the ACT-3000 will be referenced with Section 2, (Theory of Operation) of this chapter. However, for your convenience a electrical and pneumatic diagram, for the White-01060, has been added to the end of Section 2. Whenever servicing a White-01060 machine please refer to the electrical and pneumatic drawings at the end of section 2, and refer to the theory of operation text for the mode you are troubleshooting. Again, please note that you should ignore any reference to the pressure test circuitry of the unit in the theory of operation text. Effective 3/97 Page 4-1 CHAPTER 4 ACT-3000 / WHITE-01060 Page 4-2 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 AC POWER DISTRIBUTION ! THIS UNIT MUST BE PLUGGED INTO A PROPER AC OUTLET TO OPERATE CORRECTLY. REFER TO ID PLATE LOCATED ON BACK OF UNIT. EXTENSION CORDS ARE NOT RECOMMENDED, BUT IF AN EXTENSION CORD MUST BE USED, USE A CORD THAT IS LESS THAN 50 FEET WITH A 16 AWG, OR ABOVE 50 FEET AND LESS THAN 100 WITH A 14 AWG. ! USE STANDARD REFRIGERANT HANDLING SAFETY PROCEDURES WHEN PERFORMING INSTALLATION ALWAYS WEAR SAFETY GOGGLES, DON'T SPILL OR TOUCH LIQUID REFRIGERANT, AVOID FLAMES, AND EXCESSIVE HEAT. USE ONLY IN WELL VENTILATED AREA. NOTE: THIS SECTION IS FOR UNITS WITH A "TANK FULL BOARD". AC DISTRIBUTION: (REFER TO DRAWING 4-1, PAGE 4-5) Always use the "One Hand Rule" when working with AC voltages by keeping one hand in your pocket or behind your back. Before removing wires from the ACT-3000, always verify that the Tester is "OFF", and unplug the AC power cord from the AC outlet. The hot side (black wire) of the 115 VAC plug is wired directly to the High Pressure Cutoff Switch. During normal operation the high pressure switch is shorted between pins 1 and 3, therefore the AC voltage continues through the 9 pin connector and to the "ON/OFF" power switch. NOTE: THIS SECTION IS FOR UNITS WITH A "SMART BOARD". AC DISTRIBUTION: (REFER TO DRAWING 4-2, PAGE 4-7) Always use the "One Hand Rule" when working with AC voltages by keeping one hand in your pocket or behind your back. Before removing wires from the ACT-3000, always verify that the Tester is "OFF", and unplug the AC power cord from the AC outlet. The hot side (black wire) of the 110 VAC plug is wired directly to pin 6 of the 12 pin connector and to the "ON/OFF" power switch. Effective 3/97 Page 4-3 CHAPTER 4 ACT-3000 / WHITE-01060 Page 4-4 Effective 3/97 MODEL: DWG BY: TITLE: DWG: ACT-3000 T. PARSELL CHK BY: 0896 J. HINKLE AC DISTRIBUTION WITH TANK FULL BOARD 4-1 PAGE: 4-5 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-6 Effective 3/97 MODEL: DWG BY: TITLE: DWG: ACT-3000 T. PARSELL CHK BY: 0896 J. HINKLE AC DISTRIBUTION WITH SMART BOARD 4-2 PAGE: 4-7 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-8 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 THEORY OF OPERATION (TANK FULL BOARD) NOTE: This section is for units with the "TANK FULL" Board. POWER ON MODE: ELECTRICAL (REFER TO DRAWING 4-3, PAGE 4-13) The power on mode is activated by turning the Main Power Switch on the front panel to the "ON" position. When plugged in 115V AC is routed through the ACT-3000's High Pressure Switch, through pin 1 of the 9 pin connector to the "ON/OFF" switch. From the "ON/OFF" switch the AC voltage is routed to pin 6 of the Tank Full relay, out the tank full relay on pin 5 to the fan. Power is also routed from the on/off switch to the Tank Full Board. The tank full board then outputs 8 volts DC on pin 1 of the tank full board to the 9 pin connector pin 9. From the 9 pin connector the 8 volts DC is routed to pin 3 of the Tank full Probe Assembly. The tank full board also supplies 8 volts DC to the front panel digital gauge board. CYCLE START MODE: ELECTRICAL: (REFER TO DRAWING 4-5, PAGE 4-17) When the Cycle Start switch is depressed AC power is routed through the cycle start switch, to the System Operating light, which alerts the operator that the unit is now reclaiming. Power is also routed to pin 7 of the Cycle start relay which energizes the cycles start relay. AC power then runs through the Vacuum Switch to pin 3 of the cycle start relay, out pin 4 of the cycle start relay to pin 8 of the 9 pin connector. From the 9 pin connector AC power is routed to the compressor, Oil Return Solenoid Start Timer, and to the Compressor Oil Solenoid. This starts the compressor and the Oil Return solenoid timer. By starting the Oil Return Solenoid Timer we can monitor the amount of time the compressor has been running. This is important because for every 15 minutes the compressor runs power is removed from the compressor oil return solenoid for 10 seconds. PNEUMATICS: (REFER TO DRAWING 4-7, PAGE 4-21) In the Cycle Start Mode refrigerant flows in from; the system vapor hose to the filter dryer / oil separator, and from the system liquid hose, through a capillary tube and to the filter dryer / oil separator. The refrigerant coming in from the low side port goes through a condensing coil, before it gets to the oil separator. In the filter dryer / oil separator refrigerant is separated from the vehicle's oil and sent out the top port through the check valve and to the compressor. From the compressor VAPOR refrigerant is sent to the Compressor Oil separator inlet port. Here the compressors oil is separated from the refrigerant and the vapor refrigerant flows out the "OUT" port of the compressor oil separator and through the condensing coil. The condensing coil changes the refrigerant back into a liquid, it then flows through the check valve, moisture indicator, and into the tank through the liquid port. PRESSURE TEST MODE: ELECTRICAL: (REFER TO DRAWING 4-8, PAGE 4-23) With power routed as shown in the "Power On Mode" drawing the operator presses and holds . This then routes AC power through the Pressure Test switch and to the Pressure Test solenoid. The Pressure test solenoid will remain open until the operator releases switch. Effective 3/97 Page 4-9 CHAPTER 4 ACT-3000 / WHITE-01060 PRESSURE TEST MODE: CONT... PNEUMATICS: (REFER TO DRAWING 4-10, PAGE 4-27) In the Pressure Test mode vapor refrigerant from the reclaim tank passes through the S1 (pressure test) solenoid to the filter dryer side of the compressor and the vehicle (if one is hooked up to the tester). This continues until the operator releases . This allows a leak test to be performed on either the vehicle or part of the ACT's pneumatics. AUTOMATIC OIL RETURN MODE: ELECTRICAL: (REFER TO DRAWING 4-11, PAGE 4-29) For 10 seconds of every 15 minutes the compressor is running the oil return timer automatically cuts power to S2 (Oil return) solenoid. This causes the oil return solenoid to open. After 10 seconds AC power is then re-applied to the Oil Return solenoid and it closes. PNEUMATICS: (REFER TO DRAWING 4-13, PAGE 4-33) During the 10 second Automatic Oil Return Mode, Oil from the compressors oil separator is pushed through S2 (Oil return) solenoid and back into the compressor via the suction port. This ensures the compressor always has the right amount of oil in it. Page 4-10 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 THEORY OF OPERATION (SMART BOARD) NOTE: This section is for units with the "SMART" Board. POWER ON MODE: ELECTRICAL (REFER TO DRAWING 4-4, PAGE 4-15) The power on mode is activated by turning the Main Power Switch on the front panel to the "ON" position. When turned "ON" power is routed through the ACT-3000's main power switch, to the Fan, and to the Smart Board. The smart board then applies 8 volts DC to the Front panel digital gauge, and routes 8 volts DC out pin 10 to pin 9 of the 12 pin connector, to pin 3 of the Tank Full Probe Assembly. CYCLE START MODE: ELECTRICAL: (REFER TO DRAWING 4-6, PAGE 4-19) The depression of the Cycle Start switch is sensed by the ACT's Smart board. When this is sensed the Smart Board sends 115V AC out pin 9 to pin 5 of the 12 pin connector. From the 12 pin connector to the High pressure switch. Since the High pressure switch is a normally closed switch power is then routed to the Compressor, and to the Hour Meter which measures the amount of time the compressor has run. From the compressor AC power is routed back to pin 1 of the 12 pin connector to the System Operating Lamp on the front panel. During this mode power is also routed from pin 3 of the smart board to the oil return solenoid. This closes the oil return solenoid. PNEUMATICS: (REFER TO DRAWING 4-7, PAGE 4-21) In the Cycle Start Mode refrigerant flows in from both the high and low side ports to the filter dryer / oil separator. The refrigerant coming in from the low side port goes through a condensing coil before it gets to the oil separator. In the filter dryer / oil separator refrigerant is separated from the vehicle's oil and sent out the top port through the check valve and to the compressor. From the compressor VAPOR refrigerant is sent to the Compressor Oil separator inlet port. Here the compressors oil is separated from the refrigerant and the vapor refrigerant flows out the "OUT" port of the compressor oil separator and through the condensing coil. The condensing coil changes the refrigerant back into a liquid, it then flows through the check valve, moisture indicator, and into the tank through the liquid port. PRESSURE TEST MODE: ELECTRICAL: (REFER TO DRAWING 4-9, PAGE 4-25) With power routed as shown in the "Power On Mode" drawing the operator presses and holds . This then routes AC power through the Pressure Test switch and to pin 10 of the 12 pin connector. From the 12 pin connector AC power is routed to the Pressure Test solenoid. The Pressure test solenoid will remain open until the operator releases . At that time the Pressure Test solenoid will then return back to its original Normally Closed State. Effective 3/97 Page 4-11 CHAPTER 4 ACT-3000 / WHITE-01060 PRESSURE TEST MODE: CONT... PNEUMATICS: (REFER TO DRAWING 4-10, PAGE 4-27) In the Pressure Test mode vapor refrigerant from the reclaim tank passes through the S1 (pressure test) solenoid, to the filter dryer side of the compressor and the vehicle (if one is hooked up to the tester). This process continues until the operator releases . This allows a leak test to be performed on either the vehicle or part of the ACT's pneumatics. AUTOMATIC OIL RETURN MODE: ELECTRICAL: (REFER TO DRAWING 4-12, PAGE 4-31) For 10 seconds of every 15 minutes the compressor is running power is automatically removed from pin 3 of the Smart Board. This removes power from the S2 (Compressor Oil Return) Solenoid, which causes the oil return solenoid to open. At the end of the 10 seconds oil return, S2 reverts back to is energized state (Normally Closed). PNEUMATIC: (REFER TO DRAWING 4-13, PAGE 4-33) During the 10 sec Automatic Oil Return Mode, Oil from the compressors oil separator is pushed through S2 (Oil return) solenoid and back into the compressor via the suction port. This ensures a closed loop condition for the compressor oil which means the compressor will always have the right amount of oil in it. Page 4-12 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: TITLE: DWG: ACT-3000 T. PARSELL CHK BY: 0896 J. HINKLE POWER ON MODE WITH TANK FULL BOARD 4-3 PAGE: 4-13 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-14 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: ACT-3000 T. PARSELL CHK BY: 0896 J. HINKLE TITLE: SMART BOARD DWG: 4-4 PAGE: 4-15 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-16 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-18 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: TITLE: DWG: ACT-3000 T. PARSELL CHK BY: 0896 J. HINKLE CYCLE START MODE SMART BOARD 4-6 PAGE: 4-19 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-20 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: ACT-3000 J. HINKLE 0896 CHK BY: TITLE: CYCLE START MODE DWG: 4-7 PAGE: 4-21 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-22 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: TITLE: DWG: ACT-3000 T. PARSELL CHK BY: 0896 J. HINKLE PRESSURE TEST MODE WITH TANK FULL BOARD 4-8 PAGE: 4-23 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-24 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: TITLE: DWG: ACT-3000 T. PARSELL CHK BY: 0896 J. HINKLE PRESSURE TEST MODE SMART BOARD 4-9 PAGE: 4-25 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-26 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: ACT-3000 J. HINKLE 0896 CHK BY: TITLE: PRESSURE TEST MODE DWG: 4-10 PAGE: 4-27 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-28 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: TITLE: DWG: ACT-3000 T. PARSELL CHK BY: 0896 J. HINKLE COMPRESSOR OIL RETURN MODE WITH TANK FULL BOARD 4-11 PAGE: 4-29 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-30 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: TITLE: DWG: ACT-3000 T. PARSELL CHK BY: 0896 J. HINKLE COMPRESSOR OIL RETURN MODE SMART BOARD 4-12 PAGE: 4-31 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-32 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: ACT-3000 J. HINKLE 0896 CHK BY: TITLE: OIL RETURN MODE DWG: 4-13 PAGE: 4-33 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-34 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: TITLE: DWG: WHITE-01060 J. HINKLE 0896 CHK BY: SMART BOARD ELECTRICAL 4-14 PAGE: 4-35 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-36 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. MODEL: DWG BY: TITLE: DWG: White-01060 J. HINKLE 0896 CHK BY: TANK FULL ELECTRICAL 4-15 PAGE: 4-37 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-38 Effective 3/97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric. All manufacturing, use, reproduction and sales rights are reserved by Sun Electric and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric. SYSTEM GAUGE MODEL: DWG BY: WHITE-01060 J. HINKLE 0896 CHK BY: TITLE: DWG: PNEUMATIC 4-16 4-39 PAGE: CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-40 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 TESTING PROCEDURES FRONT PANEL DISPLAY CALIBRATION 1. Plug unit into AC wall outlet and depress power switch to the "ON" position. 2. Verify front panel digital gauge comes on and reads 0 to 1 psi. 3. If reading is not 0 to 1 psi continue with steps below. 4. Insert small flat blade screwdriver into small hole next to gauge. 5. Carefully find the adjusting screw and adjust until 0 or 1 psi registers on the gauge. NOTE: A fluctuation between 0 and 1 psi is normal. TANK FULL PROBE FUNCTIONAL TEST 1. Without the Tank Full Probe attached to the machine, turn the machine on using the front panel power switch. 2. The front panel Tank Full lamp should illuminate. 3. Turn the Machine "OFF". Connect a Tank Full Probe to the Tank Full cord. 4. Turn the front panel power switch to the "ON" position. 5. The front panel Tank Full lamp should go out. HIGH PRESSURE SWITCH TEST 1. Remove the Tank Liquid hose from the reclaim tank. 2. Attach the High Pressure test gauge (25007-115) from your tool kit, to the reclaim tank liquid hose. 3. Turn the machine "ON" and press . 4. The High Pressure Gauge should climb in pressure to 435psi. 5. The High Pressure lamp should illuminate and the unit will shut down. NOTE: In units with a Tank Full board, the high pressure light will illuminate, the unit will shut down, and the high pressure lamp will go out. This is due to the Oil Return Solenoid opening and allowing the unit to return to a balance start-up condition. Effective 3/97 Page 4-41 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-42 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 TROUBLESHOOTING COMPLAINT I. Will Not Recover. CORRECTIVE ACTION Recovers only while holding down the cycle start switch. • Vacuum Switch is stuck open and defective. Compressor will not stay running. • Anti-blow back valve on reclaim tank liquid hose is back seated causing high head pressure (restriction). • Check Valve on Moisture indicator is stuck closed causing high head pressure (restriction). • Customer is not purging Excess Air after EACH reclaim. Compressor not running, kicking overload. • . Check valve on top of filter canister is stuck closed • Oil in filter canister: not purging oil, causing restriction on suction side of compressor. Unit pulls down into a vacuum, pressure rises back up on gauge because vehicle still has refrigerant in it. • Anti-blow back valves on system hose: overtightened, causing restricted flow of refrigerant. II. Moisture Indicator III. Tank Full Light. Will not turn green. • Leak in unit, pulling Moisture and Air into unit. • Filter core Oil Soaked or Contaiminated. Always on, even with an empty tank. • • • • Effective 3/97 Measure the resistance on the tank full probe, pin 13, and pins 2-3. Above measurements should be between 12-17 ohms. Difference between pins 1-3 and 2-3 measurement should not be greater than 2 ohms. If any of the above are not accurate than the tank full probe needs to be replaced. Page 4-43 CHAPTER 4 ACT-3000 / WHITE-01060 NOTES: Page 4-44 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 PARTS GENERAL This chapter describes assemblies, subassemblies, and parts considered replaceable by Sun Field Service Tecnicians. NOTE: I. The following is a breakdown description for Serial Numbers: How to read SERIAL NUMBERS: NOTE: Serial # Location - Left hand side. A. In 1970's a FOUR digit serial number was used. The First digit dictates the Year Built. 1. B. EXAMPLE: 811032 = Built in 1981 In 1992 to present a 10 digit number was used. 1. 2. 3. 4. 1st digit = Year 2nd digit = Month 3rd digit = Make 4th & 5th digit = Model 5. 6th thru 9th = Lot # 6. Effective 3/97 2341 = Built in 1972 In 1980 to 1991 a SIX digit serial number was used. The first two digits dictate the Year Built. 1. C. EXAMPLE: EXAMPLE: B=1992, C=1993, ... A=January, B=February, ... W=White, S=Snap-On 2A=ACT-2000, 62=ACT-3000 80=ACT-3300, 85=ACT-3400 Number of unit coming off production line. BAS621301 = Built in 1992, January, Snap-On, ACT-3000, 1301 lot # Page 4-45 CHAPTER 4 ACT-3000 / WHITE-01060 PARTS BY PICTORIAL ACT-3000 FRONT VIEW ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 DESCRIPTION Light, Red Switch, Light Switch Latch, Door Thermometer Door & Hinge Nut, 5/16-18 Caster, Front Locking Cap, Axle Screw, 5/16-18x3/4 Wheel Axle Bracket, Hose Page 4-46 PART NUMBER K30037 K30008 K30008 K90803 K99013 K76122 K72502 K35252 K80003 K71001 3645-0047-01 K42020-206 K76019 ITEM 14 15 16 17 18 19 20 21a 21b 22 23 24 25 DESCRIPTION Frame Handle Core, Filter Valve, Pressure Access Valve, Air Purge Gauge Sticker, Green, Yellow Dot Indicator Moisture (OLD) Indicator Moisture (NEW) Panel, Top Hose, 18" Blue Hose, 20" Red Bracket, Tank Retention PART NUMBER K76125 K35538 K16200 K50503 K60059 K1101066 K91062 K16613 K16622 K35058 K25207-302 K25107-110 K76113 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 ACT-3000 INSIDE CABINET VIEW NOTE: Unit shown has a Tank Full board, 2 Relays, and a Timer. ♦ On some units the Smart Board replaces all 4 components mentioned above. However, Unit components are not interchangeable. ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DESCRIPTION Filter Assembly Switch, Vacuum Valve, Pressure Test Compressor Tube, Oil Purge Tube, Oil/Air Purge Hose, 96" Red Hose, 20" Red Hose, 96" Blue AC Power Cord Tube, Discharge Timer, Units with tank full board only. Cord, Tank Full Sensor Separator, Oil Effective 3/97 PART NUMBER K16205 K30032 K60065 K16011 K40833 K40848 K25107123 K25107-110 K25007143 6001-0189-01 K40837 K30252 ITEM 15 16 17 17a 18 a 18 b 19 20 20♦ 21 22 23 DESCRIPTION Switch, High Pressure Harness, Lower Wiring Fan Grill Indicator, Moisture (OLD) Indicator, Moisture (NEW) Hose, Compressor Tank Full Board Smart Board Tube, Oil Purge Solenoid, Oil Return Manifold, Suction PART NUMBER K30255 K1101055 0587-0504 K32531 K16613 K16622 K25007-103 K1101001 K1110019 K40833 K60058 K51059 K1101002 K16608 24 25 Valve, Check K60033 N.S. Relay (2 ) Units with K30041 Tank full board only. Page 4-47 CHAPTER 4 ACT-3000 / WHITE-01060 PARTS IN ALPHABETICAL ORDER DESCRIPTION PART NUMBER Axle Ball Valve (Blue) Ball Valve (Red) Bezel, Digital Gauge Bin Kit, Plastic Storage Board, Smart Board, Tank Full Bracket, Hose Wrap Bracket, Tank Retention Cabinet, Complete Cap, Axle Caster, Front Locking Compressor Cord, Tank Full Sensor Cord, Fan Cord, AC Power Core, Filter Cup, Measuring Depressors, Screw In Door & Hinge Element, Moisture Indicator Fan Filter Assembly Filter, Inline Fitting, Display Adapter Gauge w/ribbon cable & transducer Grill, Fan Grommet (Heyco Bushing) Handle Harness, Lower Wiring Harness, Upper Wiring Hose, 20" Yellow Hose, Compressor Suction (Blue) Hose, 96" Red Hose, 96" Blue Hose, 18" Yellow Indicator Assy, Moisture Indicator Assy, Moisture Label, "Oil Purge Port" Label, Snap-on Label, Dry Dot, Green Label, Dry Dot, Yellow Latch, Door Lens, Digital Gauge Manifold, Brass Mat, Black Rubber Meter, Hour Nut, Moisture Indicator Oil, Compressor O-Ring Kit, Neoprene O-Ring Overload kit, Compressor Klixon Panel, Top K80003 K60108 K60107 K30509 K90302 K1110019 K1101001 K76019 K76113 K76901 K90001 K35252 K16011 K1101002 K6030004 K30199 K16200 K90301 K45321 K76122 K16601 K32511 K16205 K90420 K10657 K1101066 K32531 K90041 K35538 K1101055 K1101056 K25107110 K25007103 K25107123 K25007143 K25207302 K16613 K16622 K99444 K35403 K99528 K99529 K90803 K30509 K51055 K30507 K30276 K50565 0681-0179-02 K40530 0617-0210-01 K30301 K35058 Page 4-48 COMMENTS comes with 6” hose comes with 6” hose Comes with the Bezel and Lens Plastic Bins (Divided and Storage) Sheet Metal fitting kit (w/fittings for all units comp.) Can Use 6001-0189-01 With (2) O-Rings For Oil Purge Package of 25, Used in ends of hoses Just the Element not the entire Assy. Can Use 0587-0804 Filter Dryer / Oil Seperator Inline Filter Assy. (Brass & Element) When installing new style Display bd. May need K10657 (Adapter Fitting) for AC power cord and Wiring harness Tank Vapor, with hand valve From Compressor to Filter Dryer With Hand Valve With Hand Valve Tank Liquid, with Hand Valve Old Style, (All Copper Color) New Style, (Silver and Copper Color) Part Of Label Kit K91062 Located on front door Part of Label Kit K91062 Part of Label Kit K91062 Comes with the Bezel and Lens Purge Assy. and Input Suction Assy. 3GS Oil, 10 oz. in Compressor Package Of 25 For 1/4 Turn Ball Valve Contains Comp. Relay and Overload Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 DESCRIPTION PART NUMBER COMMENTS Panel, Fan Plate, Spring Probe, Tank Full Relay Kit, Compressor Relay Separator, Oil Solenoid, Oil Return Solenoid, Pressure Test Switch, Light, Frame Front Panel Switch, Vacuum Switch, High Pressure Tank, Reclaim Thermometer Timer, Oil Return Tube Liquid Capillary Tube, Moisture Indicator Discharge Tube, Condensing Tube, 6" Capillary Tube, Oil Purge Tube, Discharge Tube, Oil/Air Purge Tubing, Digital Gauge Valve, 3 psi Check Valve, 1/3 psi Check Valve, Air Purge Valve, Pressure Access Wheel K76106 K90011 K1101037 K30301 K30041 K16608 K60058 K60065 K30008 K30032 K30255 K16419 K99013 K30252 K40832 K40541 K40854 K40807 K40833 K40539 K40848 K40849 K60122 K60119 K60059 K50503 K80002 Sheet Metal Used in Filter Dryer / Oil Seperator Effective 3/97 Contains Comp. Relay and Overload Tank Full and Cycle Start For Compressor Oil Fittings K10680, K50554 Sold Sep. Fittings K10680, K10601 Sold Sep. Switches, Lights, and Frame Opens at 10" Hg Opens at 435 psi 50 lb. Sticker thermometer on inside door On units with Tank Full Board ONLY Sys. Liquid Bulkhead Port to Manifold from Moisture Ind. to Bulkhead Fitting From Oil Sep. to Moisture Indicator From Compressor to Oil Seperator Units W/transducer on display board Moisture Indicator Top of Filter Dryer / Oil Seperator Momentary Pressure Relief On top of Filter Dryer / Oil Seperator 10" Rear wheel Page 4-49 CHAPTER 4 ACT-3000 / WHITE-01060 PARTS IN NUMERICAL ORDER PART NUMBER 0671-0210-01 0681-0179-02 K10657 K1101001 K1101002 K1101037 K1101055 K1101056 K1101066 K1110019 K16011 K16200 K16205 K16419 K16601 K16608 K16613 K16622 K25007103 K25007143 K25107110 K25207302 K30008 K30032 K30041 K30199 K30252 K30255 K30276 K30301 K30301 K30507 K30509 K30509 K32511 K32531 K35058 K35252 K35403 K35538 K40530 K40539 K40541 K40807 K40832 K40833 K40848 K40849 K40854 K45321 K50503 K50565 K51055 K25107123 Page 4-50 DESCRIPTION O-Ring Oil, Compressor Fitting, Display Adapter Board, Tank Full Cord, Tank Full Sensor Probe, Tank Full Harness, Lower Wiring Harness, Upper Wiring Gauge w/ribbon cable & transducer Board, Smart Compressor Core, Filter Filter Assembly Tank, Reclaim Element, Moisture Indicator Separator, Oil Indicator Assy, Moisture Indicator Assy, Moisture Hose, Compressor Suction (Blue) Hose, 96" Blue Hose, 20" Yellow Hose, 18" Yellow Switch, Light, Frame Front Panel Switch, Vacuum Relay Cord, AC Power Timer, Oil Return Switch, High Pressure Meter, Hour Overload kit, Compressor Klixon Relay Kit, Compressor Mat, Black Rubber Bezel, Digital Gauge Lens, Digital Gauge Fan Grill, Fan Panel, Top Caster, Front Locking Label, Snap-on Handle O-Ring Kit, Neoprene Tube, Discharge Tube, Moisture Indicator Discharge Tube, 6" Capillary Tube Liquid Capillary Tube, Oil Purge Tube, Oil/Air Purge Tubing, Digital Gauge Tube, Condensing Depressors, Screw In Valve, Pressure Access Nut, Moisture Indicator Manifold, Brass Hose, 96" Red COMMENTS For 1/4 Turn Ball Valve 3GS Oil, 10 oz. in Compressor When installing new style Display bd. May need K10657 (Adapter Fitting) fitting kit (w/fittings for all units comp.) With (2) O-Rings Filter Dryer / Oil Seperator 50 lb. Just the Element not the entire Assy. For Compressor Oil Old Style, (All Copper Color) New Style, (Silver and Copper Color) From Compressor to Filter Dryer With Hand Valve Tank Vapor, with hand valve Tank Liquid, with Hand Valve Switches, Lights, and Frame Opens at 10" Hg Tank Full and Cycle Start Can Use 6001-0189-01 On units with Tank Full Board ONLY Opens at 435 psi Contains Comp. Relay and Overload Contains Comp. Relay and Overload Comes with the Bezel and Lens Comes with the Bezel and Lens Can Use 0587-0804 Located on front door Package Of 25 From Compressor to Oil Seperator from Moisture Ind. to Bulkhead Fitting Sys. Liquid Bulkhead Port to Manifold Units W/transducer on display board From Oil Sep. to Moisture Indicator Package of 25, Used in ends of hoses On top of Filter Dryer / Oil Seperator Purge Assy. and Input Suction Assy. With Hand Valve Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 PART NUMBER K60058 K60059 K60065 K60107 K60108 K60119 K60122 K6030004 K76019 K76106 K76113 K76122 K76901 K80002 K80003 K90001 K90011 K90041 K90301 K90302 K90420 K90803 K99013 K99444 K99528 K99529 Effective 3/97 DESCRIPTION Solenoid, Oil Return Valve, Air Purge Solenoid, Pressure Test Ball Valve (Red) Ball Valve (Blue) Valve, 1/3 psi Check Valve, 3 psi Check Cord, Fan Bracket, Hose Wrap Panel, Fan Bracket, Tank Retention Door & Hinge Cabinet, Complete Wheel Axle Cap, Axle Plate, Spring Grommet (Heyco Bushing) Cup, Measuring Bin Kit, Plastic Storage Filter, Inline Latch, Door Thermometer Label, "Oil Purge Port" Label, Dry Dot, Green Label, Dry Dot, Yellow COMMENTS Fittings K10680, K50554 Sold Sep. Momentary Pressure Relief Fittings K10680, K10601 Sold Sep. comes with 6” hose comes with 6” hose Top of Filter Dryer / Oil Seperator Moisture Indicator Sheet Metal Sheet Metal 10" Rear wheel Used in Filter Dryer / Oil Seperator for AC power cord and Wiring harness For Oil Purge Plastic Bins (Divided and Storage) Inline Filter Assy. (Brass & Element) Sticker thermometer on inside door Part Of Label Kit K91062 Part of Label Kit K91062 Part of Label Kit K91062 Page 4-51 CHAPTER 4 ACT-3000 / WHITE-01060 Page 4-52 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 ACT-3000 OPERATORS MANUAL ______________________________________________________________ TABLE OF CONTENTS Page WHAT COMES WITH YOUR MACHINE ................................................................................................. 4-44 SAFETY TIPS ......................................................................................................................................... 4-45 WARRANTY ........................................................................................................................................... 4-46 Setting Up The Unit INSTALLING THE WHEELS AND CASTERS ............................................................................ 4-47 INSTALLING THE BRACKETS.................................................................................................. 4-47 INSTALLING THE FILTER CORE.............................................................................................. 4-47 INSTALLING THE TANK ........................................................................................................... 4-48 RECOVERY AND RECYCLING ............................................................................................................. 4-49 PRESSURE TEST .................................................................................................................................. 4-50 MOISTURE INDICATOR AND HOUR METER........................................................................................ 4-50 MOISTURE INDICATOR REPLACEMENT ............................................................................................. 4-50 TANK FULL ............................................................................................................................................ 4-51 HIGH PRESSURE CONDITION .............................................................................................................. 4-51 PURGING NON-CONDENSABLE GASES ............................................................................................. 4-52 USING YOUR RECYCLED TANK OF REFRIGERANT........................................................................... 4-52 CHANGING THE FILTER CORE ............................................................................................................ 4-53 REFRIGERANT CHANGE OVER PROCEDURE ................................................................................... 4-53 FACTORY RECOMMENDED DAILY PROCEDURES............................................................................. 4-54 Effective 3/97 Page 4-53 CHAPTER 4 ACT-3000 / WHITE-01060 WHAT COMES WITH YOUR MACHINE Your new refrigerant recovery recycling center includes the following: (2) (2) (1) (1) (2) (8) (8) (1) (2) (2) (2) (1) (6) (1) (2) (1) (1) (1) (1) (1) (1) (1) 50 lb. DOT approved, refillable recovery tanks Filter Cores Spring Plate Oil Measuring Cup Front Casters Front Caster Mounting Screws Front Caster Mounting Nuts Axle Rear Wheels Pal Nuts Hose Wrap Brackets Power Cord Bracket Bracket Mounting Screws Tank Retention Bracket Mounting Screws Set of Storage Bins Operations Manual Postage Paid Warranty Card Supply of multiple refrigerant identification tank labels List of Authorized Service Centers MACS Certification information sheet EPA Equipment Certification Form Page 4-54 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 A COUPLE OF SAFETY TIPS No one should operate the Refrigerant Recovery Recycling Center until the operator has read the instruction manual, reviewed the videotape and has received thorough instruction on the safe operation of the machine. The Clean Air Act stipulates that a technician certified in refrigerant recovery recycling be the only person to operate this machine. Information regarding certification has been included with your machine. Unless the operator has experience and training, unfortunate accidents can occur. Secondly, as common practice when working with refrigerant, the operator should always wear safety goggles. We know that sometimes you get in a hurry and can't find your goggles, but stop and do yourself and your eyes a favor. Find your goggles and use them! Protect yourself at all times. Effective 3/97 Page 4-55 CHAPTER 4 ACT-3000 / WHITE-01060 WARRANTY This product is warranted to be free of defects in workmanship and materials for a period of two (2) years from the date of purchase by original purchaser. If the product fails within this period, it will be repaired or replaced, at the manufacturers option, provided, (1) the product is shipped to the factory with proof of purchase date and assigned RGA number (return goods authorization), (2) the product is shipped to a Factory Authorized Service Center with proof of purchase date (see provided list), (3) transportation charges are prepaid to factory or authorized service center. This warranty does not apply to product or parts broken from accident, overload, abuse or if they have been tampered with or altered. If this warranty does not apply, then the retail purchaser shall pay all costs for labor, material and transportation. the warranty described in this paragraph shall be in lieu of any other warranty, express or implied, including but not limited to, any implied warranty of merchantability or fitness for a particular purpose. It is expressly agreed that the buyer's sole and exclusive remedy against the seller shall be for the repair or replacement of defective product or parts as provided herein. The buyer agrees that no other remedy, including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss, shall be available to buyer. Conditions: To address customer needs efficiently and maintain performance history on this product, it is imperative that the owner complete and return the postage-paid Warranty Card to the manufacturer. Upon receipt of the Warranty Card, the customer is assured of: 1. Prompt, efficient and accurate service. 2. Two year warranty as stated above. Page 4-56 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 SETTING UP THE UNIT Required Tools: Flat Edge Screwdriver 9/16" Wrench Vacuum Pump Charging Hose General: 1. 2. 3. Remove the unit and tanks from the shipping carton. Fill out postage paid warranty card and send in to manufacturer. Review operations manual. Installing the Wheels and Casters: 1. 2. 3. 4. 5. 6. 7. Feed the axle through the holes on the back part of the machine. Slide a wheel through the axle and center the pal nut on the outer side of the axle. Bracing the opposite end of the axle, push the pal nut onto the axle until it is tight. Slide the other wheel on the remaining end of the axle and secure it with a second pal nut. Using the eight (8) screws, nuts and locking washers, install the casters into the four holes provided in the cabinet. Insert the screws through the holes, attach the nuts and tighten. Follow the same procedure for the second caster. Installing the Brackets: 1. 2. 3. 4. 5. With the screws provided, install three brackets on the side of the machine. Wrap the system vapor hose and the system liquid hose around the brackets. Secure the hoses onto the hose storage mounting ports. Wrap the power cord around the final bracket. Install the tank retention bracket on the rear of the machine with the screws provided. Installing the Filter Core: 1. 2. 3. 4. 5. Using a 9/16 inch wrench, remove the six nuts on the filter canister lid. Remove the lid and set it aside. Remove the filter core from its vacuum sealed can. Immediately install filter into canister with the round metal plate facing up. Do not expose filter core to the atmosphere for more than two minutes. Doing so will shorten its service life. Install the spring plate on top of the filter core with the spring facing up. Install the canister lid on top and tighten the nuts in a crossing pattern with between 10 to 15 pounds torque. Effective 3/97 Page 4-57 CHAPTER 4 ACT-3000 / WHITE-01060 Installing the Filter Core continued: NOTE: Failure to install the filter core and canister lid properly will result in a machine malfunction. 6. Attach the tank liquid hose to a vacuum pump. If hand valves are used open the liquid valve, engage the vacuum pump and evacuate the unit for a minimum of thirty (30) minutes and continue until the moisture indicator turns green. If your unit has a hand valve on the end of the tank liquid hose, you must open the valve before engaging the vacuum pump. NOTE: To aid in evacuating, the operator can tee an AUXILIARY hose from the vacuum pump to the access port on top of the filter canister. Installing The Tank: 1. 2. 3. 4. 5. 6. 7. Remove the tank from its box and remove the plastic caps from the valve ports. Connect a vacuum pump to the vapor valve, open the vapor valve, and pull a vacuum on the tank for approximately two hours. After evacuating the tank, close the tank vapor valve and disconnect the vacuum pump. The tank is now ready to be installed into the machine. Note: Your recovery recycling machine can have either anti-blow back valves or hand valves on the ends of the tank liquid and the tank vapor hoses. For those machines with hand valves, make sure that the opened or closed status of the hand valve matches the status of the tank valve. For example, if the liquid valve on the tank is open, make sure the hand valve on the tank liquid hose is open. Connect the tank liquid hose to the liquid valve and the tank vapor hose to the vapor valve. Open the liquid valve. Make sure the vapor valve is closed. Attach the black tank sensor cord to the corresponding fitting on the tank. Remove one of the refrigerant designation labels from the supplied sheet and apply it to the tank. Using a bold marker, please check the refrigerant you will be recovering into the tank. Please be careful not to mix refrigerants. Introducing different refrigerants into the same tank will completely contaminate all the refrigerants in the tank. The unit is now ready to recover and recycle. Page 4-58 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 RECOVERING AND RECYCLING 1. 2. When recovering from systems of six pounds of refrigerant or less, you will not need to use the long red "system liquid" hose. To recover from systems with six pounds or less refrigerant, connect one of the anti-blow back valves on the long blue "system vapor" hose to the system's low-side port and the second anti-blow back valve on the long blue "system vapor" hose to the system's high-side port. When recovering from systems containing more than six pounds of refrigerant, connect the long red "system liquid" hose to the A/C system's high-side port and one of the two anti-blow back valves on the long blue "system vapor" hose to the A/C system's low side port. It makes no difference which one of the two anti-blow back valves on the long blue "system vapor" hose you connect to the system's lowside port in this application. NOTE: Be sure that when connecting the refrigerant recovery recycling machine to the system that you connect the hoses properly and that you connect the hoses to the system access ports only. Also, make sure that you are not recovering R-134a. RECOVERY OF R-134a COULD RESULT IN SERIOUS PERSONAL INJURY, WILL CAUSE IRREPARABLE DAMAGE TO YOUR MACHINE, AND WILL VOID ALL WARRANTY. 3. 4. Make sure the unit is plugged into a standard 110 volt outlet. Locate the three (3) horizontal switches on the face panel of the machine. The button on the top is the "on/off" or "power" switch. Move the "power" switch to the ON position. NOTE: The TANK FULL light will illuminate for 60 seconds after the machine is switched ON while sensors are stabilizing inside the tank. 5. 6. 7. 8. Check for positive pressure on the gauge to make sure there's refrigerant in the system. Depress and hold the cycle start button located directly below the main power switch for approximately three seconds, this will begin the recovery and recycling procedure Ensure refrigerant is flowing across the moisture indicator and the system operating light is illuminated. You should see the system pressure gauge begin to drop. In most cases, the recovery process should be complete within twenty minutes. When the system pressure reaches 20 PSI, you must purge the oil removed during the recovery process. WARNING: Failure to purge oil will result in machine malfunction and will void the warranty. 9. 10. 11. Depress and hold the oil purge valve until the oil stops flowing into the oil cup and pressure can be heard escaping from the port. To determine how much oil was removed during the recovery process, simply read the cup which is marked in both ounces and milliliters. The unit will automatically shut down once the refrigerant has been recovered. NOTE: Although the system has shut off, the fan will continue running as long as the main power switch is on. Although the fan does not need to remain on indefinitely, if you are going to service a series of vehicles in succession, we suggest you let the fan continue to run; otherwise, turn the fan off by switching the main power switch to the "off" position. Effective 3/97 Page 4-59 CHAPTER 4 ACT-3000 / WHITE-01060 If you are connecting your refrigerant recovery recycling center to an A/C charging station: 1. 2. 3. 4. 5. 6. 7. 8. Connect the refrigerant recovery recycling center's eight foot system vapor hose to the purge port on the A/C charging station. If your A/C charging station DOES NOT HAVE a purge port, you will need to use a parallel kit that consists of two (2) valves. Install the parallel kit on the high and low side ports of the A/C charging station Connect the straight ends of the high and low charging hoses on the valves that are PARALLEL, NOT PERPENDICULAR, with the ports of the charging station. Connect the system vapor hose and the system liquid hose from the refrigerant recovery recycling center to the corresponding port on the parallel kit. Connect the remaining ends of the A/C charging hoses to the high and low ports of the system. Open the valves on the parallel kit if applicable; open the purge valve on the A/C charging station. Then follow the previous instructions for starting your refrigerant recovery recycling machine. To begin charging, close off the valves of the parallel kit, if present, and the purge valve on the A/C charging station and resume normal charging operations. PRESSURE TEST This unit has an exclusive pressure test feature that allows you to locate a leak in a system void of refrigerant. When the unit is connected to a system and the panel mount gauge reads ZERO PSI, indicating that the system is void of refrigerant: 1. 2. Open the vapor valve on the refrigerant tank and, Depress the pressure test button until sufficient pressure is indicated on the panel mount gauge. We recommend that the vapor valve on the refrigerant tank remain closed unless utilizing the pressure test or air purge features. PLEASE NOTE: There must be refrigerant in the tank prior to using this feature. After you have pressurized the system, you can search for the system leak by utilizing standard leak detection procedures and equipment. Once the leak is located, remove the pressure test charge by depressing the cycle start button. The unit will automatically shut down once the test refrigerant has been recovered. MOISTURE INDICATOR and HOUR METER Before and during refrigerant recovery, the moisture indicator can vary in color. Therefore, it is very important to view the moisture indicator and hour meter for condition of the refrigerant only after the system shuts down and the recovery process is complete. If the indicator is green, the filter core is fine and you may continue recovering and recycling similar refrigerant. However, if the moisture indicator is more yellow than green, it is time to change the filter core. The hour meter, indicates the total time the machine has run in the recovery mode. This allows the operator to keep track of the total accumulated recovery time on the filter core. The filter core should be changed every 25 hours of use. Page 4-60 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 MOISTURE INDICATOR and HOUR METER continued It takes approximately 1/4 pound of refrigerant passing through the moisture indicator to signal the condition of the refrigerant. If less than 1/4 pound of refrigerant is recovered, the moisture indicator may or may not turn green. Remember, the only time to view the moisture indicator to determine the condition of the core and the refrigerant is DURING the oil purge process. Moisture Indicator replacement The moisture indicator in this machine has been improved for easier field replacement. Occasionally, the element that changes from yellow to green will become fouled and require replacement. The new design allows replacement without removing the top panel: MOISTURE INDICATOR and HOUR METER REPLACEMENT 1. Close the hand valves on the tank. Remove the Tank Liquid hose and open valve to bleed pressure from the hose assembly. Leave valve open. 2. Insert screwdriver into the slots in the viewing window assembly and unscrew the window. 3. Fully remove the window assembly from the body. 4. Pull the spring and element assembly from the body. 5. Pull the element out of the spring. NOTE: DO NOT TOUCH element; oil on hands will foul element. 6. Push the replacement element into the small end of the spring. 7. Insert the spring and element assembly back into the window assembly. 8. Check the o-ring condition, lube if necessary, and reinstall into the body. TANK FULL Your Refrigerant Recovery Recycling Center also has a tank full light which will illuminate. The unit will automatically shut off once the recovery recycling tank becomes full of refrigerant. The tank full light will also illuminate and shut the unit off if the tank sensor cord is not properly attached to the tank receptacle. NOTE: The TANK FULL light will illuminate for 60 seconds after the machine is switched ON while sensors are stabilizing inside the tank. HIGH PRESSURE CONDITION The high pressure light will illuminate when there's high pressure on the discharge side of the recovery recycling system. The three main conditions that cause high pressure are: 1. 2. 3. If you haven't opened the liquid tank valve or the hand valve on the tank liquid hose. If there is excessive air in the tank itself, or If the anti-blow back valve on the tank liquid hose is not fully engaged. As a safety precaution, when the high pressure light is illuminated, the machine will not operate. You must remedied the high pressure situation before the machine will operate. Effective 3/97 Page 4-61 CHAPTER 4 ACT-3000 / WHITE-01060 PURGING THE NON-CONDENSABLE GASES Once the tank full light illuminates, indicating a tank full condition, or the high pressure light illuminates, indicating a high pressure condition, you will need to purge the non-condensable gases or air from the tank. Before beginning this process, disconnect the hoses from the A/C system and allow sufficient time for the tank temperature to stabilize at room temperature. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Open the tank vapor valve and, if your unit has a hand valve on the end of the tank vapor hose, open the hand valve as well. Depress and hold the pressure test button. Read the amount of pressure in the tank by looking at the digital gauge on the front of the machine. Determine the ambient temperature in the room. Refer to the appropriate chart in figure 7 for the refrigerant type with which you are currently working. Find that temperature on the chart and look across to the corresponding pressure and how it relates to the pressure reading on the gauge. If the pressure on the gauge is higher than the pressure on the chart, depress the purge valve until the pressure on the gauge corresponds to the pressure on the chart. Release the pressure test button. The pressure test button and the purge button must be depressed through-out the air purge procedure. Allow the tank to stabilize for 10 minutes and check the pressure again. Repeat process and purge again ,if necessary. We recommend that the vapor valve on the refrigerant tank be closed except when utilizing the air purge or pressure test features. USING YOUR RECYCLED TANK OF REFRIGERANT After purging the non-condensable gases or air from the tank, you are now ready to use the recycled refrigerant. 1. 2. 3. 4. 5. 6. Close both tank valves. If your machine has hand valves on the TANK LIQUID and TANK VAPOR hoses, close them as well. Disconnect the TANK LIQUID and TANK VAPOR hoses and the black tank full cord. Remove the tank. This tank of refrigerant can now be used to charge an A/C system. Tank should be in the inverted position, in the charging machine and the R-12 hose should be connected to the vapor valve. Install the second tank into the recovery machine. Refer to the tank installation procedures. Page 4-62 Effective 3/97 CHAPTER 4 ACT-3000 / WHITE-01060 CHANGING THE FILTER CORE The filter core should be changed if: a) the moisture indicator shows a yellow condition after the system has shut off. b) the filter core has accumulated a total running time of 25 hours, as indicated by the hour meter. 1. Remove the cap from the port on the filter shell and release any excessive pressure by depressing the valve core. 2. Remove the lid from the shell and take out the spring plate. 3. Attach a magnet to the metal plate on the filter core and remove the core. 4. This used filter core does not contain hazardous material, so you may dispose of the used core in a responsible manner. 5. Then install a new filter core by following the procedure covered in the instructions on page NOTE: You MUST also change the filter core before recovering different types of refrigerants. REFRIGERANT CHANGE OVER PROCEDURE Your refrigerant recovery recycling center is UL listed for recovery and recycling of R-12 and meets SAE J1991 purity standards. The center is also UL listed for recovery of R-22, R-500, R-502 and R-12 from nonautomotive applications. These refrigerants pass through the same filtration system; however, the manufacturer cannot guarantee the resulting purity since no standards for these refrigerants currently exist. It is imperative that you follow the procedures each time you recover a different type of refrigerant. 1. 2. 3. 4. 5. 6. 7. Remove the cap from the port on the filter shell and release any excessive pressure by depressing the valve core. Change the filter core by following the filter core replacement procedures discussed on page 16. Close both valves on the white recovery recycle tank and disconnect the TANK VAPOR and TANK LIQUID hoses and the black tank sensor cord. Remove the tank. Release any pressure from the tank liquid hose and connect to a vacuum pump. Evacuate the system for a minimum of thirty (30) minutes and continue until the moisture indicator turns green. Install a new tank following the tank installation procedures. Be sure that the tank you install is either empty and completely evacuated or contains the same refrigerant that you are about to recover. You are now ready to recover refrigerant. Effective 3/97 Page 4-63 CHAPTER 4 ACT-3000 / WHITE-01060 FACTORY RECOMMENDED DAILY PROCEDURES 1. 2. 3. 4. 5. 6. 7. Prior to using the machine, check for excessive air pressure in the recovery tank and on the system pressure gauge. Check for oil by pressing the purge valve. Discharge any oil present into the measuring cup. Make sure tank full sensor cord is fully engaged. Check the condition of all service hoses for contamination before connecting to the A/C system. Make sure all hoses are fully engaged at tank connections. When unit is not in use, be sure to close both the liquid and vapor valves on the tank. To calibrate the system pressure gauge, use a number two screwdriver and adjust the pressure gauge through the hole provided until the gauge stabilizes between ZERO and ONE PSI. If you have questions on these or any other procedures, please call our toll free number 1-800-442-8885. Please have model number and serial number available. Page 4-64 Effective 3/97 SECTION 1 AC POWER DISTRIBUTION WARNING: DANGEROUS HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT. Always use the "One Hand Rule" when working with AC voltages by keeping one hand in your pocket or behind your back. Before removing wires from the ACT-3300, always verify that the Tester is "OFF". Turn the Power/Mode Switch on the front panel to OFF and unplug the AC power cord from the AC outlet. AC DISTRIBUTION (Refer to Functional Block Diagram 5-1 on Page 5-3) The hot side (black wire) of the 115VAC is wired directly to the center contact on a front panel, three-position rocker switch. There is no further AC distribution with the switch in the center-off position. Page 5-1 NOTES: Page 5-2 Page 5-4 SECTION II THEORY OF OPERATION RECOVER POWER ON MODE: Electrical: (Refer to Drawing 5-2 on Page 5-9) This power on mode starts when the front panel Power/Mode rocker switch is placed in the Recover position. 115VAC is distributed to the Crossover Solenoid (S2), Low Side Solenoid(S1), AC Line Filter, Fan, Air Purge Board and the Heater Blanket switch. The Air Purge Board provides DC voltages to the high and low Pressure transducers, Start Recovery switch, Tank Full Probe Assembly, Recovery Tank Pressure Sensor, and the System Pressure Sensor. Pneumatics: (Refer to Drawing 5-3 on Page 5-11) The power on mode opens normally closed Low Side solenoid (S1) and Crossover solenoid (S2). EVACUATION CHARGE POWER ON MODE: Electrical: (Refer to Drawing 5-4 on Page 5-13) This power on mode starts when the front panel Power/Mode rocker switch is placed in the Evacuation Charge position. 115VAC is distributed to the Evacuation Timer contact, the Refrigeration Charge Timer contact, the AC Line Filter, the Fan, and the Air Purge Board. The Air Purge Board provides DC voltages to the high and low Pressure transducers, the Start Recovery switch, the Tank Full Probe Assembly, the Recovery Tank Pressure Sensor, and the System Pressure Sensor. Pneumatic: (Refer to Drawing 5-3 on Page 5-11) This power on mode does not affect any pneumatic components. RECOVER MODE: Electrical: (Refer to Drawing 5-5 on Page 5-15) With the Tester in the Recover Mode, the normally closed (NC) Low Side (S1) and Crossover (S2) Solenoids are energized. Recovery is initiated when the Start Recovery switch is depressed. The switch is spring-loaded and returns to the open position when released. The Air Purge board controls the Compressor. It also monitors the compressors run time and initiates the Oil Return mode for 10 seconds every 15 minutes. The compressor is running and the Recovery light is lit indicating the mode. The hour meter starts to run and the Filter Core heater is energized. Pneumatics: (Refer to Drawing 5-6 on Page 5-17) In the Recovery Mode, refrigerant flows from both the high and low side vehicle ports through the Crossover (S2) and Low Side (S1) Solenoids to the Filter Dryer/Oil Separator. In the Filter Dryer/Oil Separator, refrigerant is separated from the vehicle's oil and sent out through the top port, then through the check valve and to the compressor. From the Compressor, VAPOR refrigerant is sent to the Compressor Oil Separator inlet port. Page 5-5 RECOVER MODE continued: Here the compressor's oil is separated from the refrigerant and the vapor refrigerant flows from the "OUT" port of the compressor oil separator and through the condensing coil. The condensing coil changes the refrigerant back into a liquid. It then flows through the check valve, moisture indicator, and into the tank through the liquid port. AUTOMATIC OIL PURGE MODE: Electrical: (Refer to Drawing 5-7 on Page 5-19) When the Recovery Mode is finished, the unit is shut down, and the Air Purge board energizes the Air Purge solenoid (S3), until 20 PSI of non-condensibles is sensed by the System Pressure Transducer P1. At that point the Air Purge Board will energize the Oil Purge Solenoid (S4). The Oil Purge Solenoid will stay open for a period of 2.5 minutes, which is determined by the Air Purge Board. Pneumatics: (Refer to Drawing 5-8 on Page 5-21) When the LOW and HIGH side gauges reach 5-10 inches of mercury, the machine automatically shuts down. The Air Purge solenoid (S3) will be opened until 20 PSI is measured by the System Pressure Transducer (P1). At that point, the Oil Purge solenoid will open and the 20 PSI of vapor refrigerant will push out the oil removed from the Vehicle's Air Conditioning system into the oil discharge cup. AIR PURGE MODE: Electrical: (Refer to Drawing 5-9 on Page 5-23) The Air Purge board monitors the Tank Pressure via the Recovery Tank Pressure transducer (P-2), and the Tank Temperature via the tank full probe, during power up and at the end of every recovery. If the pressure and temperature indicate the tank contains excess air, the Air Purge light is lit. To reduce the pressure, the Air Purge switch is depressed by the operator, and the Air Purge (S3) and Oil Purge (S4) solenoids are energized for 10 seconds. The Air purge board then recalculates to determine if the excess air has been purged. If all the excess air has not been purged, the solenoids are then energized again for 10 seconds. This process continues until the air purge board has determined that an excess air condition no longer exists Pneumatics: (Refer to Drawing 5-10 on Page 5-25) The excess pressure is purged from the tank through the Air Purge solenoid (S3) and the Oil Purge solenoid (S4) to the Oil / Air Purge cup. Solenoids S1 and S2 are also on in this mode but are not involved. AUTOMATIC OIL RETURN MODE: Electrical: (Refer to Drawing 5-11 on Page 5-27) The Compressor "ON" time is monitored by the Air Purge board. Every 15 minutes that the compressor runs, the Oil Return solenoid (S5) is deenergized for 10 seconds. Pneumatics: (Refer to Drawing 5-12 on Page 5-29) During the 10 second Automatic Oil Return Mode, Oil from the Compressor's Oil Separator is pushed through the Oil Return solenoid (S5) and back into the Compressor via the suction port. This ensures the Compressor always has the right amount of oil. Page 5-6 EVACUATION MODE: Electrical: (Refer to Drawing 5-13 on Page 5-31) With the Tester in the Evacuation Charge Mode, 110VAC is provided to the Evacuation Pump Timer contact 1. When the operator selects the desired vacuum time on the timer, AC to the Refrigeration Charge Timer is interrupted by opening contacts 1 and 4 on the Evacuation Pump Timer. Contacts 1, 2 and 3 on the Evacuation Pump Timer are closed, providing 110VAC to the Timer motor and the timing sequence starts. The Evacuation Light is now lit. 110VAC is provided to the Vacuum Pump, turning it on, through the normally closed contacts of the Vacuum Pump Lockout switch. The Vacuum Solenoid (S8) is also energized. Pneumatics: (Refer to Drawing 5-14 on Page 5-33) With the High and Low Service Hoses attached to the vehicle system, the vacuum pump will pull a vacuum on the vehicle system with the Vacuum Solenoid (S8) energized and open. If there are no leaks in the system, all gauges will hold steady. If there is more than 10 psi in the vehicle the vacuum pump lockout switch will be open, not allowing the vacuum pump to start. A reclaim must then be performed before the evacuation can be performed. OIL CHARGE MODE: Pneumatics: (Refer to Drawing 5-15 on Page 5-35) With a vacuum on the vehicle system, oil can be added to the system at the oil injection port. This is done with the oil injection syringe. The cycle will be completed when the refrigerant pushes the oil into the vehicle in the recharge mode. CHARGE RECYCLED MODE: Electrical: (Refer to Drawing 5-16 on Page 5-37) When the Evacuation Pump Timer shuts off, contacts 1, 2 and 3 open. At the same time contacts 1 and 4 close and distribute 110VAC to the Refrigeration Charge Timer. With the Refrigerant Select switch in the Recycled position, 110VAC is provided to the Recycle Charge Solenoid (S6) through the normally closed (NC) contacts of the Recycled High Pressure switch (PS2). The operator selects the desired charge amount, closing contacts 1, 2 and 3 of the Refrigerant Charge Timer. While the charge amount is being set, the Charge Hold light will be lit through the normally shorted contacts 1 and 5 of Relay 1. To start the timing sequence, the spring-loaded Start Charge switch is depressed. The switch provides a return for the Timer Motor. By keeping the switch depressed, pressure increases on the differential switch, closing the normally open (NO) contacts. When these contacts close, sufficient liquid flow will be established to cause the float in the Photocell to block the normally open (NO) photocell, causing it to close providing a path to energize Relay 1. This also allows Recycled Charge Solenoid (S6) to energize. When relay 1 energizes, contacts 1 and 2 open, extinguishing the Charge Hold Light. The Charge Light will now be lit. When the Start Charge switch is released, the charge will continue until the Refrigerant Charge Timer expires. Then, contacts 1, 2, and 3 of the Refrigerant Charge Timer will open, removing the 110VAC from the recycled charge solenoid (S6), relay 1 and extinguishing the Charging light. Page 5-7 CHARGE RECYCLED MODE continued: Pneumatics: (Refer to Drawing 5-17 on Page 5-39) In the charge recycled mode, with a vacuum on the vehicle system, the Recycled refrigerant goes through the Recycle Solenoid (S6), In-Line Filter, a check valve, Flow switch, flow regulator, and to the Vehicle Low Side Port. The Differential Pressure switch (PS4) is a normally opened switch. If the vacuum/pressure differential will not keep the switch closed, the switch opens, halting the charge of refrigerant by deenergizing the Recycle Solenoid (S6). CHARGE VIRGIN MODE: Electrical: (Refer to Drawing 5-18 on Page 5-41) When the Evacuation Pump Timer shuts off, contacts 1, 2 and 3 open. At the same time, contacts 1 and 4 close, distributing 110VAC to the Refrigeration Charge Timer. With the Refrigerant Select switch in the Virgin position, 110VAC is provided to the Virgin Charge Solenoid. With the front panel doors closed, both door interlocks will be closed and the Tank Heater switch will be turned on to provide power to the heater blanket through the normally closed contacts of the Virgin High Pressure switch (PS3). With the Tank Heater switch on, the Tank Heater light will be lit. The operator selects the desired charge amount, closing contacts 1, 2 and 3 of the Refrigerant Charge Timer. While the charge amount is being set, the Charge Hold light will be lit through the normally shorted contacts 1 and 5 of Relay 1. To start the timing sequence, the spring-loaded Start Charge switch is depressed. The switch provides a return for the Timer Motor. By keeping the switch depressed, pressure increases on the differential switch, closing the normally open (NO) contacts. When these contacts close, sufficient liquid flow will cause the float in the Photocell to block the normally open (NO) photocell, causing it to close providing a path to energize Relay 1. This also allows the Virgin Solenoid (S7) to energize. When relay 1 energizes, contacts 1 and 2 open, extinguishing the Charge Hold Light. The Charge Light will now be lighted. When the Start Charge switch is released, the charge will continue until the Refrigerant Charge Timer expires. Then, contacts 1,2, and 3 of the Refrigerant Charge Timer will open, removing the 110VAC from the Virgin Charge Solenoid, relay 1 and extinguishing the Charging light. Pneumatics: (Refer to Drawing 5-19 on Page 5-43) In the charge virgin mode, with a vacuum on the vehicle system, the Virgin refrigerant goes through the Virgin Solenoid (S7), In-Line Filters, a Check Valve, Flow switch, flow regulator, and to the Vehicle Low Side Port. The Differential Pressure switch (PS4) is a normally opened switch. If the vacuum/pressure differential will not keep the switch closed, the switch opens, halting the charge of refrigerant by deenergizing the Recycle Solenoid (S7). Page 5-8 Page 5-10 Page 5-12 Page 5-14 Page 5-16 Page 5-18 Page 5-20 Page 5-22 Page 5-24 Page 5-26 Page 5-28 Page 5-30 Page 5-32 Page 5-34 Page 5-36 Page 5-38 Page 5-40 Page 5-42 Page 5-44 SECTION III TESTING PROCEDURES Air Purge Board Function Test 1. Connect Test Box (K65109) to the Air Purge Board connector J4. 2. Ensure that a tank full probe is connected to the tank full cord. 3. Plug in the Machine. 4. While holding down the center button on the Test Box, turn the Power/Mode switch to the Recover position. You will see either "12" or "134a" displayed briefly. This should correspond to the type of machine you are working on. If the wrong notation is displayed the wrong Air Purge Board is installed in the unit. Refer to Service Bulletin 750 to convert an R134a board to an R12 board. 5. Press center button again, "Recovering" lamp will illuminate. 6. Press center button again, "Excess Air" lamp will illuminate. 7. Press center button again, "Tank Full" lamp will illuminate. 8. Press center button again, "Oil Return" solenoid will click. 9. Press center button again, "Air Purge" solenoid will click. 10. Press center button again, "Oil Purge" solenoid will click. 11. Press center button again, "High Pressure" lamp will illuminate. High and Low Transducer Test 1. To check the High and low side transducers turn the Power/Mode switch to the OFF (middle) position. 2. Open the recycled tank vapor hose. Remove the vacuum from the filter canister by pressing the access schraeder on top of the filter canister. 3. Turn the Power/Mode switch to the Recovery position. 4. Zero's should be displayed on the front panel High and Low side displays. 5. The Test Box should be reading between 4psi and 3" of Mercury. This is the High side transducer. 6. Press the center button on the Test Box. 7. The Test Box should be reading between 4psi and 3" of Mercury and the readings should be flashing. This is the Low side transducer. Page 5-45 TROUBLESHOOTING I. CHARGE HOLD light illuminates while charging VIRGIN refrigerant. Empty or nearly empty tank. Insufficient Pressure. Replace empty tank with a full tank. Set POWER/MODE switch in RECOVER or EVACUATION/RECHARGE and heat tank for at least 15 minutes before attempting to charge. Both doors must be closed. II. CHARGE HOLD light illuminates while charging RECYCLED refrigerant. Empty or near empty tank. Insufficient pressure. NOTE: 20 lbs. liquid refrigerant minimum. Replace empty tank with a full tank. Recover any partial charge which may be in the vehicle system. III. CHARGE HOLD light illuminates when setting the charge amount of RECYCLED refrigerant and the charging process will not remain engaged when the START CHARGE is depressed. Excessive pressure in RECYCLED refrigerant tank. (successive recovery operations or high ambient temperature-over 90 F.) Allow the tank to cool for 15 minutes. Charge amount can be left on timer (check charge amount and reset valve if (START CHARGE has been pressed repeatedly.) When pressure decreases to a safe level, the refrigerant charging light will remain on when the START CHARGE button is pressed and the charging process will begin. NOTE: Any of the above CHARGE HOLD conditions may be remedied by switching between "VIRGIN" and "RECYCLED", provided that the refrigerant source selected contains sufficient pressure and volume, OR by starting the engine and turning on the A/C system, then pressing the START CHARGE button. IV. Machine won't pull vacuum. Evacuation light is not on. No power to the machine. Plug in all cords. Check power on the electrical outlet. POWER/MODE switch not in the proper position. Set switch to EVACUATION/RECHARGE. Vacuum timer not set. Set timer to proper position. Excessive pressure (10 PSI) on low side gauge. Perform recovery operation. Page 5-46 V. Machine won't pull vacuum. Evacuation light is on. Possible leak in vehicle A/C system. Close hand valves on system service hoses, and see if machine will pull vacuum on itself. Pump is not on. Feel for vibration. Bad Vacuum Pump. Hand valves are closed on system service hoses. Open hand valves. Vacuum solenoid not opening. Check for vacuum on Aux port. VI. Heater blanket will not heat. Virgin tank compartment door is open. Close door. Virgin tank is over 150 PSI. Allow tank to cool. VII.Machine won't charge. No power to the machine. Plug in all power cords. Check power on electrical outlet. POWER/MODE switch not in the proper position. Set switch to EVACUATION/CHARGE. High pressure in recycle tank. Let recycled tank cool below 150 PSI. Perform air purge on recycled tank. Vacuum timer on. Turn off Vacuum Timer. To clean timer contacts, turn timer on then off several times, then retry. Refrigerant Charge selector not set. Set selector. To clean timer contacts, turn timer on then off several times, then retry. Charge tank has insufficient pressure. If using virgin tank, turn on heater blanket for approximately 15 minutes. If using recycled tank, charge approximately 1.5 lbs of virgin refrigerant into vehicle, then recover the charge. Page 5-47 Page 5-48 SECTION IV PARTS ______________________________________________________________________________________ _ GENERAL This chapter describes assemblies, subassemblies, and parts considered replaceable by a qualified Sun Field Service Technician. NOTE: The following is a breakdown description for Serial Numbers: I. How to read SERIAL NUMBERS: NOTE: Serial # Location - Left hand side. A. In 1970's a FOUR digit serial number was used. The First digit dictates the Year Built. 1. B. 2341 = Built in 1972 In 1980 to 1991 a SIX digit serial number was used. The first two digits dictate the Year Built. 1. C. EXAMPLE: EXAMPLE: 811032 = Built in 1981 In 1992 to present a 10 digit number was used. 1. 2. 3. 4. 1st digit = Year 2nd digit = Month 3rd digit = Make 4th & 5th digit = Model 5. 6th thru 10th = Lot # 6. EXAMPLE: B=1992, C=1993, ... A=January, B=February, ... W=White, S=Snap-On 2A=ACT-2000, 62=ACT-3000 80=ACT-3300, 85=ACT-3400 Number of unit coming off production line. BAS621301 = Built in 1992, January, Snap-On, ACT-3000, 1301 lot # Page 5-49 SUBSECTION A. PARTS BY PICTORIAL ACT-3300/ACTR-3400 FRONT VIEW PART NUMBER ITEM 1 ITEM Lamps DESCRIPTION K30008 6 Timer, R-12 K30263 2 Switch, Momentary K30008 7 Switch, ON/OF w/Lamp K30008 3 Timer, Vacuum K30410 8 Gauge, Digital K1101069 4 Switch, Virgin/Recycled K30268 9 Switch, Momentary K30008 5 Switch, Door Interlock K30271 10 Switch,Recover/Recharge K30224 Page 5-50 DESCRIPTION PART NUMBER ACT-3300/ACTR-3400 ELECTRICAL RECOVERY SIDE VIEW ITEM PART NUMBER ITEM Meter, Hour (Silver) K30270 5 Cord, Tank Full K1101033 Meter, Hour (Black) K30276 6 Filter, AC Line K32505 2 Compressor, w/Fittings K16011 7 Fan K32511 3 Solenoid, Oil Return K60058 8 Solenoid, Purge K60065 4 Switch, High Pressure K30255 9 Blanket, Heater K30024 1 DESCRIPTION DESCRIPTION PART NUMBER Page 5-51 ACT-3300/ACTR-3400 ELECTRICAL CHARGING SIDE VIEW PART NUMBER ITEM 1 ITEM Shell, Filter DESCRIPTION K16205 6 Valves, Solenoid (4) K60060 2 Pump, Vacuum K16019 7 Switch, Virg. 150 PSIG, K30209 3 Switch, Float K30023 8 Separator, Oil K16608 4 Switch, Safety 10 PSIG K30264 9 Compressor w/Fittings K16011 5 Valve, Flow K60021 10 Switch, Differential Press. K30023 Page 5-52 DESCRIPTION PART NUMBER ACT-3300/ACTR-3400 TUBING RECOVERY/CHARGING SIDE VIEW PART NUMBER ITEM 1 ITEM Tube, Float/Flow Valve DESCRIPTION K40534 5 Line, Oil Return DESCRIPTION K40833 PART NUMBER 2 Tube, Gauge/Low/Vac K40855 6 Tube, Comp.Discharge K40545 3 Tube, High/Low Side K40807 7 Tube, Condensing K40837 4 Tube, Moisture Indicator K40856 Page 5-53 SUBSECTION B: PARTS IN ALPHANUMERIC ORDER ACT-3300/ACT-3400 Description PART NUMBER Adapter, R-134a Low Side K04100 Vehicle Low Side Adapter Adapter, O-Ring Replacement Kit K04040 Contains 10 O-Rings and O-Ring Tool Adapter, R-134a High Side K04000 Vehicle High Side Adapter Bezel, Digital Gauge K30509 Comes with the Bezel and Lens Blanket, Heater K30044 Virgin Tank Blanket, Heater K30024 Filter Shell Board, Digital Gauge K1101069 With Transducer For High or Low Sides Board, R-134a Air Purge K1101071 Refer to SB750 to convert to R-12 Bd. Bracket Kit K76383 Float Switch, Solenoid, Timer, Filter shell Cabinet, Complete K76900 Sheet Metal Cabinet, Filter Shell K76349 Cabinet, Frame K76385 Cabinet, Control Head K76386 Cap, 1/2 " Acme w/ strap K90313 Cover for R-134a bulkhead fittings (qty 5) Cap, 1/4" flair w/ strap K90312 Cover for R-12 bulkhead fittings (qty 5) Caster, Locking K35252 Chrome Strip Kit K76377 Left and Right Chrome Strips Compressor K16011 With Fittings to fit all Units Cord, Float Switch Power K30152 For Float Switch Light Cord, AC Power K30199 Can Use 6001-0189-01 Cord, Tank Full K1101033 Cover, Door Switch K76391 Sheet Metal Cup, Oil K90301 Measuring Cup Depressors, Screw In K45321 Package of 25 Digital Gauge, Bezel K30509 Door, Right w/Hinge K76389 Door, Lock and key K35070 Door, Left R-12 K76388 Door, Left R-134a K76392 Drum, Refrigerant Timer K33001 With Label Drum, Vacuum Timer K33000 With Label Dry Dot, Green K91080 Sticker Dry Dot, Yellow K91080 Sticker Element, Moisture Indicator K16601 Element, Spring, O-Rings, Glass Element, Inline Particle Filter K90420 Package of 10 Fan K32511 Can Use 0587-0504 Filter, AC Inline K32505 AC Power Filter Filter, Brass line Particle K90423 Inline Filter Assy. (Brass & Element) Page 5-54 COMMENTS Filter, Desiccant K16200 Contains 2 filters and O-Rings Fitting, Kit Brass K51080 Fitting, Kit Compressor K32032 Fitting, 1/8 Mnpt x 1/2 Acme K50556 Gaskets, Hose K45331 Grill, Fan K32531 Grommet (Heyco Bushing) K90041 Handle, Side K35538 Harness, Recovery Lower wiring K1101038 Harness, Charging Lower wiring K1101034 Harness, Upper wiring K1101045 Hose, 3' Blue Virgin R-12 K25207-146 From Virgin Tank to Solenoid Hose, 9" Vacuum Pump K25007-139 From Vacuum Pump to Vacuum Hose, 96" Blue R-134a K24007-100 Vehicle Hose Hose, 96" Red R-134a K24107-196 Vehicle Hose Hose, 5' Yellow Vac. R134a K26207-400 Auxiliary Vacuum Hose Hose, 3' Red Virgin R-134a K24207-154 From Virgin Tank to Solenoid Hose, 24" Blue Vapor R-134a K24207-309 From Reclaim Tank to Solenoid Hose, 18" Red Recy T. L. R134a K24207-308 With Hand Valve Hose, 18" Blue Liquid R-12 K25207-312 From Reclaim Tank to Solenoid Hose, 96" Blue R-12 K25007-143 Vehicle Hose Hose, 96" Red R-12 K25107-123 Vehicle Hose Hose, Compressor K25007-103 Filter Dryer/Oil Separator to Compressor Hose, 5' Yellow Vacuum R-12 K25207-100 Auxiliary Vacuum Hose Hose, 24" Red Tank Vapor R-12 K25207-313 From Reclaim Tank to Solenoid Hose, 18" Blue Charge R-12 K25007-103 From Reclaim Tank to Solenoid Indicator, Moisture w/o Tubing K16613 Old Style, All Brass Colored Indicator, Moisture w/o Tubing K16622 New Style, Brass and Silver Colored Injector, Oil R-12 K01550 Injector, Oil R-134a K01555 Label, Snap-On Logo K35403 Front Panel Snap-On Logo Lens, Digital Gauge K30509 Comes with the Bezel and Lens Lock, Door w/Key K35070 Manifold, Kit K50604 Mat, Tool Tray K35152 Meter, Hour K30276 New Style, Small Black Meter, Hour K30270 Old Style, Large Silver O-Ring, #10 K45030 Package of 25 Oil, Compressor 0681-0179-02 3GS Oil, 10 oz. in Compressor Overload, Compressor K30301 Contains Overload, and Klixon Panel, Face K76380 R-12 Panel, Face K76345 R-134a Panel, Fan K76372 Panel, R-134a Operating Inst. K76344 Package of 25 for AC power cord and Wiring harnesses Flip Panel On Top of Machine Page 5-55 Panel, R-12 Operating Inst. K76395 Flip Panel On Top of Machine Plate, Spring K90011 On top of Desiccant Filter in Filter Shell Port, Filter Pressure Access K50503 R-12- On Top of Filter Dryer Port, Filter Pressure Access K50559 R-134a- On Top of Filter Dryer Probe, Tank Full K1101037 Pump, Vacuum K16019 1.5 CFM (Uses Vacuum Pump Oil) Relay, Float Switch K30041 Clear Plastic Relay Relay, Compressor K30301 Contains Overload, and Relay Separator, Compressor Oil K16608 Shaft, Timer knob K90022 Shell, Filter Dryer / Oil Separator K16205 Socket, Relay K30065 With Clips Solenoid, Oil Return K60058 Without Fittings Solenoid K60060 Vacuum, Charge, Low Side Solenoid, By-pass K60065 Strap, Tank K90080 18" Bungee Cord Switch, Assembly K30008 All Switches and Lights, except Rocker Switch, Float K30040 Includes Photocell, Light, and Bobber Switch, 3 Position Rocker K30224 Power / Mode Switch Switch, Virgin High Pressure K30209 Opens at 150psi Switch, Differential Pressure K30023 Switch, Vacuum Pump Lockout K30264 Opens at 10psi Switch, Door Interlock K30271 Shorted if Door Closed Switch, Rocker K30268 Refrigerant Charge Switch, High Pressure K30255 Opens at 435psi Tank, 30 lbs K16417 R-12 Tank, 50 lbs K16419 R-12 Tank, 50 lbs K16429 R-134a Timer, Bezel K30511 R-12 and R-134a Timer, R-12 K30263 Timer, Vacuum K30410 Tray, Plastic Storage K76396 Tube, Condensing K40854 Tube, Float K40534 Float Switch to Flow Valve Tube, Gauge/Low/Vac.Side K40855 Low Side Port to Flow Valve to Vac Port Tube, 6" Capillary K40807 See Page 5-52 Tube, Kit Double Stack K41080 Tube, Oil / Air Purge K40848 From Purge Solenoid to Bulkhead Port Tube, Low Side K40862 Low Side Manifold to Diff. Press. Switch Tube, Digital Gauge K40849 From Digital Gauge Bd. to Pneumatics Tube, Moisture Indicator K40856 From Moisture Indicator to Bulkhead Port Tube, Discharge Coil K40837 From Comp. Oil Separator to Moist. Ind. Tube, Purge K40852 Vacuum Pump Overflow Tube Tube, Low Side Crossover K40859 Tube in Lower Cabinet Compartment Page 5-56 Tube, Oil Standpipe R-12 K40861 Tube for R-12 Oil Injector Tube, Gauge/High Side K40833 From High Side Port to Manifold Assy. Tube, Compressor Discharge K40545 From Comp. to Comp. Oil Separator Tube, Oil Standpipe R-134a K40858 Tube for R-134a Oil Injector Valve, Check K60120 For Moisture Indicator Valve, Check K60022 On Oil Injection Bulkhead Port Valve, Flow K60021 Valve, Pressure Access K50503 Valve, Blue Ball K60108 Valve, Check K60119 Valve, Red Ball K60107 Valve, Check K60033 Vacuum Pump Valve, Schrader K99010 Screw in Schrader Valve Package of 25 Wrap, Hose K76019 On top of Filter Dryer / Oil Separator Top and Bottom of Filter Dryer Page 5-57 SUBSECTION C. PARTS IN NUMERICAL ORDER ACT-3300/ACT-3400 Description PART NUMBER Oil, Compressor 0681-0179-02 COMMENTS Injector, Oil R-12 K01550 Injector, Oil R-134a K01555 Adapter, R-134a High Side K04000 Vehicle High Side Adapter Adapter, O-Ring Replacement Kit K04040 Contains 10 O-Rings and O-Ring Tool Adapter, R-134a Low Side K04100 Vehicle Low Side Adapter Cord, Tank Full K1101033 Harness, Charging Lower wiring K1101034 Probe, Tank Full K1101037 Harness, Recovery Lower wiring K1101038 Harness, Upper wiring K1101045 Board, Digital Gauge K1101069 With Transducer For High or Low Sides Board, R-134a Air Purge K1101071 Refer to SB750 to convert to R-12 Bd. 3GS Oil, 10 oz. in Compressor Compressor K16011 With Fittings to fit all Units Pump, Vacuum K16019 1.5 CFM (Uses Vacuum Pump Oil) Filter, Desiccant K16200 Contains 2 filters and O-Rings Shell, Filter Dryer / Oil Separator K16205 Tank, 30 lbs K16417 R-12 Tank, 50 lbs K16419 R-12 Tank, 50 lbs K16429 R-134a Element, Moisture Indicator K16601 Element, Spring, O-Rings, Glass Separator, Compressor Oil K16608 Indicator, Moisture w/o Tubing K16613 Old Style, All Brass Colored Indicator, Moisture w/o Tubing K16622 New Style, Brass and Silver Colored Hose, 96" Blue R-134a K24007100 Vehicle Hose Hose, 96" Red R-134a K24107196 Vehicle Hose Hose, 3' Red Virgin R-134a K24207154 From Virgin Tank to Solenoid Hose, 18" Red Recy T. L. R134a K24207308 With Hand Valve Hose, 24" Blue Vapor R-134a K24207309 From Reclaim Tank to Solenoid Hose, Compressor K25007103 Filter Dryer/Oil Separator to Compressor Hose, 18" Blue Charge R-12 K25007103 From Reclaim Tank to Solenoid Hose, 9" Vacuum Pump K25007139 From Vacuum Pump to Vacuum Hose, 96" Blue R-12 K25007143 Vehicle Hose Hose, 96" Red R-12 K25107123 Vehicle Hose Hose, 5' Yellow Vacuum R-12 K25207100 Auxiliary Vacuum Hose Hose, 3' Blue Virgin R-12 K25207146 From Virgin Tank to Solenoid Hose, 18" Blue Liquid R-12 K25207312 From Reclaim Tank to Solenoid Page 5-58 Hose, 24" Red Tank Vapor R-12 K25207313 From Reclaim Tank to Solenoid Hose, 5' Yellow Vac. R134a K26207400 Auxillary Vacuum Hose Switch, Assembly K30008 All Switches and Lights, except Rocker Switch, Differential Pressure K30023 Blanket, Heater K30024 Filter Shell Switch, Float K30040 Includes Photocell, Light, and Bobber Relay, Float Switch K30041 Clear Plastic Relay Blanket, Heater K30044 Virgin Tank Socket, Relay K30065 With Clips Cord, Float Switch Power K30152 For Float Switch Light Cord, AC Power K30199 Can Use 6001-0189-01 Switch, Virgin High Pressure K30209 Opens at 150psi Switch, 3 Position Rocker K30224 Power / Mode Switch Switch, High Pressure K30255 Opens at 435psi Timer, R-12 K30263 Switch, Vacuum Pump Lockout K30264 Opens at 10psi Switch, Rocker K30268 Refrigerant Charge Meter, Hour K30270 Old Style, Large Silver Switch, Door Interlock K30271 Shorted if Door Closed Meter, Hour K30276 New Style, Small Black Overload, Compressor K30301 Contains Overload, and Klixon Relay, Compressor K30301 Contains Overload, and Relay Timer, Vacuum K30410 Lens, Digital Gauge K30509 Comes with the Bezel and Lens Bezel, Digital Gauge K30509 Comes with the Bezel and Lens Digital Gauge, Bezel K30509 Timer, Bezel K30511 Fitting, Kit Compressor K32032 Filter, AC Inline K32505 Fan K32511 Grill, Fan K32531 Drum, Vacuum Timer K33000 With Label With Label R-12 and R-134a AC Power Filter Drum, Refrigerant Timer K33001 Lock, Door w/Key K35070 Door, Lock and key K35070 Mat, Tool Tray K35152 Caster, Locking K35252 Label, Snap-On Logo K35403 Handle, Side K35538 Tube, Float K40534 Float Switch to Flow Valve Tube, Compressor Discharge K40545 From Comp. to Comp. Oil Separator Tube, 6" Capillary K40807 Tube, Gauge/High Side K40833 From High Side Port to Manifold Assy. Tube, Discharge Coil K40837 From Comp. Oil Separator to Moist. Ind. Front Panel Snap-On Logo Page 5-59 Tube, Oil / Air Purge K40848 From Purge Solenoid to Bulkhead Port Tube, Digital Gauge K40849 From Digital Gauge Bd. to Pneumatics Tube, Purge K40852 Vacuum Pump Overflow Tube Tube, Condensing K40854 Tube, Gauge/Low/Vac.Side K40855 Low Side Port to Flow Valve to Vac Port Tube, Moisture Indicator K40856 From Moisture Indicator to Bulkhead Port Tube, Oil Standpipe R-134a K40858 Tube for R-134a Oil Injector Tube, Low Side Crossover K40859 Tube in Lower Cabinet Compartment Tube, Oil Standpipe R-12 K40861 Tube for R-12 Oil Injector Tube, Low Side K40862 Low Side Manifold to Diff. Press. Switch Tube, Kit Double Stack K41080 O-Ring, #10 K45030 Package of 25 Depressors, Screw In K45321 Package of 25 Gaskets, Hose K45331 Package of 25 Valve, Pressure Access K50503 On top of Filter Dryer / Oil Separator Port, Filter Pressure Access K50503 R-12- On Top of Filter Dryer Fitting, 1/8 Mnpt x 1/2 Acme K50556 Port, Filter Pressure Access K50559 Manifold, Kit K50604 Fitting, Kit Brass K51080 Valve, Flow K60021 Valve, Check K60022 On Oil Injection Bulkhead Port Valve, Check K60033 Vacuum Pump Solenoid, Oil Return K60058 Without Fittings Solenoid K60060 Vacuum, Charge, Low Side Solenoid, By-pass K60065 Valve, Red Ball K60107 Valve, Blue Ball K60108 Valve, Check K60119 Top and Bottom of Filter Dryer Valve, Check K60120 For Moisture Indicator Wrap, Hose K76019 Panel, R-134a Operating Inst. K76344 Flip Panel On Top of Machine R-134a R-134a- On Top of Filter Dryer Panel, Face K76345 Cabinet, Filter Shell K76349 Panel, Fan K76372 Chrome Strip Kit K76377 Left and Right Chrome Strips Panel, Face K76380 R-12 Bracket Kit K76383 Float Switch, Solenoid, Timer, Filter shell Cabinet, Frame K76385 Cabinet, Control Head K76386 Door, Left R-12 K76388 Door, Right w/Hinge K76389 Cover, Door Switch K76391 Door, Left R-134a K76392 Page 5-60 Sheet Metal Panel, R-12 Operating Inst. K76395 Flip Panel On Top of Machine Tray, Plastic Storage K76396 Cabinet, Complete K76900 Sheet Metal Plate, Spring K90011 On top of Desiccant Filter in Filter Shell Shaft, Timer knob K90022 Grommet (Heyco Bushing) K90041 for AC power cord and Wiring harnesses Strap, Tank K90080 18" Bungee Cord Cup, Oil K90301 Measuring Cup Cap, 1/4" flair w/ strap K90312 Cover for R-12 bulkhead fittings (qty 5) Cap, 1/2 " Acme w/ strap K90313 Cover for R-134a bulkhead fittings (qty 5) Element, Inline Particle Filter K90420 Package of 10 Filter, Brass line Particle K90423 Inline Filter Assy. (Brass & Element) Dry Dot, Yellow K91080 Sticker Dry Dot, Green K91080 Sticker Valve, Schrader K99010 Screw in Schrader Valve Package of 25 Page 5-61 Page 5-62 SECTION V OPERATOR'S MANUAL TABLE OF CONTENTS Page What Comes With Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65 Testing the Vehicle A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66 Setting Up the Machine Installing the Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Hose Storage and Power Cord Brackets . . . . . . . . . . . . . . . . . . . . . Installing the Service Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Oil Discharge Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Filter Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67 5-67 5-67 5-67 5-67 Preparing the Machine for Use Installing the Recycling Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Installing the Virgin Tank of Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Recovering and Recycling Recovering and Recycling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moisture Indicator and Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Full Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Excess Air Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the Filter Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69 5-70 5-70 5-70 5-70 5-70 Evacuating and Recharging Evacuating the Vehicle A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding Lubricant to the Vehicle A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recharging the Vehicle A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Virgin Tank Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Factory Recommended Daily Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration of Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72 5-72 5-73 5-73 5-74 5-74 5-74 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75 Page 5-63 WHAT COMES WITH YOUR MACHINE Your new refrigerant recovery, recycling and recharging center includes the following: (1) 50 LB DOT Approved Recycle Tank (2) Filter Cores (1 filter core must be installed before operating machine) (1) Filter Core Spring Plate (3) Oil Discharge Cups (4) Casters (16) Caster Mounting Screws and Nuts (1) 5 feet Yellow Auxiliary Vacuum Hose (with bent ends) (1) Bungee Cord (1) Lubricant Injector (1) Copper Standpipe (6) 1/4" - 20x (Pan Head Screws) (2) Hose Wrap Brackets with Hose Mounting Ports (1) Power Cord Wrap Bucket (1) Red 8 foot Hose with Hand Valve (1) Blue 8 foot Hose with Hand Valve (4) Door Lock Keys (Be careful to safeguard keys) (1) Operations Manual (1) Operations Videotape (1) Postage-Paid Warranty Card (1) MACS Certification Information Sheet (1) MACS Environmental Poster (1) MACS Retrofit Sheet (1) List of Authorized Service Centers Page 5-64 SAFETY PRECAUTIONS DANGER: RISK OF SERIOUS INJURY OR DEATH IF THE TSD (Thermistor Shutdown Device) TANK IS CONNECTED TO ANY EQUIPMENT THAT IS NOT DESIGNED FOR USE WITH THE TSD TANKS. TANK OVERFILL AND RUPTURE IS POSSIBLE. Caution: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. To remove refrigerant from the A/C system, use service equipment certified to meet requirements of SAE J1991 (1991) (R-12 recycling equipment). If accidental discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. To avoid unfortunate accidents, only technicians who have had experience and are properly trained in refrigerant recovery recycling should operate this machine. Secondly, as common practice when working with refrigerants, the operator should always wear safety goggles. We know that sometimes you get in a hurry and can't find your goggles, but stop and do yourself and your eyes a favor. Find your goggles and use them. Protect yourself at all times. IMPORTANT: CLOSE ALL VALVES ON TANKS AND HOSES WHEN NOT IN USE, TO PREVENT LOSS OF REFRIGERANT. WHITE INDUSTRIES IS NOT RESPONSIBLE FOR LOSS OF REFRIGERANT OR FOR ANY LOSS OR DAMAGE CONSEQUENTIAL TO THE LOSS OF REFRIGERANT DUE TO OPERATOR ERROR OR EQUIPMENT MALFUNCTION. TESTING THE VEHICLE SYSTEM When you test the vehicle's A/C system, be sure to follow the procedures recommended by the original equipment manufacturer. Page 5-65 WARRANTY This product is warranted to be free of defects in workmanship and materials for a period of one (1) year from the date of purchase by original purchase by the original purchaser. If the product fails within this period, it will be repaired or replaced, at the manufacturer's option, provided, (1) the product is shipped to the factory with proof of purchase date and assigned RGA number (return goods authorization), (2) the product is shipped to the Factory Authorized Service Center with proof of purchase date (see provided list), (3) transportation charges are prepaid to factory or authorized service center. This warranty does not apply to product or parts broken from accident, overload, abuse or if they have been tampered with or altered. If this warranty does not apply, then the retail purchaser shall pay all costs for labor, material and transportation. The warranty described in this paragraph shall be in lieu of any other warranty, express or implied, including but not limited to, any implied warranty of merchantability or fitness for a particular purpose. It is expressly agreed that the buyer's sole and exclusive remedy against the seller shall be for the repair or replacement of defective product or parts as provided herein. The buyer agrees that no other remedy, including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss, shall be available to buyer. Conditions: To address customer needs efficiently and maintain performance history on this product, it is imperative that the owner complete and return the postage-paid Warranty Card to the manufacturer. Upon receipt of the Warranty Card, the customer is assured of: 1.Prompt, efficient and accurate service. 2.One year warranty as stated above. 3.Semiannual factory newsletter with updated industry developments. In addition, updated Authorized Service Center listings Page 5-66 SETTING UP THE MACHINE Installing the Casters: 1. 2. 3. Support the center of the machine with the four (4) cardboard corner pieces from the shipping carton. Install the fixed casters using the screws and nuts provided. Install the nuts on the inside of the cabinet to provide wheel clearance. Installing the Hose Storage and Power Cord Brackets: 1. 2. 3. With the screws provided, install the two (2) supplied storage brackets with the hose mounting ports in the top two (2) sets of holes provided on back of machine. Install the remaining storage bracket in the bottom set of holes provided on the back of the machine. Loosely wrap the power cord around the bottom cord bracket. Installing the Service Hoses: 1. 2. 3. Install the 8 foot blue service hose on the A/C system low port on the back panel of the machine. Install the 8 foot red service hose on the A/C system high port on the back panel of the machine. Loosely wrap the hoses around the two uppermost storage brackets and screw the hose ends onto the storage plugs. Installing the Oil Discharge Cups: 1. TIP: 2. 3. Remove the shipping plug from the discharge port on the recharging (right) side, then install the oil discharge cups on the slots provided on the underside of both the recovery system and recharging system shelf. You may need to squeeze the cup slightly to assist you in installing the oil discharge cups. Install the third oil discharge cup in the bracket provided on the inside of the recharging doors. Install the oil injector assembly in the slot provided on the inside of the recharging doors. Installing the Filter Core: NOTE: Machine is shipped without filter core installed. 1. Remove the filter shell lid (located on top of the machine). If the gasket on the inside of the filter shell lid is damaged, remove the gasket. 2. Remove the filter core from the vacuum sealed can. Immediately install the filter core into the canister. NOTE: Do not expose filter core to atmosphere for more than two(2) minutes. Doing so will shorten its service life. 3. Install spring plate (spring facing up). 4. Lightly lubricate the gasket with refrigerant oil, replace filter shell lid and tighten nuts evenly in a crossing pattern 1/8 to 1/4 turn past finger tight. (10-15 foot pounds) NOTE: Follow "Factory Recommended Procedures". Page 5-67 PREPARING THE MACHINE FOR USE Installing the Recycling Tank: 1. 2. 3. Remove the recycle tank from the box and remove the plastic caps from the valve ports. Place the tank in the left cabinet compartment. Connect the TANK LIQUID hose to the liquid valve on the tank and open both the valve on the hose and the liquid valve on the tank. 4. Connect the YELLOW auxiliary Vacuum hose to the vapor valve on the tank. Connect the remaining end of the YELLOW hose to the Auxiliary Vacuum Port and make sure the vapor valve on the tank is open. 5. Attach the black sensor cord to the corresponding receptacle on the tank. The connector has an index slot that must be aligned to engage the sensor cord. The TANK FULL light will flash and machine will not operate if the sensor cord is not properly connected or if the cord is pinched. 6. Plug the power cord into a 115V grounded receptacle. 7. Push the POWER/MODE switch to the EVACUATION/RECHARGE position. 8. Set vacuum timer to at least 30 minutes. NOTE: If possible, set vacuum timer to CONTINUOUS RUN and allow machine to evacuate for 2-4 hours. This will remove any trace amounts of moisture that might reside in the plumbing or tank. 9. After evacuating the tank and machine, close the vapor valve and disconnect the YELLOW auxiliary vacuum hose from the tank and the auxiliary vacuum port. 10. Connect the TANK VAPOR hose to the vapor valve on the tank and open both the valve on the tank and on the hose. Installing the Virgin Tank of Refrigerant: 1. 2. 3. 4. 5. To install a virgin tank of refrigerant connect the TANK LIQUID hose located in the right-hand compartment to a virgin tank of the appropriate refrigerant, and open both the valve on the tank and the valve on the hose. Place the virgin tank in the right-hand compartment with the tank sitting on its handles (inverted). Pull the two straps on the heater blanket until the blanket is wrapped securely around the tank. Secure the tank with the bungee cord provided and close the cabinet door. The heater blanket will only operate when both doors are closed. he machine is now ready to recover, recycle, and recharge refrigerant. Page 5-68 RECOVERING AND RECYCLING PROCEDURE NOTE: Before starting recovery, run engine for 5 minutes without the A/C system running, to warm refrigerant. A warm engine will decrease recovery time. After the vehicle's engine has warmed, turn the vehicle's engine off. 1. 2. 3. 4. 5. 6. 7. 8. The BLUE service hose connects to the low side service port on the vehicle's system and the RED service hose connects to the high side port on the vehicle's system. Make sure the power cord is plugged in, and both the tank valves and hose valves are open. Close and lock the cabinet doors. Check for positive pressure on the LOW and HIGH side pressure gauges of the machine to make sure there is refrigerant in the vehicle's system. If there is no positive pressure (e.g. no refrigerant is in the system), DO NOT RECOVER. Set the POWER/MODE switch to RECOVER. When you turn this switch on, the fan turns on automatically. As long as the POWER/MODE switch is on, the fan will remain on and continue to cool the machine. Depress and hold the STRAT/RECOVER button for approximately three seconds. The RECOVERY light will illuminate. Ensure that refrigerant is flowing across the moisture indicator and the RECOVERY light is illuminated. You should see the LOW and HIGH side gauges begin to drop. When the LOW and HIGH side gauges reach 5-10 in-Hg and the machine automatically shuts down. The oil removed from the vehicle's A/C system will automatically purge into the oil discharge cup located inside the left-hand door on the underside of the upper compartment. (This process could take up to 2 1/2 minutes and there may be little or no oil removed.) To determine how much oil was removed during the recovery process, simply remove the cup and read the amount that is marked in both ounces and milliliters. CAUTION!! Replace any oil removed with the proper lubricant for the A/C system being recovered. Do not mix lubricants. Check with vehicle manufacturers published service procedures for correct lubricant. 9. 10. 11. 12. Dispose of the oil in accordance with any federal, state, or local ordinances and reinstall the cup. After the machine shuts down, wait for five (5) minutes; if the gauges rise above 0 PSI, restart the recovery process. Repeat as many times as necessary until system pressure remains stable in a vacuum for two (2) minutes. View the moisture indicator and the hour meter immediately after recovering to determine the condition of the filter core per the instructions on page 5-66 The recovery process is now complete. Close the valves on the BLUE and RED hoses. NOTE: Although the system has shut off, the fan will continue running as long as the main power switch is on. Although the fan does not need to remain on indefinitely, if you are going to service a series of vehicles in succession, it is suggested you let the fan continue to run; otherwise, turn the fan off by switching the main power switch to the off position. This is a one-pass recovery/recycling operation meaning that the refrigerant comes out of the A./C system, into the machine, through the filtration system, and into the tank. The refrigerant in the tank at this time is clean and there is NO separate recycling operation required. It is a true one-pass filtration system. Page 5-69 MOISTURE INDICATOR and HOUR METER Before and during refrigerant recovery, the moisture indicator can vary in color. Therefore, it is very important to view the moisture indicator and hour meter for condition of the refrigerant only after the system shuts down and the recovery and recycling process is complete. If the indicator is green, the filter condition is fine and you may continue recovering and recycling refrigerant. However, if the moisture indicator is more yellow than green it is time to change the filter core. The hour meter, located on the back of the machine, indicates the total time the machine has run in the recovery mode. This allows the operator to keep track of the total accumulated recovery time on the filter core. The filter core should be changed after every 25 hours of use. Remember, the only time to view the moisture indicator and the hour meter, to determine the condition of the core and the refrigerant, is immediately AFTER the machine has shut off and the recovery and recycle process is complete. TANK FULL LIGHT Your machine has a TANK FULL light which will illuminate. The machine will automatically shut off once the recycling tank becomes full of refrigerant. The TANK FULL light will also flash and shut the system off if the tank sensor cord is not properly attached to the tank receptacle. NOTE:Before refrigerant is introduced to the tank, the TANK FULL light will sometimes illuminate while the tank is in a vacuum. When the TANK FULL light illuminates: 1. 2. Make sure the tank sensor cord is fully engaged. (The index slot must be aligned to make a complete connection.) Check for a full tank. If full, replace the tank following the tank installation instructions. HIGH PRESSURE LIGHT The HIGH PRESSURE light will illuminate when there is high pressure on the high side of the recovery system. The main condition that causes high pressure is failure to open the valves on the tank and /or the valves on the hoses to allow the refrigerant to flow into the tank. As a safety precaution, when the HIGH PRESSURE light illuminates, the machine will not operate. You must remedy the high pressure condition before the machine will operate. To remedy a high pressure condition: 1. 2. Make sure both valves on the tank and both valves on the tank hoses are fully open. Turn the POWER/MODE switch off momentarily and then back on to reset the high pressure function. EXCESS AIR LIGHT The EXCESS AIR light will illuminate if there is excess air in the tank. When the EXCESS AIR light illuminates: IMPORTANT!! Do not Air Purge when hooked to an A/C System. 1. 2. Properly dispose of any oil in the vehicle system oil discharge cup and reinstall. Press the AIR PURGE switch to start the Air Purge process. The Air Purge will automatically shut off once the air has been expelled. Page 5-70 CHANGING THE FILTER CORE The filter core should be changed if: a) After recovering a minimum of one pound of refrigerant, the machine has shut off and the moisture indicator remains yellow. b) The filter core has accumulated a total running time of 25 hours, as indicated by the hour meter. Moisture Indicator: If the total accumulated running time on the filter core exceeds 25 hours, the contents of the tank could exceed the limit of moisture content allowable. To ensure that the refrigerant moisture content is acceptable, the following procedure will recycle the refrigerant in the recycle tank: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Change the filter core per the instructions below, "To Change the Filter Core." Close the vapor valve on the recycle tank and the valve on the TANK/VAPOR hose. Disconnect the TANK VAPOR hose from the recycle tank. Connect the vehicle system "high" pressure hose to the vapor valve on the recycle tank. Open the vapor valve on the tank and the valve on the system "high" pressure hose. Set the POWER/MODE switch to RECOVER, the POWER switch on, and press the START RECOVERY button. Allow the machine to run in the recovery mode for approximately one hour. The moisture indicator should be green at this time. Close the vapor valve on the recycle tank and allow the machine to shut off automatically. Close the valve on the vehicle system "high" pressure hose, disconnect from the recycle tank and reconnect the TANK VAPOR hose to the vapor valve on the tank. Open the vapor valves on the tank and on the hose. The machine is now ready to continue recovering. To Change the Filter Core: 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the cap from the port on the filter shell and release any residual pressure or vacuum by depressing the valve core. Remove the lid from the shell and take out the spring plate. If the gasket on the inside of the filter shell lid is damaged, remove it. Attach a magnet to the metal plate on the filter core and remove the core. This used filter core does not contain hazardous material, so you may dispose of the used core in a responsible manner. Remove the new filter core from the sealed canister and immediately install the new core into the shell with the metal end on top. A new gasket is supplied with each filter core to use in the event the gasket in the filter shell lid has been damaged. Install the spring plate on top of the filter/core with the spring facing up. Lightly lubricate the gasket with refrigerant oil, replace the filter shell lid and tighten the nuts evenly in a crossing pattern, 1/8 to 1/4 turn past finger tight (10-15 ft.lbs.) After installing the new core, attach the YELLOW auxiliary hose between the service port on top of the filter shell and the Auxiliary Vacuum Port on the back of the machine. Set the POWER/MODE selector to EVACUATION/RECHARGE and turn the vacuum timer on. Evacuate the filter shell to a minimum of 27-28 in-Hg vacuum to remove the air in the shell. Make note of the hour reading on the chart. Page 5-71 EVACUATING AND RECHARGING THE VEHICLE A/C SYSTEM Evacuating the vehicle A/C System: 1. 2. 3. 4. NOTE: Connect the HIGH and LOW service hoses to the vehicle system and open the valves on the hoses. Set the POWER/MODE switch to EVACUATION/RECHARGE. Set the desired vacuum time on the timer. When the timer shuts off, gauge readings should hold if there are no leaks in the vehicle system. Vacuum Pump will not operate if the vehicle has pressure. Adding Lubricant to the Vehicle A/C System: NOTE: Lubricant can be added to the vehicle system only when the system is in a vacuum; follow the evacuating procedures above. 1. Attach the copper standpipe to the lubricant injector hose. 2. Immerse the standpipe into the proper lubricant. 3. Draw the desired amount of lubricant into the injector. 4. Disconnect the standpipe from the lubricant injector hose and attach the hose to the 'Vehicle System Lubricant Injection' port located on the back of the machine. The vacuum in the system will draw the lubricant from the injector. 5. Recharge the system with refrigerant to ensure that all of the lubricant is carried into the system. Page 5-72 RECHARGING THE VEHICLE A/C SYSTEM NOTE: The vehicle system must be in a vacuum before recharging. 1. Connect both HIGH and LOW service hoses to the vehicle system and open the valves on the hoses. 2. Set the POWER/MODE switch to EVACUATION/RECHARGE. Close the cabinet doors. (Doors must be closed for at least 15 minutes prior to charging). Turn on Tank Heater Blanket switch for a minimum of 15 minutes before charging with refrigerant. 3. Set the refrigerant switch to VIRGIN or RECYCLE (See NOTE 1 below) 4. Set the desired charge amount on the selector (the CHARGE HOLD light will illuminate while the charge amount is being set). 5. Press the START CHARGE button to begin charging. The CHARGING light will illuminate while charging refrigerant (See NOTE 2 below). 6. When charging is complete, the charge selector will reach zero and the charging light will go off. 7. Check the HIGH and LOW pressure gauge readings and the system output temperature to ensure that the vehicle's A/C system is performing within specifications. 8. Close both hand valves, disconnect from the car, and reinstall on mounting ports. 9. Set the POWER/MODE switch to RECOVER and press the START RECOVERY button. This will recover the refrigerant vapor left in the hoses. 10. Close the valves on recycling tank and valve on virgin tank and all hose valves. NOTE 1: It is recommended that the first choice always be to charge with RECYCLED refrigerant. To charge RECYCLED refrigerant the following criteria must be met: a. a minimum of 10 pounds of refrigerant in tank, OR b. proper pressure for charging (from recovery operation). NOTE 2: The charge will be stopped and the CHARGE HOLD light will be illuminate if: a. the tank being charged from is empty or low, OR b. the tank being charged from has insufficient pressure for charging. VIRGIN TANK DISPOSAL When the virgin tank is "EMPTY" it may still contain up to a pound of refrigerant in the gaseous state. After replacing a virgin tank, this remaining refrigerant should be recovered before disposing the tank. To recover this refrigerant: 1. Set the POWER/MODE switch to RECOVER. 2. Close the tank valve and the valve on the virgin tank hose and remove the tank from the machine compartment. 3. Connect the system low side hose to the virgin tank and open the hand valve on the hose. 4. Open the tank valve, set the POWER/MODE switch to RECOVER, and depress the START RECOVERY switch for three (3) seconds. 5. Allow the machine to recover the refrigerant until both System Pressure Gauges read between 0 PSI and 5 In. Hg. 6. Set the POWER/MODE switch to OFF before the machine automatically shuts off at 10 in. Hg. 7. Disconnect the system low side hose. 8. Leave the tank valve open and mark the tank "EMPTY". Dispose of the empty tank in accordance with all federal, state, and local laws. Page 5-73 VACUUM PUMP MAINTENANCE After every 25 evacuations or after evacuating a system that has been open to the atmosphere for a prolonged period of time (24 hours or more), the vacuum pump oil must be changed. Important!! Disconnect the machine from the vehicle before performing this procedure. 1. 2. 3. 4. 5. Open the petcock in the bottom of the pump through the access hole located to the left and behind the oil discharge cup. Allow all of the oil to drain into a container capable of holding at least 12 ounces and dispose of the oil in accordance to federal, state, and local ordinances. Close the petcock. Connect the YELLOW auxiliary hose to the Auxiliary Vacuum port on the back of the unit. Immerse the other end of the hose into 12 ounces of quality vacuum pump oil and turn the vacuum pump on. The pump will draw the oil into itself. CAUTION!! DO NOT OVERFILL. THE PUMP CAPACITY IS 12 OUNCES. FACTORY RECOMMENDED DAILY PROCEDURES 1. 2. 3. 4. 5. Make sure tank full sensor cord is fully engaged and the cord is not pinched. Visually check the condition of all service hoses for contamination before connecting to the A/C system. Make sure all hoses are fully engaged at tank connections. When machine is not in use, be sure to close tank valves and tank hose valves. If you have questions on these or any other procedures, please call out toll free number. CALIBRATION OF GAUGES Plug machine into power supply and depress the POWER/MODE switch to the EVACUATION/RECHARGE position. Verify that the machine gauges come on and read 0 or 1 PSI. If reading is not accurate, recalibrate to 0 or 1 PSI. Hoses should be open to the atmosphere for 0 PSI reading. NOTE: Gauge calibration hole is located on right side of gauge. a. b. Insert small flat blade screwdriver into small hole next to gauge. Carefully find the adjusting screw and adjust until 0 or 1 PSI registers on the gauge. NOTE: A fluctuation between 0 and 1 PSI is normal. Page 5-74 STORAGE PROCEDURE WHEN STORING THIS MACHINE FOR A PROLONGED PERIOD, A FEW SIMPLE PRECAUTIONS WILL ENSURE PROPER PERFORMANCE WHEN YOU ARE READY TO USE THE MACHINE AGAIN. Your machine is equipped with a petcock; use the following procedure: 1. 2. 3. 4. 5. Change the vacuum pump oil. a. Open the petcock. b. Allow oil to drain completely. c. Close petcock. d. Connect auxiliary vacuum hose to auxiliary vacuum port. e. Place suction hose into 12 ounces of quality vacuum pump oil. f. Plug in unit. g. Turn POWER/MODE switch to EVACUATION/RECHARGE. h. Turn vacuum timer on. i. The 12 ounces of fluid will be drawn into the Pump. Do not overfill. Make sure all hoses are sealed on their ports or hangers. Make sure all valves on the hoses and tanks are closed. Pull a vacuum for five (5) minutes on the low side hose, leave this vacuum on the hose during storage. Wipe the unit and all hoses with soap and water. NOTE: If your machine is equipped with a drain plug, please call the service number for assistance. Page 5-75