SECTION I AC POWER DISTRIBUTION...ELECTRICAL (REFER TO FIGURE 1-7) With the Vacuum Switch in the...

SECTION I

AC POWER DISTRIBUTION_____________________________________________________________

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 orbehind your back. Before removing wires from the ACT-1500, always verify that the Tester is "OFF". Turn offthe 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 tothe "ON/OFF" front panel power switch.

FIGURE 1-1 AC DISTRIBUTION

VACUUMSWITCH

CHARGESELECT

VACUUMPILOT

R-12PILOT

OILPILOT

HOT

NEUTRAL

HOT

GND

NEUTRAL

CB1

MASTERSWITCH

GND

ON

OFF

OIL

R-12 R12TIMER

OILTIMER

R-12SOLENOID

OILSOLENOID

VACUUMSOLENOID

- 1

! C A U T I O N !

THIS UNIT MUST BE PLUGGED IN TO A PROPER AC OUTLET FOR UNITTO OPERATE CORRECTLY. REFER TO UNIT ID PLATE LOCATED ONBACK OF UNIT. EXTENSION CORDS ARE NOT RECOMMENDED, BUTIF AN EXTENSION CORD MUST BE USED, USE A CORD THAT IS LESSTHAN 50 FEET WITH A 16 AWG, OR ABOVE 50 FEET AND LESS THAN100 FEET WITH A 14 AWG.

USE STANDARD REFRIGERANT HANDLINGSAFETY PROCEDURES WHEN PERFORMING INSTALLATION

ALWAYS WEAR SAFETY GOGGLES, DON'T SPILL OR TOUCH LIQUIDREFRIGERANT, AVOID FLAMES, & EXCESSIVE HEAT. USE ONLY INWELL VENTILATED AREA.

! W A R N I N G !

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. Whenturned on, the light in the ACT-1500's master switch will light. This routes power to the Vacuum Switch, aswell as the Charge Selector Switch, if the Vacuum Switch is in the off position.

FIGURE 1-2 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.

VACUUMSWITCH

CHARGESELECT

VACUUMPILOT

R-12PILOT

OILPILOT

HOT

NEUTRAL

HOT

GND

NEUTRAL

CB1

MASTERSWITCH

GND

ON

OFF

OIL

R-12 R12TIMER

OILTIMER

R-12SOLENOID

OILSOLENOID

VACUUMSOLENOID

Page 1 - 3

VACUUM MODE


Power is routed from the Master Power Switch through the Vacuum Switch. Once the Vacuum Switch isturned "ON", the Vacuum Pilot will turn "ON" and the Vacuum Solenoid will energize. The AC Outlet is wiredto the Vacuum Solenoid. Therefore, 115 volts AC is present at the outlet to run the Vacuum Pump and theHeater Blanket.

FIGURE 1-3 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 theamount of vacuum in Inches of Mercury (Hg).

FIGURE 1-4 VACUUM MODE (PNEUMATICS)

VACUUMSWITCH

CHARGESELECT

VACUUMPILOT

R-12PILOT

OILPILOT

HOT

NEUTRAL

HOT

GND

NEUTRAL

CB1

MASTERSWITCH

GND

ON

OFF

OIL

R-12 R12TIMER

OILTIMER

R-12SOLENOID

OILSOLENOID

VACUUMSOLENOID

NC

NC

NC

LOWGAUGE

S3

S2

S1

LowSidePort

HighSidePort

LEFT SIDEPANEL

FlowRegulator

FlowIndicator

ManualPurgeValve

PurgePort

In LineFilter

RefrigerantPort

OilPort

VacuumPort

BackPanel

HIGHGAUGE Check

Valve

CheckValve

Page 1 - 4

OIL CHARGE MODE


With the Vacuum Switch in the "Off" position, power is routed to the Charge Select Switch. With the ChargeSelect Switch set to "OIL", and the Oil Timer set for a charge amount, power is then routed to the Oil Pilot, OilSolenoid, and Oil Timer itself. This starts the Oil Timer, opens the Oil Solenoid, and Lights the Oil Pilot light.

FIGURE 1-5 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 outthe Oil Cylinder (due to the 100 lb charge of Nitrogen in the Oil Cylinder), through S3 (Oil solenoid), CheckValve, Flow Indicator, Flow Regulator, through an In-Line Filter and out to the vehicle. Oil continues to flow inthis manner until the Oil Timer has expired.

FIGURE 1-6 OIL CHARGE MODE (PNEUMATICS)R12 CHARGE MODE

VACUUMSWITCH

CHARGESELECT

VACUUMPILOT

R-12PILOT

OILPILOT

HOT

NEUTRAL

HOT

GND

NEUTRAL

CB1

MASTERSWITCH

GND

ON

OFF

OIL

R-12 R12TIMER

OILTIMER

R-12SOLENOID

OILSOLENOID

VACUUMSOLENOID

NC

NC

NC

LOWGAUGE

S3

S2S1

LowSidePort

HighSidePort

LEFT SIDEPANEL

FlowRegulator

FlowIndicator

ManualPurgeValve

PurgePort

In LineFilter

RefrigerantPort

OilPort

VacuumPort

BackPanel

HIGHGAUGE Check

Valve

CheckValve

Page 1 - 5


With the Vacuum Switch in the "Off" position, power is routed to the Charge Select Switch. With the ChargeSelect Switch set for R-12, and the R-12 Timer set for a charge amount, power is routed 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 theR-12 Pilot.

FIGURE 1-7 R-12 CHARGE MODE (ELECTRICAL)

PNEUMATIC (REFER TO FIGURE 1-8)

With the vehicle in a deep vacuum (from the Vacuum Mode) refrigerant is drawn from the RefrigerantCylinder, 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 outto the vehicle. Refrigerant continues to flow in this manner until the R12 Timer has expired.

FIGURE 1-8 R-12 CHARGE MODE (PNEUMATICS)

VACUUMSWITCH

CHARGESELECT

VACUUMPILOT

R-12PILOT

OILPILOT

HOT

NEUTRAL

HOT

GND

NEUTRAL

CB1

MASTERSWITCH

GND

ON

OFF

OIL

R-12 R12TIMER

OILTIMER

R-12SOLENOID

OILSOLENOID

VACUUMSOLENOID

NC

NC

NC

LOWGAUGE

S3

S2S1

LowSidePort

HighSidePort

LEFT SIDEPANEL

FlowRegulator

FlowIndicator

ManualPurgeValve

PurgePort

In LineFilter

RefrigerantPort

OilPort

VacuumPort

BackPanel

HIGHGAUGE Check

Valve

CheckValve

Page 1 - 6

I. Unit will not power up.

_______________________________

II. Unit will not pull a vacuum.

_______________________________

III. One or more lamps will notlight.

_______________________________

IV. Timer(s) will not run.

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 CircuitBreaker.

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.______________________________________________________

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______________________________________________________

Check for 115 Volts on lamps with the correct operating mode. Besure that the Timers are on for OIL or R-12.

Replace lamp if voltage is present.

Refer to complaint I.______________________________________________________

With the Vacuum Switch in the off position, and the Charge Selectorin the OIL/R-12 Mode, turn the timer clockwise.

Check for 115 Volts on the three terminals closest to eachother.

Replace Timer Assy.

Page 1 - 7

SECTION III

TROUBLESHOOTING

Refer to Complaint V.

_______________________________

V. Charge Selector Switch notworking correctly.

_______________________________

VI. Unit will not chargeRefrigerant.

______________________________________________________

With the Vacuum Switch in the off position, check for 115 Volts onthe Red lead from the Vacuum Switch to the Charge SelectorSwitch.

Replace the Vacuum Switch.

Refer to complaint II.

Check for 115 Volts on the Charge Selector Switch set for OILcharge. (Orange lead right)

Replace Charge Selector Switch.

Check for 115 Volts on the Charge Selector Switch set for R-12charge. (Orange lead left)

Replace Charge Selector Switch.

______________________________________________________

Ensure voltage is getting to R-12 Charge Timer.

If present, check output of timer.

If not present, and master switch light is lighted, checkVacuum 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


1 Handle Not Available 6 Solenoid, Oil K60060

2 Cable, AC K30151 7 Solenoid, R-12 K600603 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


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


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

DESCRIPTION PART NUMBER

Axle K80003Cable, AC K30151Caster, Front K80001Circuit Breaker K30051Gauge, Low Side K15032Gauge, High Side K15022Hose, 48" Blue K25007160Hose, 48" Red K25107161Hose, 36" Yellow K25207146Indicator, Flow & TubingK40820Knob, Bleed Valve K40801Knob, Timer K90005Light, Pilot K30505Nut, Pal 5/8" K90001Outlet 115 Volt K30060Solenoid, Vacuum K60060Solenoid, R-12 K60060Solenoid, Oil K60060Switch, Master K30011Switch, Charge Selector K30198Switch, Vacuum K30198Timer, R-12 K30400Timer, Oil K30420Tubing, High Side K40801Tubing, Low Side K40813Valve, Flow K60021Wheel, Rear K80002

PART NUMBER DESCRIPTION

K15022 Gauge, High Side K15032 Gauge, Low Side K25007160 Hose, 48" Blue K25107161 Hose, 48" Red K25207146 Hose, 36" Yellow K30011 Switch, Master K30051 Circuit Breaker K30060 Outlet 115 Volt K30151 Cable, AC K30198 Switch, Charge Selector K30198 Switch, Vacuum K30400 Timer, R-12 K30420 Timer, Oil K30505 Light, Pilot K40801 Tubing, High Side K40801 Knob, Bleed Valve K40813 Tubing, Low Side K40820 Indicator, Flow & Tubing K60021 Valve, Flow K60060 Solenoid, Vacuum K60060 Solenoid, Oil K60060 Solenoid, R-12 K80001 Caster, Front K80002 Wheel, Rear K80003 Axle K90001 Nut, Pal 5/8" K90005 Knob, Timer

Page 1 - 14

SUBSECTION B. PARTS INALPHABETICAL ORDER

SUBSECTION C. PARTS INNUMERICAL ORDER

SECTION V

OPERATORS MANUAL_____________________________________________________________

_

TABLE OF CONTENTS

PageWarranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17Refrigerant Tank Replacement and Air Purging Procedure . . . . . . . . . . 1-17Oil Tank Replacement and Air Purging Procedures . . . . . . . . . . . . . . . . . 1-18

Operating InstructionsTesting Air Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18Use with Recovery Recycling Equipment . . . . . . . . . . . . . . . . . . . . . 1-18Evacuating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19Oil Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19Charging with Unheated R-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19Charging with Heated R-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

MaintenanceVacuum Pump Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20Purge Valve Ball Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20Hose Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20Tubing and Solenoid Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20Solenoid Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21Flow Valve Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 fromdate of purchase by original purchaser. If the product fails within this period, it will be repaired or replaced atsellers option, provided (1) the product is submitted with proof of purchase date, (2) transportation chargesare prepaid to the factory. Liability under this warranty is expressly limited to repairing or replacing theproduct 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 purchasershall 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 onback of cabinet.

1. HIGH HOSE PLACEMENT- The 96" red hose is connected between the discharge port on the airconditioner 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 hoseat any time -- leave it installed.

2. LOW HOSE PLACEMENT- The 96" blue hose is connected between the suction port on the airconditioner system and the console port marked "LOW".

3. R-12 HOSE PLACEMENT- The 48" blue hose is connected between the port marked R-12 and theR-12 tank. After connection is made, open R-12 tank valve. Be CERTAIN tank valve is not leaking.

4. OIL HOSE PLACEMENT- The 48" red hose is connected between the port marked oil and the oiltank.

5. VACUUM HOSE PLACEMENT- The 36" yellow hose is connected between the port marked vacuumand the vacuum pump suction port.

IMPORTANTWear safety goggles when installing internal hoses.

REFRIGERANT TANK REPLACEMENTAND AIR PURGING PROCEDURES

IMPORTANTWear safety goggles during this procedure.

1. Turn master switch "OFF". 2. Remove blue hose from empty tank and connect to replacement tank. 3. Turn tank valve "ON". Check tank valve for leak. 4. The R-12 tank must be positioned such that liquid is flowing from the port. 5. Loosen blue hose at back of console to bleed air from hose. 6. Turn master switch on. Resume charging process.

Page 1 - 17

OIL TANK REPLACEMENTAND AIR PURGING PROCEDURES


1. Turn master switch "OFF". 2. Remove red hose from empty tank. 3. Connect red hose to new tank. Place tank on its handles and turn tank valve on. 4. (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 threeseconds.

(b) If the tank ran empty while charging oil into an evacuated system. purge air from the lines byturning the master switch "ON" and then the vacuum pump "ON" for approximately twominutes.

OPERATING INSTRUCTIONS

IMPORTANTAlways wear safety goggles when servicing a system and operation service center.

TESTING AIR CONDITIONERS:

1. With engine off, attach hoses-red to high side, blue to low. 2. On compressors with manual service valve, mid-seat both valves. 3. Bleed air from hoses at right side of cabinet. 4. Start engine and adjust speed to fast idle. 5. Set air conditioner controls at "MAX" cooling and "HIGH" fan speed. Insert thermometer in air outlet

nearest the evaporator.6. 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. Attach hose from recovery machine to the purge port. 2. Open purge valve and start recovery machine. 3. Close purge valve when recovery is complete.

Page 1 - 18

EVACUATING:

1. Turn vacuum pump on for ten minutes. (Bubbles in flow indicator normal.) 2. Turn pump off. Gauge readings should hold for two to three minutes. If there are no leaks in the

system. 3. Turn pump on for thirty minutes. If vacuum pump cycles on and off, change vacuum pump oil.

OIL CHARGING:

1. Select the temperature scale nearest the ambient temperature.2. 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 switchoff 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.

CHARGING WITH UNHEATED R-12:

1. Bypass cycling clutch controls on cycling clutch system. 2. Set charge selector switch to R-12 . (Vacuum pump switch must be off.) 3. 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 masterswitch off and refer to R-12 tank replacement.

4. Start car after 1/2 lb. of refrigerant has been dispensed.

CHARGING WITH HEATED R-12:

1. Allow 5-15 minutes for pressure to build in the tank before beginning to charge R-12. (This can beaccomplished 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 intoan A/C system that is NOT operating. Unheated R-12 can be charged while the system is inoperation.)

R-12 flow must be monitored in the flow indicator. If R-12 supply is depleted and flow stops whilecharging, 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 afterevacuating a contaminated system: i.e. compressor failure, dehydrator failure, or system left open. Mostfailures of the vacuum pump occur from contaminated pump oil. To change oil:

1. Remove plug in bottom of pump. 2. Allow oil to drain completely. 3. Replace the plug making sure the O-ring seal is not damaged. 4. Unscrew vacuum pump suction hose from solenoid valve. 5. Place suction hose into 12 ounces of General Motors transmission fluid "type A" (Dextron). 6. 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 mightbegin 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. Toremove the gaskets on the straight end, pry up on the gasket with an ice pick, then press in a new gasket. Toremove the gaskets on bent end, use needle nose pliers to unscrew old gasket, then screw in new gasket.

TUBING AND SOLENOID FLUSHING:

1. Disconnect power cord and remove bottom cover.2. Remove flow valve.3. Lay a rag under the tubing port that points downward.4. 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.

5. 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.

6. Install flow valve.7. 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.8. 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. Disconnect power cord and remove bottom cover.2. Disconnect hose, tubing and fittings from solenoid to be cleaned. 3. Remove retainer nut and ID plate from end of valve assembly. 4. Slide brass valve assembly out of electrical coil and bracket. 5. Place brass body in a vise. (Avoid crushing ports)6. Use right angle truarc pliers to unscrew collar from brass body. 7. Disassemble and clean inside of valve thoroughly.8. Reassemble valve making certain that spring is in end of plunger with tapered end out and plunger is

free in tube. 9. 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. 10. 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. Remove valve from machine. 2. Remove knurled nut. 3. Remove top, piston and spring. 4. Clean in mineral spirits and blow dry. 5. 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. 6. Insert spring into cylinder to rest on adjusting screw. 7. Insert piston into cylinder. (Be certain spring enters cavity in piston and small orifice is out.)8. Place the cap and knurled nut on body and tighten securely.9. Before replacing in machine, flush the tubing. 10. 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 properperformance when you are ready to use the machine again.

1. Change the Vacuum Pump Oil. 2. Make sure all hoses are sealed. 3. Leave purge valve slightly open to relieve pressure. 4. Pull a vacuum for 5 minutes on the low hose. (Handvalve must be closed.) Leave this vacuum on

hose during storage.

Page 1 - 22

Effective8/96 Page 2-1

CHAPTER 2 ACT-2000 / WHITE-01016

INTRODUCTION:

GENERAL OVERVIEWThis chapter provides service information for the Snap-on branded White Industries built ACT-2000, and theWhite 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 theACT-2000 will be referenced with Section 2, (Theory of Operation) of this chapter. However, for yourconvenience 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 ofsection 2, and refer to the theory of operation text for the mode you are troubleshooting. Again, please notethat you should ignore any reference to the beeper or beeper relay in the theory of operation text.


EffectivePage 2-2 8/96

NOTE:



AC POWER DISTRIBUTION

!THIS UNIT MUST BE PLUGGED INTO A PROPER AC OUTLET

TO OPERATE CORRECTLY. REFER TO ID PLATELOCATED 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 TOUCHLIQUID 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 behindyour 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 thecharging 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, andR12 Timer.

For specific charging station functions and the AC routing pertinent to that function, refer to SECTION II.



NOTES:

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All information contained or disclosed in thisdocument is considered confidential andproprietary by Sun Electric. Allmanufacturing, use, reproduction and sales rightsare reserved by Sun Electric andthe information contained herein shall notbe used in whole or in part without the expresswritten consent of Sun Electric.



NOTES:



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 optionalheater blanket outlet as well as the outlets on the side of the unit. Power is also routed through the Vacuumtimer, 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, andthe Vacuum timer (i.e.. It also routes power to itself). This causes the Vacuum Solenoid to beenergized, the Vacuum Pump to run, the Vacuum Pilot light to light and the vacuum timerstarts.

PNEUMATICS: (REFER TO DRAWING 2-4, PAGE 2-13)

In the Vacuum Mode the only pneumatic components involved are the Vacuum pump, S1Vacuum solenoid, In-line Filter, Low Side Gauge, and the Low side port. The Vacuum pumppulls a vacuum through the S1 Vacuum solenoid, the In-line filter, and finally to the low sideport. 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:


With the Vacuum Timer in the Off position power is routed to the Oil timer. With the oil timerset for a charge amount, power is then routed to the Oil Pilot Light, Oil Solenoid, and the OilTimer itself. This starts the Oil Timer, Opens the Oil Solenoid, and Lights the Oil Pilot light.


With the vehicle in a deep vacuum (from the vacuum mode) Oil is drawn from the oil tank, andpushed out the Oil tank (due to the 100lb charge of Nitrogen in the Oil Tank), through the twoIn-line filters, S3 Oil solenoid, flow indicator and flow valve, through another In-line filter andout to the vehicle. Oil continues to flow in this manner until the Oil timer has expired. In thatinstance the Oil timer contacts open and power is routed to the R12 timer.



R12 CHARGE MODE:


With the vacuum timer and the Oil timer in the "OFF" position AC power is routed to the R12timer. If the R12 timer has a charge amount selected power is then routed to the S2 R12Solenoid, Flow Switch light, R12 Float relay, Beeper Relay, and the R12 Timer itself. Thisstarts the R12 Timer, opens the R12 solenoid, lights the flow switch light, energizes the Beeperrelay, 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, throughthe check valve and flow indicator, through the flow valve, to the low side gauge, through thelast In-line filter, and out the low side port to the vehicle.

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PNEUMATIC

2-10 2-25



TROUBLESHOOTING

COMPLAINT CORRECTIVE ACTION

I. LOW TANK LIGHT illuminateswhile charging refrigerant.

Empty or nearly empty tank. Insufficient Flow.

• Replace empty tank with a full tank.

Flow Switch is sticking Down.

• Press Float Reset Switch on front panel.

• Clean Oil Soaked switch

II. CHARGING DIFFERENTIALPRESSURE light illuminates whilecharging refrigerant.

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 offeven though all indications arethe machine is functioningproperly.

Beeper relay is sticking in the Normally Closed position.

• Replace Beeper relay.

IV. Differential Pressure light comeson too soon.

Differential pressure switch is out of calibration.

• Replace Differential Pressure Switch.

V. Vacuum Pump Will not run. Dirty Oil in Pump.

• Change Oil in Pump every 25 evacuations.

Pump Low on Oil.

• Vacuum timer is being turned on with pressure on lowside gauge.

Pump Overfilled with Oil.

• Oil timer is being turned on out of sequence, thenturning on the vacuum timer.

VI. Insufficient Low Tank Light staysON.

Float Switch is Sticking.

• Oil in the float switch is sticking causing bobber tostick in the down position.



TROUBLESHOOTING CONT...


VII. Inaccurately charges Oil Out of Oil.

• Replace empty oil tank.

Pneumatics Dirty.

• Clean Pneumatics. (In-line Filters...)

Timer not moving.

• Change Timer

VIII. Inaccurately ChargesRefrigerant.

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.

• Replace Timer.



PARTS

GENERAL


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. EXAMPLE: 2341 = Built in 1972

B. In 1980 to 1991 a SIX digit serial number was used. The first two digits dictate the Year Built.


C. In 1992 to present a 10 digit number was used.

1. 1st digit = Year B=1992, C=1993, ...2. 2nd digit = Month A=January, B=February, ...3. 3rd digit = Make W=White, S=Snap-On4. 4th & 5th digit = Model 2A=ACT-2000, 62=ACT-3000

80=ACT-3300, 85=ACT-34005. 6th thru 10th = Lot # Number of unit coming off production line.

6. EXAMPLE: BAS621301=Built in 1992, January, Snap-On, ACT-3000, 1301 lot#



PARTS BY PICTORIAL

ACT-2000 UPPER CONSOLE VIEW

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Gauge, High K15022 16 Solenoid, Vac. w/o fittings K600602 Light, Pilot K30505 17 Relay, Beeper K300413 Timer, R-12 K30400 18 Relay, Float Switch K300414 Beeper K30555 19 Solenoid, R-12 w/o fittings K600605 Timer, Vacuum K30410 20 Switch, Diff. Pressure K300236 Switch, Float Reset K30042 21 Switch, ON/OFF K300117 Gauge, Low K15032 22 Outlet, 115V K300608 Timer, Oil K30420 23 Breaker, Circuit 8 amp K300519 Tubing, Flow Indicator K40820 NS Knob, Timers K9000510 Receptacle, Heater K30061 NS Thermometer K9900811 Solenoid, Oil, w/o fittings K60060 NS Cord, Power K3015112 Valve, Check, Duck Bill K60025 NS Tubing, Low Circuit K4081313 Filter, Oil K90423 NS Tubing, Accessory K4082814 Tubing, High Circuit K40801 NS Tubing, Purge Port K4084015 Valve, Flow K60021 NS Low Gauge adapter fitting K10681

Todd Wilson

BULK HEAD FITTING KIT K51016



ACT-2000 LOWER CABINET VIEW

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Filter, Oil K90423 6 Tube, R-12 Supply K405802 Filter, R-12 K90423 7 Strap, Tank K900803 Hose, 3' Red K25107221 8 Hose, 3' Blue K250072204 Hose, 2' Blue K25207222 NS Float Switch K300405 Cylinder, Oil Charge 1G. K90800 NS Float Switch Box K35150

Todd Wilson

HEATER-K30044 HEATER KIT-K01105



ACT-2000 VACUUM PUMP ASSEMBLY

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Vacuum Pump K16019 3b Relay, Compressor K303142 Tube, Drain Not Available 6 Mounts, Shock Not Available3 Cap, relay, Breaker assy. K30314 7 Case, Relay K303143a Breaker, Compressor K30314



PARTS IN ALPHABETICAL ORDER

DESCRIPTION PART NUMBER COMMENTSAdapter, Fitting K10681 Back Side of Low Side GaugeBeeper K30555 110 VoltBox, Float Switch K35150 Sheet MetalBreaker, 8 Amp Circuit K30051Cabinet, Complete K35006 Sheet MetalCap, 1/4 Flair K90312 To Cover Outside Bulkhead PortsCaster K80001Catches, Magnetic Door K35120Chrome Strip kit (left & right) K35402Cord, Float Switch Power K30152Cord, Power K30151Depressors, Screw in K45321Door, Left K35035Door, Right K35036Drawer K35051Filter, Screen K90420 Package Of 10 Screen FiltersFilter, Inline Particle K90423 Brass Assy. Oil or R-12Gasket, Hose K45331Gauge, High K15022 Liquid Filled Gauges No longer AvailableGauge, Low K15032 Liquid Filled Gauges No longer AvailableGrommet (Heyco Bushing) K90041 Power Cord, Float Cord, Pump CordHandle, Drawer K35091 With ScrewsHanger, Hose K35100Harness, Complete Wiring K31018Hose, 96" Blue K25007160 Vehicle Hose Without Hand ValveHose, 96" Red K25107161 Vehicle Hose Without Hand ValveHose, 96" Yellow K25207162 Auxiliary Vacuum HoseHose, 36" Blue K25007220 From Virgin Tank To Float Switch AssyHose, 24" Yellow K25207223Hose, 36" Red K25107221 From Oil Tank To Oil Charge SolenoidHose, 24" Yellow K25207222 Vacuum Pump To Vacuum SolenoidKnob, Timers K90005Label, Snap-On Logo K35403 Logo on Front DrawerLight, Pilot K30505 All Front Panel IndicatorsLock and Key, Drawer K35070Mats, Rubber K35145 Contains Both Black Rubber MatsO-Ring, Neoprene K45030 Package of 25Oil, R-12 Refrigerant K90800 1 GallonOutlet, Single 115V K30061Outlet, Dual 115V K30060Panel, Back K35029Panel, Front K35401Relay K30041 Beeper and Float SwitchRelay, Overload, Cap, and Case K30314 For Old Style Vacuum PumpSlides, Drawer K35110Solenoid K60060 R-12, Oil, and Vacuum W/out fittingsStrap, Tank K90080Switch, Float Reset K30042Switch, Float K30040 Includes Photocell, Light, and BobberSwitch, ON/OFF K30011Switch, Differential Pressure K30023Thermometer K99008Timer, Vacuum K30410Timer, Oil K30420



DESCRIPTION PART NUMBER COMMENTSTimer, R-12 K30400Tube, Differential Pressure Switch K40512 From Dif. Press. Switch To Brass TeeTube, Drain K40750Tube, R-12 Supply K40580 From Float Switch Assy. To SolenoidTubing, Flow Indicator K40823 Old StyleTubing, Purge K40840 Contains Flow IndicatorTubing, Low Circuit K40813 To Low side gaugeTubing, Flow Indicator K40820 New StyleTubing, High Circuit K40801 Contains Purge Valve, To High side gaugeTubing, Accessory K40828 To R-12 Charge solenoidVacuum Pump K16019Valve, Antiblow-back K60072 Female EndValve, Flow K60021Valve, Schrader K99011 Used In Bulkhead Ports on Side of UnitValve, Antiblow-back K60070 Male EndValve, Check (Duck Bill) K60025Valve, Check (Non-Duck Bill) K60119



PARTS IN NUMERICAL ORDER

PART NUMBER DESCRIPTION COMMENTSK10681 Adapter Fitting Back Side of Low Side GaugeK15022 Gauge, High Liquid Filled Gauges No longer AvailableK15032 Gauge, Low Liquid Filled Gauges No longer AvailableK16019 Vacuum PumpK25007160 Hose, 96" Blue Vehicle Hose Without Hand ValveK25007220 Hose, 36" Blue From Virgin Tank To Float Switch AssyK25107161 Hose, 96" Red Vehicle Hose Without Hand ValveK25107221 Hose, 36" Red From Oil Tank To Oil Charge SolenoidK25207162 Hose, 96" Yellow Auxiliary Vacuum HoseK25207222 Hose, 24" Yellow Vacuum Pump To Vacuum SolenoidK25207223 Hose, 24" YellowK30011 Switch, ON/OFFK30023 Switch, Differential PressureK30040 Switch, Float Includes Photocell, Light, and BobberK30041 Relay Beeper and Float SwitchK30042 Switch, Float ResetK30051 Breaker, 8 Amp CircuitK30060 Outlet, Dual 115VK30061 Outlet, Single 115VK30151 Cord, PowerK30152 Cord, Float Switch PowerK30314 Relay, Overload, Cap, and Case For Old Style Vacuum PumpK30400 Timer, R-12K30410 Timer, VacuumK30420 Timer, OilK30505 Light, Pilot All Front Panel IndicatorsK30555 Beeper 110 VoltK31018 Harness, Complete WiringK35006 Cabinet, Complete Sheet MetalK35029 Panel, BackK35035 Door, LeftK35036 Door, RightK35051 DrawerK35070 Lock and Key, DrawerK35091 Handle, Drawer With ScrewsK35100 Hanger, HoseK35110 Slides, DrawerK35120 Catches, Magnetic DoorK35145 Mats, Rubber Contains Both Black Rubber MatsK35150 Box, Float Switch Sheet MetalK35401 Panel, FrontK35402 Chrome Strip kit (left & right)K35403 Label, Snap-On Logo Logo on Front DrawerK40512 Tube, Differential Pressure Switch From Dif. Press. Switch To Brass TeeK40580 Tube, R-12 Supply From Float Switch Assy. To SolenoidK40750 Tube, DrainK40801 Tubing, High Circuit Contains Purge Valve, To High side gaugeK40813 Tubing, Low Circuit To Low side gaugeK40820 Tubing, Flow Indicator New StyleK40823 Tubing, Flow Indicator Old StyleK40828 Tubing, Accessory To R-12 Charge solenoidK40840 Tubing, Purge Contains Flow IndicatorK45030 O-Ring, Neoprene Package of 25



PART NUMBER DESCRIPTION COMMENTSK45321 Depressors, Screw inK45331 Gasket, HoseK60021 Valve, FlowK60025 Valve, Check (Duck Bill)K60060 Solenoid R-12, Oil, and Vacuum W/out fittingsK60070 Valve, Antiblow-back Male EndK60072 Valve, Antiblow-back Female EndK60119 Valve, Check (Non-Duck Bill)K80001 CasterK90005 Knob, TimersK90041 Grommet (Heyco Bushing) Power Cord, Float Cord, Pump CordK90080 Strap, TankK90312 Cap, 1/4 Flair To Cover Outside Bulkhead PortsK90420 Filter, Screen Package Of 10 Screen FiltersK90423 Filter, Inline Particle Brass Assy. Oil or R-12K90800 Oil, R-12 Refrigerant 1 GallonK99008 ThermometerK99011 Valve, Schrader Used In Bulkhead Ports on Side of Unit



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



WARRANTY

This product is warranted to be free of defects in workmanship and materials for a period ofone year from the date of purchase by original manufacturer. If the product fails within thisperiod, it will be repaired or replaced at sellers option, provided (1) the product is submittedwith proof of purchase date, (2) transportation charges are prepaid to the factory. Liabilityunder 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 ifthey have been tampered with or altered. If this warranty does not apply, then the retailpurchaser shall pay all costs for labor, material and transportation.



ASSEMBLY INSTRUCTIONS

1. INSTALL WHEELS USING BOLTS PROVIDE. Install WITH NUTS "UP" TO PROVIDE WHEEL

CLEARANCE.

2. Install handles on drawer and front doors using screws provided.

3. 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 theside 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.)

IMPORTANTAnti-blow back valve is attached to 45 end of red hose.

DO NOT REMOVE from red hose at any time.

2. INTERNAL HOSE PLACEMENT

IMPORTANTWear 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.



REFRIGERANT TANK REPLACEMENTAND AIR PURGING PROCEDURES


1. Turn master switch "OFF".

2. Remove blue hose from empty tank and connect to the replacement tank.

3. Turn tank valve "ON". Check tank valve for leak.

4. The R-12 tank must be positioned such that liquid is flowing from the port.

5. Turn master switch "ON".

6. Turn R-12 timer "ON". (If R-12 tank became empty while charging an air conditioner the R-12 timer will

already be on.)

7. Momentarily depress the float reset switch until float switch light goes out.

8. Refrigerant charging system is now ready for use.

OIL TANK REPLACEMENTAND AIR PURGING PROCEDURES.


1. Turn master switch "OFF".

2. Remove red hose from empty tank.

3. Connect red hose to new tank. Place tank on its handles and turn tank valve on.

4. 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" forapproximately two minutes.



OPERATING INSTRUCTIONS

IMPORTANTAlways wear safety goggles when servicing a system and operating service center.

Testing Air Conditioner:

1. With engine off, attach hoses-red to high side and blue to low side.

2. On compressors with manual service valve, mid-seat both valves.

3. Bleed air from hoses at right side of cabinet.

4. Start engine and adjust speed to fast idle.

5. Set air conditioner controls at "MAX" cooling and "HIGH" fan speed. Insert thermometer in air outlet

nearest the evaporator.

6. 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:

IMPORTANTConsult local laws governing discharge of R-12 to the atmosphere.

1. With the engine off, open purge valve.

2. When low side pressure drops below 10 PSI, vacuum pump can be turned "ON".

3. Close purge valve and turn off vacuum pump when low side pressure drops below 0 PSI.

Use with Recovery Recycling Equipment:

1. Attach hose from the recovery machine to the purge port.

2. Open purge valve and start recovery machine.

3. Close purge valve when recovery is complete.

Evacuating:

1. Set vacuum timer for ten minutes. (Bubbles in flow indicator normal.)

2. When timer shuts off, gauge readings should hold for two to three minutes if there are no leaks in the

system.

3. Reset timer for thirty minutes. If vacuum pump cycles on and off, change vacuum pump oil.

Oil Charging:

IMPORTANTCharge 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 whilecharging, 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.



Charging with Unheated R-12:

1. Bypass cycling clutch controls on cycling clutch system.

2. 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.

3. Start car after 1/2 lb. of refrigerant has been dispensed.

Charging with Heated R-12:

1. 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

into an A/C system that is NOT operating. Unheated R-12 can be charged while the system is in

operation.)

Charging through Accessory Port:

1. Connect safety dispensing valve to can.

2. Connect 24" hose to safety dispensing valve, then connect other end of hose (with core depressor)

to accessory fitting.

3. Open dispensing valve and charge in liquid position.

4. Monitor sight glass until it clears.

5. Shut engine off, remove and plug hoses. Replace system service cap and turn service center

master switch "OFF".

.

When

not

in

use,

ALWAYS

REMOVE

HOSE

FROM

ACCESSORY

PORT

AND

CAP

T



MAINTENANCE

Vacuum Pump Oil Change:

The vacuum pump should have the oil changed after every 25 evacuations and must be changed afterevacuating a contaminated system, i.e., compressor failure, dehydrator failure, or system left open. Mostfailures of the vacuum pump occur from contaminated pump oil. To change the oil:

1. Remove plug in bottom of pump.

2. Allow oil to drain completely.

3. Replace the plug making sure the O-ring seal is not damaged.

4. Unscrew vacuum pump suction hose from the solenoid valve.

5. Place suction hose into 12 ounces of General Motors' transmission fluid "type A" (DEXTRON).

6. 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 mightbegin 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. Toremove the gaskets on the straight end, pry the gasket out with an ice pick. Then press in a new gasket. Toremove the gaskets on the bent end, use needle nose pliers to unscrew old gasket, then screw in new gasket.



Tubing and Solenoid Flushing:1. Disconnect power cord and remove bottom cover.

2. Remove the flow valve.

3. Lay a rag under the tubing port that points downward.

4. 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.

5. 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.

6. Install flow valve.

7. 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.

8. If the solenoid valve still malfunctions, see Solenoid Cleaning section.

Solenoid Cleaning:1. Disconnect power cord and remove bottom cover.

2. Disconnect hose, tubing and fittings from solenoid to be cleaned.

3. Remove retainer nut and ID plate from end of valve assembly.

4. Slide brass valve assembly out of electrical coil and bracket.

5. Place brass body in a vise. (Avoid crushing ports)

6. Use right angle truarc pliers to unscrew collar from brass body.

7. Disassemble and clean inside of valve thoroughly.

8. Reassemble valve making certain that spring is in end of plunger with tapered end out and plunger is

free in tube.

9. 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.

10. 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. Remove valve from machine.

2. Remove knurled nut.

3. Remove top, piston, and spring.

4. Clean in mineral spirits and blow dry.

5. 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.

6. Insert spring into cylinder to rest on adjusting screw.

7. Insert piston into cylinder. (Be certain spring enters cavity in piston and small orifice is out.)

8. Place the cap and knurled nut on body and tighten securely.

9. Before replacing in machine, flush the tubing.

10. Replace valve in machine.

STORAGE

When storing the machine for a prolonged period of over a month, a few simple precautions will insure properperformance when you are ready to use the machine again.

1. Change the vacuum pump oil.

2. Make sure all hoses are sealed.

3. 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.

SECTION I

AC POWER DISTRIBUTION_____________________________________________________________

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 orbehind 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 isrouted 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-PinConnector on Pin 3 which supplies AC volts to the Master Relay Pin 6. AC is located on the Master RelayPins 1, 2, and 5 via Pin 6.

The Neutral line is routed to the Compressor, Solenoids, 9-Pin Connector Pin 1, Fan, Lamps, and theMaster Relay Pin 7.

Page 3 - 1

THIS UNIT MUST BE PLUGGED IN TO A PROPER AC OUTLET FORUNIT TO OPERATE CORRECTLY. REFER TO UNIT ID PLATE LOCATEDON BACK OF UNIT. EXTENSION CORDS ARE NOT RECOMMENDED,BUT IF AN EXTENSION CORD MUST BE USED, USE A CORD THAT ISLESS THAN 50 FEET WITH A 16 AWG, OR ABOVE 50 FEET AND LESSTHAN 100 FEET WITH A 14 AWG.

USE STANDARD REFRIGERANT HANDLINGSAFETY PROCEDURES WHEN PERFORMING INSTALLATION

ALWAYS WEAR SAFETY GOGGLES, DON'T SPILL OR TOUCH LIQUIDREFRIGERANT, AVOID FLAMES, & EXCESSIVE HEAT. USE ONLY INWELL VENTILATED AREA.

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Page 3 - 2

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 the9-Pin Connector pin-2 and also through the (NC) Vacuum Switch. AC from the Vacuum Switch is routed tothe 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 OperatingLamp, Selector Switch, Fan, Compressor, and the Master Relay pin-8. Once the Cycle start switch isreleased the Master Relay will energize and supply AC to pin-3 from pin-6 on the Master Relay. This, in turnsupplies 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 thevehicle.

If the Vacuum Switch is open, AC will not be present at the 9-Pin Connector pin-3. Therefore, the CycleStart 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 StartMode). Selecting RECOVER, using the Selector Switch, will route AC to the 9-Pin Connector pin-5, to theCommon pin on the Tank Full Switch. If the tank is full, power is routed through the NO pin on the Tank Fullswitch 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 thusopening 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 thatmay contaminate the system. The refrigerant then travels through the System Pressure Gauge so theoperator 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 Switchstops 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 collectany oil that may come from the automobile AC system during Recovery. The Oil Separator requires manualpurging after every recovery. The oil free refrigerant then travels into the Filter Dryer that removes anymoisture, then through a one way Check Valve that prevents back flow. The refrigerant then enters thesuction (LOW) side of the compressor where it is converted from a low pressure vapor to a high pressurevapor that exits the discharge (HIGH) side of the compressor. Next the refrigerant enters the Temprite OilReservoir 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 thebottom. At any point above 2.5 inches from the bottom, a ball float inside the Temprite will rise and open aneedle valve which will let some oil return to the pump through the RETURN port, thus keeping the pump atthe 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 pressurevapor into a high pressure liquid. The high pressure liquid refrigerant empties into the Reclaim Tank via aone 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 ReclaimTank, and the purpose of the Oil Separator is to collect any oil that may come from the refrigerant leavingthe 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 wayCheck Valve that prevents back flow. The refrigerant then enters the suction (LOW) side of the compressorwhere 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 thebottom. At any point above 2.5 inches from the bottom, a ball float inside the Temprite will rise and open aneedle valve which will let some oil return to the pump through the RETURN port, thus keeping the pump atthe 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 pressurevapor into a high pressure liquid. The high pressure liquid "Cleaned" refrigerant empties into the ReclaimTank 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

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Page 3 - 8

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. If you do not feel suction at the Recovery Port, see Troubleshooting (Page 22).b. 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).c. 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. If the Tank Full Light Remains ON, see Scale Calibration. (Page 20).b. 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 Filtershell. The gauge should go down into a vacuum of 10-20 inches of mercury and the SystemOperating Light should go out as the unit automatically turns itself OFF. If the Air Purge Gaugegoes down to 10-20 inches of mercury, but the machine does not turn OFF, then:

a. The Vacuum Switch (K30030-A) needs to be replaced or, b. 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. Old style switch should cut off at 250-275 PSI.b. 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 bereplaced.

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 onthe Scale Plate. Does the Tank Full Light turn OFF? If so, proceed to step 2. If not proceed totroubleshooting.

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 willnot light when Cycle StartSwitch is depressed.

The System Operating Lamp is burned out.

While holding down the Cycle Start Switch, Check for 115Volts 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 itis 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 inthe reclaim tank. If < 320psi in tank replace pressureswitch.

Open wire between High Pressure Switch and Cycle StartSwitch.

Check resistance between pin 2 of the 9-Pin Connector tothe Cycle Start Switch and the High Pressure Switch.

II. System Operating Lamp willnot stay lit after Cycle StartSwitch was released.

Master Relay will not energize.

Hold down the Cycle Start Switch, and check for 115 VoltsAC 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 VoltsAC 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 VacuumSwitch.

If voltage is present on both sides, ENDTROUBLESHOOTING.

If voltage is not present on one side, and there is not avacuum at the Filter Dryer, replace Vacuum Switch.

Page 3 - 21

III. Compressor will not startrunning when the SystemOperating 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 theReclaim Tank is not full orempty.

NOTE: The System Operating Lampmust be on to perform thistest.

Tank Switch stuck open.

Place the Selector Switch in the RECOVER mode andcheck the voltage on the 9-Pin Connector pin 6.

If voltage is present, check for 115 Volts on the RecoverySolenoid.

If voltage is not present, replace Tank Switch.

If voltage is present, Tank Switch is shorted internal toboth connectors, replace Tank Switch.

V. Recovery unit will not pullfrom 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 excessair 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 notcontinue running afterstarting 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 afterrunning a short time inRECYCLE mode.

Excessive air in tank.


VIII. Moisture Indicator will notturn green.

Insufficient process time.

Run in RECYCLE mode longer.

Filter/Dryer contaminated.

Change Filter.

Indicator fouled.

Change indicator element.

IX. Recovery unit will not shutoff automatically in ENDCYCLE mode.

Recovery tank has excessive air.


Defective Vacuum Switch.

Replace switch.

The two large quick connects are not fully engaged to the tank.

Check connections.

Page 3 - 23

TROUBLESHOOTING Cont...

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Page 3 - 24

SECTION IV

PARTS_______________________________________________________________________________________

GENERAL


NOTE: The following is a breakdown description for Serial Numbers:










6. EXAMPLE: BAS621301 = Built in 1992, January, Snap-On, ACT-3000, 1301 lot #

Page 3 - 25


ACT-2500 FRONT VIEW

Page 3 - 26

ACT-2500 FRONT VIEW ITEMS


1 Core, Filter K16200 12 Spring, Scale K90660

2a

GaugeGauge Lens

K15041K15005

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


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


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

DESCRIPTION PART NUMBER COMMENTS

Axle K80003

Cabinet, Complete K35025 Sheet Metal Only

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 Package of 25

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 K32531

Grommet (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

SUBSECTION B. PARTS IN ALPHABETICAL ORDER

Label, Snap-On Logo K35403 On front panel of unit

Latch, Door K90801

Lens, Gauge K15005 Plastic cover for Front Panel Gauge

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 From Compressor To Oil Separator Inlet

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

Page 3 - 31

PART NUMBER DESCRIPTION COMMENTS

K14004 Door

K15005 Lens, Gauge Plastic cover for Front Panel Gauge

K15041 Gauge

K16011 Compressor Includes all Compressor Fittings

K16200 Filter, Core (Desiccant) Package of 2, With O-rings

K16202 Filter, Shell

K16601 Element Kit, Moisture Indicator Contains Spring, Seals, Glass, and Element

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 Can Use 0587-0504

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 On front panel of unit

Handle

Page 3 - 32

SUBSECTION C. PARTS IN NUMERICAL ORDER

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 With Capillary Tube

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 Gasket, Oil Discharg Valve, Schrader Valve

K80002 Wheel, 10" Rear

K80003 Axle

K90001 Cap, Axle

K90011 Plate, Spring Used In Filter Dryer

K90041 Grommet (Heyco Bushing) 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 Green and Yellow Dots, Clean/Dirty Label

K99013 Thermometer

Page 3 - 33

NOTES

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Page 3 - 34

SECTION V

OPERATORS MANUAL______________________________________________________________

TABLE OF CONTENTS

PageWarranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37Setting Up the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37Recovering Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Gauge Manifold Hook Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38Charging Station Hook Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Recycling Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39Excess Air Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39Moisture and Oil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Replacing the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40Changing the Filter Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40Scale Plate Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

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WARRANTY

This product is warranted to be free of defects in workmanship and materials for a periodof one year from the date of purchase by original manufacturer. If the product fails withinthis period, it will be repaired or replaced at sellers option, provided (1) the product issubmitted with proof of purchase date, (2) transportation charges are prepaid to thefactory. Liability under this warranty is expressly limited to repairing or replacing theproduct or parts thereof. This warranty does not apply to product or parts broken fromaccident, overload, abuse or if they have been tampered with or altered. If this warrantydoes not apply, then the retail purchaser shall pay all costs for labor, material andtransportation.

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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 efficientoperation. Improper use could cause serious injury or damage to the A/C System or the RecoveryRecycling Center.

WARNINGAlways wear eye protection when working with refrigerants.

To avoid possible loss of refrigerant to the atmosphere, always use the quick disconnect fittings andanti-blow back valves supplied with this unit and replace hoses as needed to maintain optimum performanceof 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. Remove the unit and recovery tanks from the shipping carton.

2. Install the handle on the unit using (4) #10-32x1 screws.

3. Remove filter canister lid (located on top of machine), spring plate, and shipping material from

inside canister.

4. 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.

5. Immediately install filter into canister (metal plate facing up).

6. Replace spring plate (spring facing up).

7. Replace filter canister lid and tighten nuts evenly in a crossing pattern to 10-15 ft.-lb torque.

8. Vent the shipping charge of pressure from one of the recovery tanks by opening the liquid valve.

9. 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.

10. Connect the two large "Quick Disconnects" onto the two large male ports located in the center of the

tank. These connections are reversible.

11. 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. After evacuating the tank close the liquid valve and disconnect the vacuum pump.

14. 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.

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RECOVERING REFRIGERANT

CAUTIONAlways wear eye protection when working with refrigerants

The magnetic label should be applied to the tank at this time with the "CONTAMINATED" side showing toindicate that the refrigerant being recovered must be recycled before being dispensed.

1. 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.

2. Close the liquid valve on the tank during recovery.

3. 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.

4. After all connections have been made push the rocker switch (located on face plate) to the

RECOVER position.

5. Momentarily depress the CYCLE START button (2-3 seconds). The SYSTEM OPERATING light

will come on as the unit begins the recovery process.

6. 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.

7. With the unit off, disconnect it from the vehicles A/C system. You are now ready to perform normal

A/C service.

8. 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.

9. 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.

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RECYCLING REFRIGERANT

CAUTIONRecovered 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. Let the tank stabilize for 2 hours minimum to insure the refrigerant is at room temperature.

2. Install the air purge valve assembly to the air purge port on top of the tank.

3. Read the tank pressure on the gauge of the air purge valve and refer to the "Excess Air Purge

Chart."

4. Find temperature of the room that you are currently in, in the table inside the front door of the unit.

5. If the pressure reading of the gauge is above the pressure given in the table, excess air must be

removed from the tank.

6. If air must be removed, open the air purge valve and slowly bleed off the pressure.

7. Continue to purge until the gauge reading drops below the value given in the table for the

temperature you are currently in.

8. 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.

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.

5. 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.

6. Close the liquid valve on the tank, disconnect all of the hoses on the tank and remove tank from the

unit.

7. Apply the magnetic label to the tank to indicate that it has been recycled and is ready for use.

8. The second tank may be installed at this time.

Page 3 - 39

REPLACING THE TANK

CAUTIONAlways wear eye protection when working with refrigerant.

IMPORTANTUse only the refrigerant recovery tank designed for this unit.

1. 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.

2. To install the tank, open the door on the front of the unit and place the tank on the scale plate.

IMPORTANTPlace the tank within the flanges of the scale plate so that the unit will shut off when the tank is full.

3. 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.

4. 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.

5. The system is now ready to begin recovering.

CHANGING THE FILTER CORE

CAUTIONAlways wear eye protection when working with refrigerants.

1. Place the rocker switch in the END CYCLE position and depress the CYCLE START button.

2. 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.

3. 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. Remove the six flange bolts and remove the canister lid.

5. 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.)

7. Clean the inside of the shell if necessary. DO NOT REMOVE THE STRAINER IN THE BOTTOM

OF THE SHELL.

8. Remove the new core from its canister.

IMPORTANTDO NOT EXPOSE FILTER TO THE OPEN ATMOSPHERE FOR MORE THAT TWO MINUTES.

DOING SO CAN DEPLETE MOISTURE CAPACITY.

9. Install the filter core into the shell with the metal end plate up.

10. Install the spring plate on top of the core with the spring up.

Page 3 - 40

CHANGING THE FILTER CORE continued

11. Replace gasket in the canister lid if it is damaged.

NOTE: Lubricate the new gasket with refrigerant oil.

12. Replace the lid and flange nuts and tighten evenly in a cross pattern to 10-15 ft.-lb torque.

13. Connect a vacuum pump to the port on the lid and evacuate for 30 minutes to remove any air in the

shell.

14. The unit is now ready for use.

SCALE PLATE CALIBRATION

1. Remove the tank from the unit.

2. Remove NUT #1 on top of the calibration unit.

3. Turn the calibration bolt counter-clockwise (upward) until it stops.

4. 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.)

5. 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.

6. Continue turning the bolt slowly until you hear a light "click" from the microswitch.

7. Carefully remove the tank or weights.

8. With a 1/2" wrench, tighten down NUT #1 while holding NUT#2 with a 3/8" wrench.

9. The scale is now calibrated for the 50 pound tank.

Page 3 - 41

NOTES

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Page 3 - 42



INTRODUCTION

GENERAL OVERVIEW:This chapter provides service information for the Snap-on branded White Industries Built ACT-3000, and theWhite Industries built 01060.

There are currently two version of these units in the field. The early version uses a timer, relays and a TankFull Board to control pneumatic components; the newer version has a Smart Board that replaces thesecomponents.

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 TestFront Panel Switch or the Pressure Test Solenoid.

Since the two model machines are nearly identical, only the electrical and pneumatic diagrams for theACT-3000 will be referenced with Section 2, (Theory of Operation) of this chapter. However, for yourconvenience 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 ofsection 2, and refer to the theory of operation text for the mode you are troubleshooting. Again, please notethat you should ignore any reference to the pressure test circuitry of the unit in the theory of operation text.




!THIS UNIT MUST BE PLUGGED INTO A PROPER AC OUTLET

TO OPERATE CORRECTLY. REFER TO ID PLATELOCATED 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 TOUCHLIQUID REFRIGERANT, AVOID FLAMES, AND EXCESSIVE HEAT.

USE ONLY IN WELL VENTILATED AREA.

NOTE: THIS SECTION IS FOR UNITS WITH A "TANK FULL BOARD".


Always use the "One Hand Rule" when working with AC voltages by keeping one hand in your pocket or behindyour back. Before removing wires from the ACT-3000, always verify that the Tester is "OFF", and unplug theAC 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. Duringnormal operation the high pressure switch is shorted between pins 1 and 3, therefore the AC voltage continuesthrough the 9 pin connector and to the "ON/OFF" power switch.

NOTE: THIS SECTION IS FOR UNITS WITH A "SMART BOARD".


Always use the "One Hand Rule" when working with AC voltages by keeping one hand in your pocket or behindyour back. Before removing wires from the ACT-3000, always verify that the Tester is "OFF", and unplug theAC 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.

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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 pinconnector to the "ON/OFF" switch. From the "ON/OFF" switch the AC voltage is routed to pin 6 of the TankFull relay, out the tank full relay on pin 5 to the fan. Power is also routed from the on/off switch to the Tank FullBoard. 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 boardalso 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, tothe System Operating light, which alerts the operator that the unit is now reclaiming. Power isalso routed to pin 7 of the Cycle start relay which energizes the cycles start relay. AC powerthen runs through the Vacuum Switch to pin 3 of the cycle start relay, out pin 4 of the cyclestart relay to pin 8 of the 9 pin connector. From the 9 pin connector AC power is routed to thecompressor, Oil Return Solenoid Start Timer, and to the Compressor Oil Solenoid. This startsthe compressor and the Oil Return solenoid timer. By starting the Oil Return Solenoid Timerwe can monitor the amount of time the compressor has been running. This is importantbecause for every 15 minutes the compressor runs power is removed from the compressor oilreturn solenoid for 10 seconds.


In the Cycle Start Mode refrigerant flows in from; the system vapor hose to the filter dryer / oilseparator, and from the system liquid hose, through a capillary tube and to the filter dryer / oilseparator. 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 fromthe 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 outthe "OUT" port of the compressor oil separator and through the condensing coil. Thecondensing coil changes the refrigerant back into a liquid, it then flows through the checkvalve, 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<PRESSURE TEST>. This then routes AC power through the Pressure Test switch and to thePressure Test solenoid. The Pressure test solenoid will remain open until the operatorreleases <PRESSURE TEST> switch.



PRESSURE TEST MODE: CONT...


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 ishooked up to the tester). This continues until the operator releases <PRESSURE TEST>.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 timerautomatically cuts power to S2 (Oil return) solenoid. This causes the oil return solenoid toopen. After 10 seconds AC power is then re-applied to the Oil Return solenoid and it closes.


During the 10 second Automatic Oil Return Mode, Oil from the compressors oil separator ispushed 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.



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 SmartBoard. The smart board then applies 8 volts DC to the Front panel digital gauge, and routes 8 volts DC out pin10 to pin 9 of the 12 pin connector, to pin 3 of the Tank Full Probe Assembly.

CYCLE START MODE:


The depression of the Cycle Start switch is sensed by the ACT's Smart board. When this issensed the Smart Board sends 115V AC out pin 9 to pin 5 of the 12 pin connector. From the12 pin connector to the High pressure switch. Since the High pressure switch is a normallyclosed switch power is then routed to the Compressor, and to the Hour Meter which measuresthe amount of time the compressor has run. From the compressor AC power is routed back topin 1 of the 12 pin connector to the System Operating Lamp on the front panel. During thismode power is also routed from pin 3 of the smart board to the oil return solenoid. This closesthe oil return solenoid.


In the Cycle Start Mode refrigerant flows in from both the high and low side ports to the filterdryer / oil separator. The refrigerant coming in from the low side port goes through acondensing coil before it gets to the oil separator. In the filter dryer / oil separator refrigerant isseparated from the vehicle's oil and sent out the top port through the check valve and to thecompressor. From the compressor VAPOR refrigerant is sent to the Compressor Oil separatorinlet port. Here the compressors oil is separated from the refrigerant and the vapor refrigerantflows out the "OUT" port of the compressor oil separator and through the condensing coil. Thecondensing coil changes the refrigerant back into a liquid, it then flows through the checkvalve, moisture indicator, and into the tank through the liquid port.

PRESSURE TEST MODE:


With power routed as shown in the "Power On Mode" drawing the operator presses and holds<PRESSURE TEST>. This then routes AC power through the Pressure Test switch and to pin10 of the 12 pin connector. From the 12 pin connector AC power is routed to the Pressure Testsolenoid. The Pressure test solenoid will remain open until the operator releases <PressureTest>. At that time the Pressure Test solenoid will then return back to its original NormallyClosed State.



PRESSURE TEST MODE: CONT...


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 ishooked up to the tester). This process continues until the operator releases <PRESSURETEST>. This allows a leak test to be performed on either the vehicle or part of the ACT'spneumatics.

AUTOMATIC OIL RETURN MODE:


For 10 seconds of every 15 minutes the compressor is running power is automatically removedfrom 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 pushedthrough S2 (Oil return) solenoid and back into the compressor via the suction port. Thisensures a closed loop condition for the compressor oil which means the compressor will alwayshave the right amount of oil in it.

ACT-3000T. PARSELL

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POWER ON MODEWITH TANK FULL BOARD

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All information contained or disclosed in thisdocument is considered confidential andproprietary by Sun Electric Allmanufacturing, use, reproduction and sales rightsare reserved by Sun Electric andthe information contained herein shall notbe used in whole or in part without the expresswritten consent of Sun Electric.



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SMART BOARD

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ACT-3000T. PARSELL

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CYCLE START MODESMART BOARD

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CYCLE START MODE

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PRESSURE TEST MODEWITH TANK FULL BOARD

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PRESSURE TEST MODESMART BOARD

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PRESSURE TEST MODE

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COMPRESSOR OIL RETURN MODESMART BOARD

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OIL RETURN MODE

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WHITE-01060 0896

SMART BOARDELECTRICAL

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White-01060 0896

TANK FULLELECTRICAL

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PNEUMATIC4-394-16

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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 powerswitch.

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 <CYCLE START>.

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 andallowing the unit to return to a balance start-up condition.



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TROUBLESHOOTING


I. Will Not Recover. Recovers only while holding down the cycle startswitch.

• Vacuum Switch is stuck open and defective.

Compressor will not stay running.

• Anti-blow back valve on reclaim tank liquid hose isback seated causing high head pressure (restriction).

• Check Valve on Moisture indicator is stuck closedcausing high head pressure (restriction).

• Customer is not purging Excess Air after EACHreclaim.

Compressor not running, kicking overload.

• Check valve on top of filter canister is stuck closed.

• Oil in filter canister: not purging oil, causingrestriction on suction side of compressor.

Unit pulls down into a vacuum, pressure rises back upon gauge because vehicle still has refrigerant in it.

• Anti-blow back valves on system hose:overtightened, causing restricted flow of refrigerant.

II. Moisture Indicator Will not turn green.

• Leak in unit, pulling Moisture and Air into unit.

• Filter core Oil Soaked or Contaiminated.

III. Tank Full Light. Always on, even with an empty tank.

• Measure the resistance on the tank full probe, pin 1-3, and pins 2-3.

• Above measurements should be between 12-17ohms.

• Difference between pins 1-3 and 2-3 measurementshould not be greater than 2 ohms.

• If any of the above are not accurate than the tankfull probe needs to be replaced.



NOTES:



PARTS

GENERAL

This chapter describes assemblies, subassemblies, and parts considered replaceable by Sun Field ServiceTecnicians.














PARTS BY PICTORIAL

ACT-3000 FRONT VIEW

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Light, Red K30037 14 Frame K761252 Switch, Light K30008 15 Handle K355383 Switch K30008 16 Core, Filter K162004 Latch, Door K90803 17 Valve, Pressure Access K505035 Thermometer K99013 18 Valve, Air Purge K600596 Door & Hinge K76122 19 Gauge K11010667 Nut, 5/16-18 K72502 20 Sticker, Green, Yellow Dot K910628 Caster, Front Locking K35252 21a Indicator Moisture (OLD) K166139 Cap, Axle K80003 21b Indicator Moisture (NEW) K1662210 Screw, 5/16-18x3/4 K71001 22 Panel, Top K3505811 Wheel 3645-0047-01 23 Hose, 18" Blue K25207-30212 Axle K42020-206 24 Hose, 20" Red K25107-11013 Bracket, Hose K76019 25 Bracket, Tank Retention K76113



ACT-3000 INSIDE CABINET VIEW

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Filter Assembly K16205 15 Switch, High Pressure K302552 Switch, Vacuum K30032 16 Harness, Lower Wiring K11010553 Valve, Pressure Test K60065 17 Fan 0587-05044 Compressor K16011 17a Grill K325315 Tube, Oil Purge K40833 18 a Indicator, Moisture (OLD) K166136 Tube, Oil/Air Purge K40848 18 b Indicator, Moisture (NEW) K166227 Hose, 96" Red K25107123 19 Hose, Compressor K25007-1038 Hose, 20" Red K25107-110 20 Tank Full Board K11010019 Hose, 96" Blue K25007143 20♦ Smart Board K111001910 AC Power Cord 6001-0189-01 21 Tube, Oil Purge K4083311 Tube, Discharge K40837 22 Solenoid, Oil Return K6005812 Timer, Units with tank full

board only.K30252 23 Manifold, Suction K51059

13 Cord, Tank Full Sensor K1101002 24 Valve, Check K6003314 Separator, Oil K16608 25 N.S. Relay (2 ) Units with

Tank full board only.K30041

NOTE:

Unit shown has aTank Full board, 2Relays, and aTimer.

♦ On some unitsthe Smart Boardreplaces all 4componentsmentioned above.

However, Unitcomponents are notinterchangeable.



PARTS IN ALPHABETICAL ORDER

DESCRIPTION PART NUMBER COMMENTSAxle K80003Ball Valve (Blue) K60108 comes with 6” hoseBall Valve (Red) K60107 comes with 6” hoseBezel, Digital Gauge K30509 Comes with the Bezel and LensBin Kit, Plastic Storage K90302 Plastic Bins (Divided and Storage)Board, Smart K1110019Board, Tank Full K1101001Bracket, Hose Wrap K76019Bracket, Tank Retention K76113Cabinet, Complete K76901 Sheet MetalCap, Axle K90001Caster, Front Locking K35252Compressor K16011 fitting kit (w/fittings for all units comp.)Cord, Tank Full Sensor K1101002Cord, Fan K6030004Cord, AC Power K30199 Can Use 6001-0189-01Core, Filter K16200 With (2) O-RingsCup, Measuring K90301 For Oil PurgeDepressors, Screw In K45321 Package of 25, Used in ends of hosesDoor & Hinge K76122Element, Moisture Indicator K16601 Just the Element not the entire Assy.Fan K32511 Can Use 0587-0804Filter Assembly K16205 Filter Dryer / Oil SeperatorFilter, Inline K90420 Inline Filter Assy. (Brass & Element)Fitting, Display Adapter K10657 When installing new style Display bd.Gauge w/ribbon cable & transducer K1101066 May need K10657 (Adapter Fitting)Grill, Fan K32531Grommet (Heyco Bushing) K90041 for AC power cord and Wiring harnessHandle K35538Harness, Lower Wiring K1101055Harness, Upper Wiring K1101056Hose, 20" Yellow K25107110 Tank Vapor, with hand valveHose, Compressor Suction (Blue) K25007103 From Compressor to Filter DryerHose, 96" Red K25107123 With Hand ValveHose, 96" Blue K25007143 With Hand ValveHose, 18" Yellow K25207302 Tank Liquid, with Hand ValveIndicator Assy, Moisture K16613 Old Style, (All Copper Color)Indicator Assy, Moisture K16622 New Style, (Silver and Copper Color)Label, "Oil Purge Port" K99444 Part Of Label Kit K91062Label, Snap-on K35403 Located on front doorLabel, Dry Dot, Green K99528 Part of Label Kit K91062Label, Dry Dot, Yellow K99529 Part of Label Kit K91062Latch, Door K90803Lens, Digital Gauge K30509 Comes with the Bezel and LensManifold, Brass K51055 Purge Assy. and Input Suction Assy.Mat, Black Rubber K30507Meter, Hour K30276Nut, Moisture Indicator K50565Oil, Compressor 0681-0179-02 3GS Oil, 10 oz. in CompressorO-Ring Kit, Neoprene K40530 Package Of 25O-Ring 0617-0210-01 For 1/4 Turn Ball ValveOverload kit, Compressor Klixon K30301 Contains Comp. Relay and OverloadPanel, Top K35058



DESCRIPTION PART NUMBER COMMENTSPanel, Fan K76106 Sheet MetalPlate, Spring K90011 Used in Filter Dryer / Oil SeperatorProbe, Tank Full K1101037Relay Kit, Compressor K30301 Contains Comp. Relay and OverloadRelay K30041 Tank Full and Cycle StartSeparator, Oil K16608 For Compressor OilSolenoid, Oil Return K60058 Fittings K10680, K50554 Sold Sep.Solenoid, Pressure Test K60065 Fittings K10680, K10601 Sold Sep.Switch, Light, Frame Front Panel K30008 Switches, Lights, and FrameSwitch, Vacuum K30032 Opens at 10" HgSwitch, High Pressure K30255 Opens at 435 psiTank, Reclaim K16419 50 lb.Thermometer K99013 Sticker thermometer on inside doorTimer, Oil Return K30252 On units with Tank Full Board ONLYTube Liquid Capillary K40832 Sys. Liquid Bulkhead Port to ManifoldTube, Moisture Indicator Discharge K40541 from Moisture Ind. to Bulkhead FittingTube, Condensing K40854 From Oil Sep. to Moisture IndicatorTube, 6" Capillary K40807Tube, Oil Purge K40833Tube, Discharge K40539 From Compressor to Oil SeperatorTube, Oil/Air Purge K40848Tubing, Digital Gauge K40849 Units W/transducer on display boardValve, 3 psi Check K60122 Moisture IndicatorValve, 1/3 psi Check K60119 Top of Filter Dryer / Oil SeperatorValve, Air Purge K60059 Momentary Pressure ReliefValve, Pressure Access K50503 On top of Filter Dryer / Oil SeperatorWheel K80002 10" Rear wheel



PARTS IN NUMERICAL ORDER

PART NUMBER DESCRIPTION COMMENTS0671-0210-01 O-Ring For 1/4 Turn Ball Valve0681-0179-02 Oil, Compressor 3GS Oil, 10 oz. in CompressorK10657 Fitting, Display Adapter When installing new style Display bd.K1101001 Board, Tank FullK1101002 Cord, Tank Full SensorK1101037 Probe, Tank FullK1101055 Harness, Lower WiringK1101056 Harness, Upper WiringK1101066 Gauge w/ribbon cable & transducer May need K10657 (Adapter Fitting)K1110019 Board, SmartK16011 Compressor fitting kit (w/fittings for all units comp.)K16200 Core, Filter With (2) O-RingsK16205 Filter Assembly Filter Dryer / Oil SeperatorK16419 Tank, Reclaim 50 lb.K16601 Element, Moisture Indicator Just the Element not the entire Assy.K16608 Separator, Oil For Compressor OilK16613 Indicator Assy, Moisture Old Style, (All Copper Color)K16622 Indicator Assy, Moisture New Style, (Silver and Copper Color)K25007103 Hose, Compressor Suction (Blue) From Compressor to Filter DryerK25007143 Hose, 96" Blue With Hand ValveK25107110 Hose, 20" Yellow Tank Vapor, with hand valveK25207302 Hose, 18" Yellow Tank Liquid, with Hand ValveK30008 Switch, Light, Frame Front Panel Switches, Lights, and FrameK30032 Switch, Vacuum Opens at 10" HgK30041 Relay Tank Full and Cycle StartK30199 Cord, AC Power Can Use 6001-0189-01K30252 Timer, Oil Return On units with Tank Full Board ONLYK30255 Switch, High Pressure Opens at 435 psiK30276 Meter, HourK30301 Overload kit, Compressor Klixon Contains Comp. Relay and OverloadK30301 Relay Kit, Compressor Contains Comp. Relay and OverloadK30507 Mat, Black RubberK30509 Bezel, Digital Gauge Comes with the Bezel and LensK30509 Lens, Digital Gauge Comes with the Bezel and LensK32511 Fan Can Use 0587-0804K32531 Grill, FanK35058 Panel, TopK35252 Caster, Front LockingK35403 Label, Snap-on Located on front doorK35538 HandleK40530 O-Ring Kit, Neoprene Package Of 25K40539 Tube, Discharge From Compressor to Oil SeperatorK40541 Tube, Moisture Indicator Discharge from Moisture Ind. to Bulkhead FittingK40807 Tube, 6" CapillaryK40832 Tube Liquid Capillary Sys. Liquid Bulkhead Port to ManifoldK40833 Tube, Oil PurgeK40848 Tube, Oil/Air PurgeK40849 Tubing, Digital Gauge Units W/transducer on display boardK40854 Tube, Condensing From Oil Sep. to Moisture IndicatorK45321 Depressors, Screw In Package of 25, Used in ends of hosesK50503 Valve, Pressure Access On top of Filter Dryer / Oil SeperatorK50565 Nut, Moisture IndicatorK51055 Manifold, Brass Purge Assy. and Input Suction Assy.K25107123 Hose, 96" Red With Hand Valve



PART NUMBER DESCRIPTION COMMENTSK60058 Solenoid, Oil Return Fittings K10680, K50554 Sold Sep.K60059 Valve, Air Purge Momentary Pressure ReliefK60065 Solenoid, Pressure Test Fittings K10680, K10601 Sold Sep.K60107 Ball Valve (Red) comes with 6” hoseK60108 Ball Valve (Blue) comes with 6” hoseK60119 Valve, 1/3 psi Check Top of Filter Dryer / Oil SeperatorK60122 Valve, 3 psi Check Moisture IndicatorK6030004 Cord, FanK76019 Bracket, Hose WrapK76106 Panel, Fan Sheet MetalK76113 Bracket, Tank RetentionK76122 Door & HingeK76901 Cabinet, Complete Sheet MetalK80002 Wheel 10" Rear wheelK80003 AxleK90001 Cap, AxleK90011 Plate, Spring Used in Filter Dryer / Oil SeperatorK90041 Grommet (Heyco Bushing) for AC power cord and Wiring harnessK90301 Cup, Measuring For Oil PurgeK90302 Bin Kit, Plastic Storage Plastic Bins (Divided and Storage)K90420 Filter, Inline Inline Filter Assy. (Brass & Element)K90803 Latch, DoorK99013 Thermometer Sticker thermometer on inside doorK99444 Label, "Oil Purge Port" Part Of Label Kit K91062K99528 Label, Dry Dot, Green Part of Label Kit K91062K99529 Label, Dry Dot, Yellow Part of Label Kit K91062



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



WHAT COMES WITH YOUR MACHINE

Your new refrigerant recovery recycling center includes the following:

(2) 50 lb. DOT approved, refillable recovery tanks(2) Filter Cores(1) Spring Plate(1) Oil Measuring Cup(2) Front Casters(8) Front Caster Mounting Screws(8) Front Caster Mounting Nuts(1) Axle(2) Rear Wheels(2) Pal Nuts(2) Hose Wrap Brackets(1) Power Cord Bracket(6) Bracket Mounting Screws(1) Tank Retention Bracket(2) Mounting Screws(1) Set of Storage Bins(1) Operations Manual(1) Postage Paid Warranty Card(1) Supply of multiple refrigerant identification tank labels(1) List of Authorized Service Centers(1) MACS Certification information sheet(1) EPA Equipment Certification Form



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.



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.



SETTING UP THE UNIT

Required Tools:

Flat Edge Screwdriver9/16" WrenchVacuum PumpCharging Hose

General:

1. Remove the unit and tanks from the shipping carton.

2. Fill out postage paid warranty card and send in to manufacturer.

3. Review operations manual.

Installing the Wheels and Casters:

1. Feed the axle through the holes on the back part of the machine.

2. Slide a wheel through the axle and center the pal nut on the outer side of the axle.

3. Bracing the opposite end of the axle, push the pal nut onto the axle until it is tight.

4. Slide the other wheel on the remaining end of the axle and secure it with a second pal nut.

5. Using the eight (8) screws, nuts and locking washers, install the casters into the four holes provided in

the cabinet.

6. Insert the screws through the holes, attach the nuts and tighten.

7. Follow the same procedure for the second caster.

Installing the Brackets:

1. With the screws provided, install three brackets on the side of the machine.

2. Wrap the system vapor hose and the system liquid hose around the brackets.

3. Secure the hoses onto the hose storage mounting ports.

4. Wrap the power cord around the final bracket.

5. Install the tank retention bracket on the rear of the machine with the screws provided.

Installing the Filter Core:

1. Using a 9/16 inch wrench, remove the six nuts on the filter canister lid.

2. Remove the lid and set it aside.

3. 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.

4. Install the spring plate on top of the filter core with the spring facing up.

5. Install the canister lid on top and tighten the nuts in a crossing pattern with between 10 to 15 pounds

torque.



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. Remove the tank from its box and remove the plastic caps from the valve ports.

2. Connect a vacuum pump to the vapor valve, open the vapor valve, and pull a vacuum on the tank for

approximately two hours.

3. 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.

4. 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.

5. Attach the black tank sensor cord to the corresponding fitting on the tank.

6. 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.

7. The unit is now ready to recover and recycle.



RECOVERING AND RECYCLING

1. 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.

2. 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 low-

side port in this application.

NOTE: Be sure that when connecting the refrigerant recovery recycling machine to the system that youconnect 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 SERIOUSPERSONAL INJURY, WILL CAUSE IRREPARABLE DAMAGE TO YOUR MACHINE, AND WILL VOIDALL WARRANTY.

3. Make sure the unit is plugged into a standard 110 volt outlet.

4. 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 arestabilizing inside the tank.

5. Check for positive pressure on the gauge to make sure there's refrigerant in the system.

6. 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

7. 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.

8. 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. 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.

10. To determine how much oil was removed during the recovery process, simply read the cup which is

marked in both ounces and milliliters.

11. 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 vehiclesin succession, we suggest you let the fan continue to run; otherwise, turn the fan off by switching themain power switch to the "off" position.



If you are connecting your refrigerant recovery recycling center to an A/C charging station:

1. 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.

2. Install the parallel kit on the high and low side ports of the A/C charging station

3. 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.

4. Connect the system vapor hose and the system liquid hose from the refrigerant recovery recycling

center to the corresponding port on the parallel kit.

5. Connect the remaining ends of the A/C charging hoses to the high and low ports of the system.

6. Open the valves on the parallel kit if applicable; open the purge valve on the A/C charging station.

7. Then follow the previous instructions for starting your refrigerant recovery recycling machine.

8. 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 thesystem is void of refrigerant:

1. Open the vapor valve on the refrigerant tank and,

2. 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 orair purge features. PLEASE NOTE: There must be refrigerant in the tank prior to using this feature. After youhave pressurized the system, you can search for the system leak by utilizing standard leak detectionprocedures and equipment. Once the leak is located, remove the pressure test charge by depressing the cyclestart 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 importantto view the moisture indicator and hour meter for condition of the refrigerant only after the system shuts downand the recovery process is complete. If the indicator is green, the filter core is fine and you may continuerecovering and recycling similar refrigerant.

However, if the moisture indicator is more yellow than green, it is time to change the filter core. The hourmeter, indicates the total time the machine has run in the recovery mode. This allows the operator to keep trackof the total accumulated recovery time on the filter core. The filter core should be changed every 25 hours ofuse.



MOISTURE INDICATOR and HOUR METER continued

It takes approximately 1/4 pound of refrigerant passing through the moisture indicator to signal the condition ofthe refrigerant. If less than 1/4 pound of refrigerant is recovered, the moisture indicator may or may not turngreen. Remember, the only time to view the moisture indicator to determine the condition of the core and therefrigerant is DURING the oil purge process. Moisture Indicator replacement The moisture indicator in thismachine has been improved for easier field replacement.Occasionally, the element that changes from yellow to green will become fouled and require replacement. Thenew 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 willautomatically shut off once the recovery recycling tank becomes full of refrigerant. The tank full light will alsoilluminate 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 arestabilizing inside the tank.

HIGH PRESSURE CONDITION

The high pressure light will illuminate when there's high pressure on the discharge side of the recoveryrecycling system. The three main conditions that cause high pressure are:

1. If you haven't opened the liquid tank valve or the hand valve on the tank liquid hose.

2. If there is excessive air in the tank itself, or3. 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 highpressure situation before the machine will operate.



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 tanktemperature to stabilize at room temperature.

1. 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.

2. Depress and hold the pressure test button.

3. Read the amount of pressure in the tank by looking at the digital gauge on the front of the machine.

4. Determine the ambient temperature in the room.

5. Refer to the appropriate chart in figure 7 for the refrigerant type with which you are currently working.

6. Find that temperature on the chart and look across to the corresponding pressure and how it relates to

the pressure reading on the gauge.

7. 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.

8. Release the pressure test button. The pressure test button and the purge button must be depressed

through-out the air purge procedure.

9. Allow the tank to stabilize for 10 minutes and check the pressure again.

10. Repeat process and purge again ,if necessary.

11. 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 recycledrefrigerant.

1. Close both tank valves.

2. If your machine has hand valves on the TANK LIQUID and TANK VAPOR hoses, close them as well.

3. Disconnect the TANK LIQUID and TANK VAPOR hoses and the black tank full cord.

4. Remove the tank.

5. 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.

6. Install the second tank into the recovery machine. Refer to the tank installation procedures.




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 SAEJ1991 purity standards. The center is also UL listed for recovery of R-22, R-500, R-502 and R-12 from non-automotive applications. These refrigerants pass through the same filtration system; however, themanufacturer cannot guarantee the resulting purity since no standards for these refrigerants currently exist. It isimperative that you follow the procedures each time you recover a different type of refrigerant.

1. Remove the cap from the port on the filter shell and release any excessive pressure by depressing the

valve core.

2. Change the filter core by following the filter core replacement procedures discussed on page 16.

3. Close both valves on the white recovery recycle tank and disconnect the TANK VAPOR and TANK

LIQUID hoses and the black tank sensor cord.

4. Remove the tank.

5. 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.

6. 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.7. You are now ready to recover refrigerant.



FACTORY RECOMMENDED DAILY PROCEDURES

1. Prior to using the machine, check for excessive air pressure in the recovery tank and on the system

pressure gauge.

2. Check for oil by pressing the purge valve. Discharge any oil present into the measuring cup.

3. Make sure tank full sensor cord is fully engaged.

4. Check the condition of all service hoses for contamination before connecting to the A/C system.

5. Make sure all hoses are fully engaged at tank connections.

6. When unit is not in use, be sure to close both the liquid and vapor valves on the tank.

7. 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.

SECTION 1


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 yourpocket or behind your back. Before removing wires from the ACT-3300, always verify thatthe Tester is "OFF". Turn the Power/Mode Switch on the front panel to OFF and unplug theAC 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-positionrocker switch. There is no further AC distribution with the switch in the center-off position.

Page 5-1

NOTES:

Page 5-2

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 Recoverposition. 115VAC is distributed to the Crossover Solenoid (S2), Low Side Solenoid(S1), AC LineFilter, Fan, Air Purge Board and the Heater Blanket switch. The Air Purge Board provides DCvoltages 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 theEvacuation Charge position. 115VAC is distributed to the Evacuation Timer contact, the RefrigerationCharge Timer contact, the AC Line Filter, the Fan, and the Air Purge Board. The Air Purge Boardprovides DC voltages to the high and low Pressure transducers, the Start Recovery switch, the TankFull 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:


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. Theswitch is spring-loaded and returns to the open position when released. The Air Purge board controlsthe Compressor. It also monitors the compressors run time and initiates the Oil Return mode for 10seconds every 15 minutes. The compressor is running and the Recovery light is lit indicating themode. The hour meter starts to run and the Filter Core heater is energized.


In the Recovery Mode, refrigerant flows from both the high and low side vehicle ports through theCrossover (S2) and Low Side (S1) Solenoids to the Filter Dryer/Oil Separator. In the Filter Dryer/OilSeparator, refrigerant is separated from the vehicle's oil and sent out through the top port, thenthrough the check valve and to the compressor. From the Compressor, VAPOR refrigerant is sent tothe 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 coilchanges 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:


When the Recovery Mode is finished, the unit is shut down, and the Air Purge board energizes the AirPurge solenoid (S3), until 20 PSI of non-condensibles is sensed by the System Pressure TransducerP1. At that point the Air Purge Board will energize the Oil Purge Solenoid (S4). The Oil PurgeSolenoid will stay open for a period of 2.5 minutes, which is determined by the Air Purge Board.


When the LOW and HIGH side gauges reach 5-10 inches of mercury, the machine automaticallyshuts down. The Air Purge solenoid (S3) will be opened until 20 PSI is measured by the SystemPressure Transducer (P1). At that point, the Oil Purge solenoid will open and the 20 PSI of vaporrefrigerant will push out the oil removed from the Vehicle's Air Conditioning system into the oildischarge cup.

AIR PURGE MODE:


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. Toreduce the pressure, the Air Purge switch is depressed by the operator, and the Air Purge (S3) andOil Purge (S4) solenoids are energized for 10 seconds. The Air purge board then recalculates todetermine if the excess air has been purged. If all the excess air has not been purged, the solenoidsare then energized again for 10 seconds. This process continues until the air purge board hasdetermined that an excess air condition no longer exists


The excess pressure is purged from the tank through the Air Purge solenoid (S3) and the Oil Purgesolenoid (S4) to the Oil / Air Purge cup. Solenoids S1 and S2 are also on in this mode but are notinvolved.

AUTOMATIC OIL RETURN MODE:


The Compressor "ON" time is monitored by the Air Purge board. Every 15 minutes that thecompressor runs, the Oil Return solenoid (S5) is deenergized for 10 seconds.


During the 10 second Automatic Oil Return Mode, Oil from the Compressor's Oil Separator is pushedthrough the Oil Return solenoid (S5) and back into the Compressor via the suction port. This ensuresthe Compressor always has the right amount of oil.

Page 5-6

EVACUATION MODE:


With the Tester in the Evacuation Charge Mode, 110VAC is provided to the Evacuation Pump Timercontact 1. When the operator selects the desired vacuum time on the timer, AC to the RefrigerationCharge 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 thetiming 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 VacuumSolenoid (S8) is also energized.


With the High and Low Service Hoses attached to the vehicle system, the vacuum pump will pull avacuum on the vehicle system with the Vacuum Solenoid (S8) energized and open. If there are noleaks in the system, all gauges will hold steady. If there is more than 10 psi in the vehicle the vacuumpump lockout switch will be open, not allowing the vacuum pump to start. A reclaim must then beperformed before the evacuation can be performed.

OIL CHARGE MODE:


With a vacuum on the vehicle system, oil can be added to the system at the oil injection port. This isdone with the oil injection syringe. The cycle will be completed when the refrigerant pushes the oil intothe vehicle in the recharge mode.

CHARGE RECYCLED MODE:


When the Evacuation Pump Timer shuts off, contacts 1, 2 and 3 open. At the same time contacts 1and 4 close and distribute 110VAC to the Refrigeration Charge Timer. With the Refrigerant Selectswitch in the Recycled position, 110VAC is provided to the Recycle Charge Solenoid (S6) through thenormally 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 RefrigerantCharge Timer. While the charge amount is being set, the Charge Hold light will be lit through thenormally shorted contacts 1 and 5 of Relay 1.

To start the timing sequence, the spring-loaded Start Charge switch is depressed. The switchprovides a return for the Timer Motor. By keeping the switch depressed, pressure increases on thedifferential 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 ChargeSolenoid (S6) to energize. When relay 1 energizes, contacts 1 and 2 open, extinguishing the ChargeHold Light. The Charge Light will now be lit.

When the Start Charge switch is released, the charge will continue until the Refrigerant Charge Timerexpires. Then, contacts 1, 2, and 3 of the Refrigerant Charge Timer will open, removing the 110VACfrom the recycled charge solenoid (S6), relay 1 and extinguishing the Charging light.

Page 5-7

CHARGE RECYCLED MODE continued:


In the charge recycled mode, with a vacuum on the vehicle system, the Recycled refrigerant goesthrough the Recycle Solenoid (S6), In-Line Filter, a check valve, Flow switch, flow regulator, and tothe Vehicle Low Side Port. The Differential Pressure switch (PS4) is a normally opened switch. If thevacuum/pressure differential will not keep the switch closed, the switch opens, halting the charge ofrefrigerant by deenergizing the Recycle Solenoid (S6).

CHARGE VIRGIN MODE:


When the Evacuation Pump Timer shuts off, contacts 1, 2 and 3 open. At the same time, contacts 1and 4 close, distributing 110VAC to the Refrigeration Charge Timer. With the Refrigerant Selectswitch 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 willbe turned on to provide power to the heater blanket through the normally closed contacts of the VirginHigh 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 RefrigerantCharge Timer. While the charge amount is being set, the Charge Hold light will be lit through thenormally shorted contacts 1 and 5 of Relay 1.

To start the timing sequence, the spring-loaded Start Charge switch is depressed. The switchprovides a return for the Timer Motor. By keeping the switch depressed, pressure increases on thedifferential 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 toclose 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 ChargeLight will now be lighted.

When the Start Charge switch is released, the charge will continue until the Refrigerant Charge Timerexpires. Then, contacts 1,2, and 3 of the Refrigerant Charge Timer will open, removing the 110VACfrom the Virgin Charge Solenoid, relay 1 and extinguishing the Charging light.


In the charge virgin mode, with a vacuum on the vehicle system, the Virgin refrigerant goes throughthe Virgin Solenoid (S7), In-Line Filters, a Check Valve, Flow switch, flow regulator, and to the VehicleLow Side Port. The Differential Pressure switch (PS4) is a normally opened switch. If thevacuum/pressure differential will not keep the switch closed, the switch opens, halting the charge ofrefrigerant by deenergizing the Recycle Solenoid (S7).

Page 5-8

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 Recoverposition. You will see either "12" or "134a" displayed briefly. This should correspond to the type ofmachine you are working on. If the wrong notation is displayed the wrong Air Purge Board is installedin 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 theaccess 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 illuminateswhile charging VIRGIN refrigerant.

Empty or nearly empty tank. Insufficient Pressure.

Replace empty tank with a full tank.

Set POWER/MODE switch in RECOVER orEVACUATION/RECHARGE and heat tank for at least15 minutes before attempting to charge. Both doorsmust be closed.

II. CHARGE HOLD light illuminateswhile charging RECYCLEDrefrigerant.

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 vehiclesystem.

III. CHARGE HOLD light illuminateswhen setting the charge amountof RECYCLED refrigerant and thecharging process will not remainengaged when the STARTCHARGE is depressed.

Excessive pressure in RECYCLED refrigerant tank.(successive recovery operations or high ambienttemperature-over 90 F.)

Allow the tank to cool for 15 minutes. Charge amountcan be left on timer (check charge amount and resetvalve if (START CHARGE has been pressedrepeatedly.) When pressure decreases to a safe level,the refrigerant charging light will remain on when theSTART CHARGE button is pressed and the chargingprocess 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 CHARGEbutton.

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 seeif 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 electricaloutlet.

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 airpurge on recycled tank.

Vacuum timer on.

Turn off Vacuum Timer. To clean timer contacts, turntimer on then off several times, then retry.

Refrigerant Charge selector not set.

Set selector. To clean timer contacts, turn timer onthen off several times, then retry.

Charge tank has insufficient pressure.

If using virgin tank, turn on heater blanket forapproximately 15 minutes. If using recycled tank,charge approximately 1.5 lbs of virgin refrigerant intovehicle, then recover the charge.

Page 5-47

SECTION IV

PARTS______________________________________________________________________________________

_

GENERAL

This chapter describes assemblies, subassemblies, and parts considered replaceable by a qualified Sun FieldService Technician.












Page 5-49


ACT-3300/ACTR-3400 FRONT VIEW


1 Lamps 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

ACT-3300/ACTR-3400 ELECTRICAL RECOVERY SIDE VIEW


1 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

Page 5-51

ACT-3300/ACTR-3400 ELECTRICAL CHARGING SIDE VIEW


1 Shell, Filter 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

ACT-3300/ACTR-3400 TUBING RECOVERY/CHARGING SIDE VIEW


1 Tube, Float/Flow Valve K40534 5 Line, Oil Return K40833

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

Description PART NUMBER COMMENTSAdapter, 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


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

SUBSECTION B: PARTS IN ALPHANUMERIC ORDER

ACT-3300/ACT-3400

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 Package of 25

Grill, Fan K32531

Grommet (Heyco Bushing) K90041 for AC power cord and Wiring harnesses

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 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


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 On top of Filter Dryer / Oil Separator

Valve, Blue Ball K60108

Valve, Check K60119 Top and Bottom of Filter Dryer

Valve, Red Ball K60107

Valve, Check K60033 Vacuum Pump

Valve, Schrader K99010 Screw in Schrader Valve Package of 25

Wrap, Hose K76019

Page 5-57

Description PART NUMBER COMMENTSOil, Compressor 0681-0179-02 3GS Oil, 10 oz. in Compressor

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.

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


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

SUBSECTION C. PARTS IN NUMERICAL ORDER

ACT-3300/ACT-3400

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 R-12 and R-134a

Fitting, Kit Compressor K32032

Filter, AC Inline K32505 AC Power Filter

Fan K32511

Grill, Fan K32531

Drum, Vacuum Timer K33000 With Label

Drum, Refrigerant Timer K33001 With Label

Lock, Door w/Key K35070

Door, Lock and key K35070

Mat, Tool Tray K35152

Caster, Locking K35252

Label, Snap-On Logo K35403 Front Panel Snap-On Logo

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.

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


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 R-134a- On Top of Filter Dryer

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

Panel, Face K76345 R-134a

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 Sheet Metal

Door, Left R-134a K76392

Page 5-60

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

SECTION V

OPERATOR'S MANUAL

TABLE OF CONTENTSPage

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 MachineInstalling the Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67Installing the Hose Storage and Power Cord Brackets . . . . . . . . . . . . . . . . . . . . . 5-67Installing the Service Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67Installing the Oil Discharge Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67Installing the Filter Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67

Preparing the Machine for UseInstalling the Recycling Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68Installing the Virgin Tank of Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68

Recovering and RecyclingRecovering and Recycling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69Moisture Indicator and Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70Tank Full Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70High Pressure Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70Excess Air Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70Changing the Filter Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70

Evacuating and RechargingEvacuating the Vehicle A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72Adding Lubricant to the Vehicle A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72Recharging the Vehicle A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73Virgin Tank Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73Vacuum Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74Factory Recommended Daily Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74Calibration of Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. Toremove 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 resumingservice. Additional health and safety information may be obtained from refrigerant and lubricantmanufacturers.

To avoid unfortunate accidents, only technicians who have had experience and are properly trained inrefrigerant 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 stopand 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 OFREFRIGERANT. WHITE INDUSTRIES IS NOT RESPONSIBLE FOR LOSS OF REFRIGERANT OR FORANY LOSS OR DAMAGE CONSEQUENTIAL TO THE LOSS OF REFRIGERANT DUE TO OPERATORERROR 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 originalequipment 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. Support the center of the machine with the four (4) cardboard corner pieces from the shipping carton.2. Install the fixed casters using the screws and nuts provided.3. Install the nuts on the inside of the cabinet to provide wheel clearance.

Installing the Hose Storage and Power Cord Brackets:

1. With the screws provided, install the two (2) supplied storage brackets with the hose mounting ports inthe top two (2) sets of holes provided on back of machine.

2. Install the remaining storage bracket in the bottom set of holes provided on the back of the machine.3. Loosely wrap the power cord around the bottom cord bracket.

Installing the Service Hoses:

1. Install the 8 foot blue service hose on the A/C system low port on the back panel of the machine.2. Install the 8 foot red service hose on the A/C system high port on the back panel of the machine.3. 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. Remove the shipping plug from the discharge port on the recharging (right) side, then install the oildischarge cups on the slots provided on the underside of both the recovery system and rechargingsystem shelf.

TIP: You may need to squeeze the cup slightly to assist you in installing the oil discharge cups.2. Install the third oil discharge cup in the bracket provided on the inside of the recharging doors.3. 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 itsservice 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. Remove the recycle tank from the box and remove the plastic caps from the valve ports.2. Place the tank in the left cabinet compartment.

3. Connect the TANK LIQUID hose to the liquid valve on the tank and open both the valve on the hoseand the liquid valve on the tank.

4. Connect the YELLOW auxiliary Vacuum hose to the vapor valve on the tank. Connect the remainingend of the YELLOW hose to the Auxiliary Vacuum Port and make sure the vapor valve on the tank isopen.

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 willnot 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 auxiliaryvacuum 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 tankand on the hose.

Installing the Virgin Tank of Refrigerant:

1. To install a virgin tank of refrigerant connect the TANK LIQUID hose located in the right-handcompartment to a virgin tank of the appropriate refrigerant, and open both the valve on the tank andthe valve on the hose.

2. Place the virgin tank in the right-hand compartment with the tank sitting on its handles (inverted).3. Pull the two straps on the heater blanket until the blanket is wrapped securely around the tank.4. Secure the tank with the bungee cord provided and close the cabinet door. The heater blanket will

only operate when both doors are closed.5. 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 warmrefrigerant. A warm engine will decrease recovery time. After the vehicle's engine has warmed, turnthe vehicle's engine off.

1. The BLUE service hose connects to the low side service port on the vehicle's system and the REDservice hose connects to the high side port on the vehicle's system.

2. Make sure the power cord is plugged in, and both the tank valves and hose valves are open. Closeand lock the cabinet doors.

3. Check for positive pressure on the LOW and HIGH side pressure gauges of the machine to makesure there is refrigerant in the vehicle's system. If there is no positive pressure (e.g. no refrigerant is inthe system), DO NOT RECOVER.

4. Set the POWER/MODE switch to RECOVER. When you turn this switch on, the fan turns onautomatically. As long as the POWER/MODE switch is on, the fan will remain on and continue to coolthe machine.

5. Depress and hold the STRAT/RECOVER button for approximately three seconds. The RECOVERYlight will illuminate.

6. Ensure that refrigerant is flowing across the moisture indicator and the RECOVERY light isilluminated. You should see the LOW and HIGH side gauges begin to drop.

7. 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 cuplocated inside the left-hand door on the underside of the upper compartment. (This process couldtake up to 2 1/2 minutes and there may be little or no oil removed.)

8. To determine how much oil was removed during the recovery process, simply remove the cup andread 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 mixlubricants. Check with vehicle manufacturers published service procedures for correct lubricant.

9. Dispose of the oil in accordance with any federal, state, or local ordinances and reinstall the cup.10. 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 avacuum for two (2) minutes.

11. View the moisture indicator and the hour meter immediately after recovering to determine thecondition of the filter core per the instructions on page 5-66

12. 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 ison. Although the fan does not need to remain on indefinitely, if you are going to service a series ofvehicles in succession, it is suggested you let the fan continue to run; otherwise, turn the fan off byswitching 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./Csystem, into the machine, through the filtration system, and into the tank. The refrigerant in the tankat this time is clean and there is NO separate recycling operation required. It is a true one-passfiltration 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 importantto view the moisture indicator and hour meter for condition of the refrigerant only after the system shuts downand the recovery and recycling process is complete. If the indicator is green, the filter condition is fine and youmay continue recovering and recycling refrigerant. However, if the moisture indicator is more yellow thangreen 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 therecovery mode. This allows the operator to keep track of the total accumulated recovery time on the filtercore. 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 thecore and the refrigerant, is immediately AFTER the machine has shut off and the recovery and recycleprocess is complete.

TANK FULL LIGHT

Your machine has a TANK FULL light which will illuminate. The machine will automatically shut off once therecycling tank becomes full of refrigerant. The TANK FULL light will also flash and shut the system off if thetank 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 thetank is in a vacuum.

When the TANK FULL light illuminates:

1. Make sure the tank sensor cord is fully engaged. (The index slot must be aligned to make a completeconnection.)

2. 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 recoverysystem. The main condition that causes high pressure is failure to open the valves on the tank and /or thevalves 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 mustremedy the high pressure condition before the machine will operate.

To remedy a high pressure condition:

1. Make sure both valves on the tank and both valves on the tank hoses are fully open.2. 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 lightilluminates:

IMPORTANT!!Do not Air Purge when hooked to an A/C System.

1. Properly dispose of any oil in the vehicle system oil discharge cup and reinstall.2. 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


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 couldexceed 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. Change the filter core per the instructions below, "To Change the Filter Core."

2. Close the vapor valve on the recycle tank and the valve on the TANK/VAPOR hose.3. Disconnect the TANK VAPOR hose from the recycle tank.4. Connect the vehicle system "high" pressure hose to the vapor valve on the recycle tank.5. Open the vapor valve on the tank and the valve on the system "high" pressure hose.

6. Set the POWER/MODE switch to RECOVER, the POWER switch on, and press the STARTRECOVERY button.

7. Allow the machine to run in the recovery mode for approximately one hour. The moisture indicatorshould be green at this time.

8. Close the vapor valve on the recycle tank and allow the machine to shut off automatically.9. 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.10. Open the vapor valves on the tank and on the hose.11. The machine is now ready to continue recovering.

To Change the Filter Core:

1. Remove the cap from the port on the filter shell and release any residual pressure or vacuum bydepressing the valve core.

2. Remove the lid from the shell and take out the spring plate. If the gasket on the inside of the filtershell lid is damaged, remove it.

3. Attach a magnet to the metal plate on the filter core and remove the core. This used filter core doesnot contain hazardous material, so you may dispose of the used core in a responsible manner.

4. Remove the new filter core from the sealed canister and immediately install the new core into the shellwith the metal end on top. A new gasket is supplied with each filter core to use in the event thegasket in the filter shell lid has been damaged.

5. Install the spring plate on top of the filter/core with the spring facing up.6. 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.)

7. After installing the new core, attach the YELLOW auxiliary hose between the service port on top ofthe filter shell and the Auxiliary Vacuum Port on the back of the machine.

8. 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.

9. 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. Connect the 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.3. Set the desired vacuum time on the timer.4. When the timer shuts off, gauge readings should hold if there are no leaks in the vehicle system.NOTE: 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 theevacuating 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 thelubricant 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 aminimum 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. Tocharge RECYCLED refrigerant the following criteria must be met:

a. a minimum of 10 pounds of refrigerant in tank, ORb. 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, ORb. 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.

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VACUUM PUMP MAINTENANCE

After every 25 evacuations or after evacuating a system that has been open to the atmosphere for aprolonged 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. Open the petcock in the bottom of the pump through the access hole located to the left and behind theoil discharge cup.

2. Allow all of the oil to drain into a container capable of holding at least 12 ounces and dispose of the oilin accordance to federal, state, and local ordinances.

3. Close the petcock.

4. Connect the YELLOW auxiliary hose to the Auxiliary Vacuum port on the back of the unit.5. 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. Make sure tank full sensor cord is fully engaged and the cord is not pinched.2. Visually check the condition of all service hoses for contamination before connecting to the A/C

system.3. Make sure all hoses are fully engaged at tank connections.4. When machine is not in use, be sure to close tank valves and tank hose valves.5. 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/RECHARGEposition. Verify that the machine gauges come on and read 0 or 1 PSI. If reading is not accurate, recalibrateto 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. Insert small flat blade screwdriver into small hole next to gauge.b. 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.

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STORAGE PROCEDURE

WHEN STORING THIS MACHINE FOR A PROLONGED PERIOD, A FEW SIMPLEPRECAUTIONS 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. 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.

2. Make sure all hoses are sealed on their ports or hangers.3. Make sure all valves on the hoses and tanks are closed.4. Pull a vacuum for five (5) minutes on the low side hose, leave this vacuum on the hose during storage.5. 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

SECTION I AC POWER DISTRIBUTION...ELECTRICAL (REFER TO FIGURE 1-7) With the Vacuum Switch in the...

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