MAHLE ACX1180 User manual

MAHLE ACX1180
EN
Original instructions
AC Service Units

© MAHLE
2 | ACX1180 |en
1 . Sym b ol s u se 4
1.1 In the documentation 4
1.1.1 Warning notices—Structure and meaning 4
1.1.2 Symbols in this documentation 4
1.2 On the product 4
2. Important notes 4
2.1 User group 4
2.2 Agreement 4
2.3 Obligation of contractor 5
2.4 Safety regulations 6
2.4.1 ACX1180 6
2.4.2 Refrigerant identication unit 7
2.5 Safety devices 7
3. Product description 8
3.1 Application 8
3.2 Scope of delivery 8
3.3 Description of unit 9
3.3.1 Selection and function keys 10
3.3.2 Input keys 10
3.3.3 Printer (Optional) 11
3.3.4 Service doors 11
3.3.5 Oil bottles 12
3.3.6 Service quick-release couplings 12
3.3.7 Inline lters 13
3.3.8 Locking caster brakes 13
3.3.9 Power supply cable and switch 13
3.4 Refrigerant identication unit (Optional) 13
3.4.1 Delivery 13
3.5 Functional description 14
4. Commissioning 15
4.1 Removing transportation packaging 15
4.2 Attaching handle 15
4.3 ACX1180 16
4.3.1 Setting language 16
4.3.2 Setting date and time 16
4.3.3 Activating / deactivating
printer, buzzer 16
4.4 Setup 16
4.4.1 Selectable Options 16
4.4.2 Default Values 17
4.4.3 Maintenance Options 17
4.4.4 Total Capacities 17
4.6 Filling internal refrigerant bottle 18
4.5 Checking type of connection of
external refrigerant bottle 18
5. A/C service preparation 19
6. Operation 20
6.1 Service phases 20
6.2 A/C Database 20
6.3 Refrigerant identication unit 20
6.3.1 Refrigerant analysis 20
6.4 Automatic A/C service 21
6.5 Manual A/C service 21
6.6 Automatic/manual vehicle A/C
service overview 22
6.6.1 Recovery 22
6.6.2 Vacuum 22
6.6.3 Charging with refrigerant 22
6.7 Flushing after changing type of oil 22
6.8 Setting service parameters 22
6.9 Non-condensable gases 23
Contents

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| ACX1180 | 3ACX1180 | 3| 3 en
7. Maintenance 24
7.1 Maintenance interval 24
7.2 Calibration of refrigerant scale 24
7.3 Calibration check 24
7.4 Replacing inline lters 24
7.5 Vacuum pump 25
7.5.1 Changing vacuum pump oil 25
7.6 Combo lter 26
7.6.1 Changing Combo-Filter 26
7.6.2 Resetting lter replacement interval 26
7.7 Software update 27
7.8 Replacing printer paper 27
7.9 Replacing white sample lter
(Refrigerant identication unit) 27
7.10 Resetting the circuit breaker 27
7.11 System information 27
7.12 Spare and wearing parts 28
7.12.1 ACX1180 28
7.12.2 Refrigerant identication unit 28
8. Disposal 28
8.1 Disposal of electronic parts 28
8.2 Disposal of LCD screen 28
8.3 Disposal of refrigerants, UV dye,
lubricants and oils 28
8.4 Disposal of combo lter 28
9. Technical data 29
9.1 ACX1180 29
9.2 Electromagnetic compatibility 29
10. Glossary 29
11. Notes 30

© MAHLE
4 | ACX1180 | Symbols useen
1. Symbols use
1.1 In the documentation
1.1.1 Warning notices—Structure and meaning
Warning notices warn of dangers to the user or people in
the vicinity. Warning notices also indicate the consequences
of the hazard as well as preventive action. Warning notices
have the following structure:
Warning
symbol
KEY WORD – Nature and source of hazard!
Consequences of hazard in the event of fail-
ure to observe action and information given.
h Hazard prevention action and information.
The key word indicates the likelihood of occurrence and the
severity of the hazard in the event of non-observance:
Key word Probability of
occurrence
Severity of danger
if instructions not
observed
DANGER Im m ed iat e impending
danger
Dea t h or sever e injury
WARNING Possible impending
danger
Dea t h or sever e injury
CAUTION Possible dangerous
situation
M i nor injury
1.1.2 Symbols in this documentation
Symbol Designation Explanation
m
Attention Warns about possible property damage.
t
Information Practical hints and other
useful information.
1.
2.
Multi-step
operation
Instruction consisting of several steps.
hOne-step
operation
Instruction consisting of one step.
Intermediate
result
An instruction produces a visible
intermediate result.
Final result There is a visible final result on
completion of the instruction.
1.2 On the product
m
Observe all warning notices on products and ensure they
remain legible.
h Wear protective goggles.
h Wear protective gloves.
2. Important notes
Before start up, connecting and operating
MAHLE products it is absolutely essential that
the Original instructions/owner’s manual and,
in particular, the safety instructions are studied
carefully. By doing so you can eliminate any uncertainties in
handling MAHLE products and thus associated safety risks
upfront; something which is in the interests of your own
safety and will ultimately help avoid damage to the device.
When a MAHLE product is handed over to another person,
not only the Original instructions but also the safety instruc-
tions and information on its designated use must be handed
over to the person.
2.1 User group
The product may be used by skilled and instructed
personnel only. Personnel scheduled to be trained,
familiarized, instructed or to take part in a general
training course may only work with the product under
the supervision of an experienced person.
All work conducted on pressurized equipment may be
performed by persons with sufficient knowledge and
experience in the field of refrigeration, cooling systems
and coolants and, also be aware of the risks involved in
the use of pressurized devices.
2.2 Agreement
By using the product you agree to the following regulations:
Copyright
Software and data are the property of MAHLE or its sup-
pliers and protected against copying by copyright laws,
international agreements and other national legal regula-
tions. Copying or selling of data and software or any part
thereof is impermissible and punishable; in the event of any
infringements MAHLE reserves the right to proceed with
criminal prosecution and to claim for damages.

© MAHLE
Sym b o l s u s e | ACX 1 1 8 0 | 5ACX1180 | 5| 5 en
2.3 Obligation of contractor
The contractor is obliged to ensure that all measures geared
towards the prevention of accidents, industrial diseases,
labor-related health risks are taken and measures towards
making the workplace fit for people to work in are carried
out.
Basic rules
The contractor is bound to ensure that all electrical equip-
ment and operating material is set up, modified and main-
tained by skilled electricians only or under the guidance
and supervision of a skilled electrician in accordance with
electrical engineering principles.
Furthermore, the contractor must ensure that all electrical
equipment and operating material is operated in keeping
with electrical engineering principles.
If a piece of electrical equipment or operating material is
found to be defective, i.e. it does not or no longer com-
plies with electrical engineering principles, the contractor
must ensure that the fault is rectified immediately and, in
the event that imminent danger exists, also ensure that the
electrical equipment or the electrical operating material is
not used.
Tests:
y The contractor must ensure that all electrical systems
and equipment are tested by a qualified electrician or
under the guidance of a qualified electrician to ensure
they are in proper working order:
— Before starting for the first time.
— After modification or repair before starting for the
first time.
— At given intervals. Set intervals such as to ensure
that faults that can be expected to occur are deter-
mined in good time.
y The test is to take the electrical engineering principles
relating hereto into account.
y Upon request of the trade association, a test manual is
to be maintained into which specific entries are made.
Liability
All data in this program is based—where possible—on
manufacturer and importer details. MAHLE does not accept
liability for the correctness and completeness of software
and data; liability for damage caused by faulty software and
data is ruled out. Whatever the event, MAHLE liability is re-
stricted to the amount for which the customer actually pays
for this product. This disclaimer of liability does not apply to
damages caused by intent or gross negligence on the part
of MAHLE.
War r an t y
Any use of non-approved hardware and software will result
in a modification to our product and thus to exclusion of any
liability and warranty, even if the hardware or software has
in the meantime been removed or deleted.
No changes may be made to our products. Our products
may only be used in combination with original accessories
and original service parts. Failing to do so, will render null
and void all warranty claims.
This product may only be operated using MAHLE ap-
proved operating systems. If the product is operated using
an operating system other than the approved one, then
our warranty obligation pursuant to our supply conditions
will be rendered null and void. Furthermore, we will not be
held liable for damage and consequential damage incurred
through the use of a non-approved operating system.

© MAHLE
6 | ACX1180 | Symbols useen
2.4 Safety regulations
2.4.1 ACX1180
Always carefully study and follow all the safety regulations
before using the MAHLE product.
Avoid all skin contact with the refrigerant. The
low boiling point of the refrigerant (approx.
–30°C) can lead to frostbite. Should refrigerant
come into contact with the skin, remove any
moistened clothing immediately and rinse the
area of skin affected with generous amounts of
water.
y Avoid all skin contact with the UV dye. Should UV dye
come into contact with the skin, remove any moistened
clothing immediately and rinse the area of skin affected
with generous amounts of water.
y R134a is colorless, with weak characteristic smell and
heavier than air. It may flow into repair pits. Should re-
frigerant escape, provide for sufficient ventilation
(particularly in repair pits) and leave the workshop.
Never inhale refrigerant, dye and oil vapors. The
vapors can irritate the eyes, nose and respiratory
system. If liquid refrigerant or UV dye comes into
contact with the eyes, rinse them thoroughly
with water for 15 minutes. Then obtain medical
attention even if no pain is felt.
y Never swallow UV dye. Should it be swallowed inadvert-
ently, never attempt to induce vomiting. Drink generous
amounts of water and obtain medical attention.
y Before connecting the ACX1180 to a vehicle air condi-
tioning system or an external refrigerant bottle, make
sure the quick-release couplings are not leaking. Only
ever use external refrigerant bottles provided with safety
valves and certified inline with the applicable standards.
y Before switching off the ACX1180, make sure all charg-
ing and drainage operations have been completed. This
prevents damage to the unit and reduces risk of refriger-
ant escaping into the environment.
Never use compressed air with R134a. Certain
mixtures of air and R134a are highly flammable.
Such mixtures are a potential hazard and may
lead to fire or explosions and thus cause dam-
age or injury.
y Refrigerant extracted from a vehicle air conditioning
system may be contaminated with moisture, lubricant,
dirt and traces of other gases.
y The ACX1180 is provided with a refrigerant identification
system designed to prevent contamination with other
refrigerants.
y If the refrigerant has been contaminated by being mixed
with other gases, remove the contaminated refrigerant
and add fresh R134a before using the ACX1180 for A/C
service.
y R134a is not to be used in areas in which there is a
danger of explosion. Fire, open flames and smoking are
prohibited. Welding and soldering are not permitted.
y
y
The ACX1180 unit should not be exposed to excess
moisture or be operated in wet areas.
y R134a is not to be mixed with other refrigerants. The
mixing of refrigerants could damage the vehicle air con-
ditioning system.
If high-voltage components or high-voltage
wires are handled incorrectly, there is a risk of
fatal injury from high voltage and the possible
transmission of current through the body.
y De-energizing is only to be performed by a qualified
electrician, a qualified electrician for specific tasks (hy-
brid) or a power systems engineer.
y Work on vehicles with high-voltage components is only
ever to be performed in a safe, de-energized condition
by persons with the minimum qualification "Trained to
perform electrical work".
y Even after deactivating a high-voltage vehicle electrical
system, the high-voltage battery may still be live.
y Operating condition cannot be established from any
running noise, as the electric machine is silent when
stationary.
y In gear positions "P" and "N" the engine or electric
motor may start spontaneously depending on the charge
of the high-voltage battery.
y Never open or damage high-voltage batteries.
y On vehicles that have been in an accident, never touch
high-voltage components or exposed high-voltage
wires before deactivating high-voltage vehicle electrical
system.
y The ACX1180 must be constantly monitored when in
operation. Never leave the ACX1180 unattended when in
operation.
y Vehicle A/C service using the ACX1180 must be pre-
pared and implemented such that the vehicle air condi-
tioning system circuit does not have to be opened (for
example by removing the radiator or engine).
y Position the ACX1180 on all four wheels on a flat,
vibration-proof surface so that proper operation of the
scales is guaranteed.
y The ACX1180 can be secured in position by locking the
caster brake.
y The ACX1180 must always be transported in its operat-
ing position. Never lay the ACX1180 on its side, as oil
could then escape from the vacuum pump or the built in
compressor could be damaged.

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Sym b o l s u s e | ACX 1 1 8 0 | 7ACX1180 | 7| 7 en
y There are no additional safety systems for protecting the
ACX1180 against damage resulting from natural catas-
trophes.
y Never remove any components from inside the ACX1180
except for maintenance or repair purposes.
y Follow the pertinent legal regulations or directives to
ensure safe handling of pressurized devices.
y We recommend calibrating the scales at least once per
year. Contact customer service for calibration of the
scales.
y The ACX1180 must be subjected to regular maintenance
by service personnel or authorized agents to ensure the
safety of the unit.
y Disconnect power before performing any maintenance or
service to unit.
y Never perform any maintenance work which is not ex-
pressly recommended in this manual. Contact customer
service if components have to be replaced other than in
the course of maintenance work.
y ACX1180 must be connected to a properly grounded
electrical connection.
y If there is damage to the ACX1180, terminate usage im-
mediately and contact customer service.
y The service hoses and service quick-release couplings
must be regularly checked for wear and replaced if dam-
aged.
y The ACX1180 must be operated in an environment that
will provide at least four air changes per hour.
y Observe local laws or directives as to ensure the safety
of the pressurized device.
y For safety reasons it is advisable to use a residual cur-
rent operated circuit breaker (rccb) with the following
specifications:
Parameters Specification
Rated voltage 120 VAC ± 10 %
Rated frequency 50/60 Hz
Rated current 10 A
Rated tripping current 30 mA
Tripping switch C
• Avoid using an extension cord with the unit. If necessary,
use a good condition (three wire grounded, #14AWG or
larger) extension cord of the shortest possible length. In
addtion, the current drawn by all devices connected to
the wall socket must not exceed 15A total.
2.4.2 Refrigerant identification unit
y Inspect the outside diameter of the white sample filter
element before and after each use of this unit. As soon
as red spots begin to appear on any portion of the white
element outside diameter, the filter requires replacement.
Failure to replace the filter when so indicated may result
in damage to the identification unit (out of warranty).
y This unit requires connection of the sample fitting to the
LP side port of the source vehicle or refrigerant cylinder.
Connection of the test hose to the high, or liquid, port of
the source vehicle or refrigerant bottle will result in dam-
age to the unit (out of warranty).
y Inspect the test hose before and after each use of the
unit. Immediately replace the hose if it appears cracked,
obstructed, or fouled with oil.
y Never use a test hose other than those approved for use
with the Identifier.
y Never connect the Identifier to any refrigerant source that
exceeds 300 psi pressure.
2.5 Safety devices
Description Function
Pressure switch Switches the compressor off if the normal
operating pressure is exceeded.
Safety valve The safety valve opens if the design pressure
is exceeded.
Circuit Breaker Interrupts the power supply if overcurrent is
applied to the ACX1180.
Vents The ACX1180 is provided with vents
in the bottom of the housing to ensure the
exchange of air even when switched off.

© MAHLE
8 | ACX1180 | Product descriptionen
3. Product description
3.1 Application
ACX1180 is suitable for vehicles with a conventional engine
as well as for hybrid and electric vehicles. ACX1180 features
all the functions required for vehicle A/C service.
The following functions can be implemented:
y Refrigerant recovery and recharging.
y Vacuum generation.
y Flushing.
y Refrigerant identification.
m The ACX1180 can only be operated with R134a. The
ACX1180 is not to be used for service work on vehicles
with air conditioning systems employing refrigerants
other than R134a, as this will cause damage. Prior to
A/C service check the type of refrigerant used in the
vehicle air conditioning system.
3.2 Scope of delivery
Description
Handle
Service hose (high pressure)
Service hose (low pressure)
Quick-release coupling (high pressure)
Quick-release coupling (low pressure)
Used oil bottle
Original instructions
Quick manual
Adapter (external bottle)
US Acme 1/2
Calibration check ball
Inline filter set (2x)
Refrigerant identifier (optional item)
Printer (optional item)
Fresh oil bottle ("C" version units only)
1) May be included in delivery, depending on the version ordered

© MAHLE
Product description | ACX1180 | 9ACX1180 | 9| 9 en
Fig. 2: Rear view
1 Service door for used oil and vacuum pump oil
2 Power supply cable inlet, circuit breaker
3 Fan
4 Power supply cable
5 Kick plate
6 Spare refrigerant bottle/Flush device storage shelf
Fig. 3: Left-rear view
1. Low-side parking/ush adapter (depending on unit model)
2. High-side parking/ush adapter (depending on unit model)
3. Service hose
4. Service hose connections
5. Power switch
6. Used oil bottle
7. Vacuum pump oil ll access port
8. Service door for oil bottles and vacuum pump
3.3 Description of unit
Fig. 1: Front view
1 Rear handle and grip
2 Tool tray and storage
3 Display and operating unit
4 Front handle
5 ACX1180 front housing
6 Locking caster
7 Rear wheel
8 Service door
9 Vacuum pump sight glass viewing window
10 USB port

© MAHLE
10 | ACX1180 | Product descriptionen
Fig. 4: Display and operating unit
1 TechALERT mounting area (Accessory)
2 LCD
3 Selection and function keys
4 Refrigerant identier (Accessory)
5 Printer (Accessory)
6 Low-pressure gauge
7 Input keys
8 High-pressure gauge
The pressure gauges (Fig. 4, Pos. 6, 8) of the display and
operating unit are used to monitor the pressure during the
individual vehicle A/C service phases. The status of the
various service phases during maintenance is displayed on
the multicolor LCD screen (Fig. 4, Pos. 2). The necessary
entries are made by way of the input keys (Fig. 4, Pos. 7) on
the keypad.
The selection and function keys (Fig. 4, Pos. 3) on the
keypad are used to control the operator interface menu
options.
MAHLE supplies a USB stick for updating the ACX1180
software. If required, the USB stick can be inserted in the
USB socket to perform updating of the firmware/software.
t Refer to Section 7.9 for detailed information on the
software updating procedure.
3.3.1 Selection and function keys
Keys Name Function
Yes Confirm and store
No Stop procedure, Exit menu
 or 
Up or down control
 or 
Right or left control
Automatic Takes operator directly to Automatic process
Recycle Takes operator directly to Recycle process
Vacuum Takes operator directly to Vacuum process
Charge Takes operator directly to Charge process
Unit of
Measure
Toggle units displayed on LCD display.
Various functions are assigned to the function keys in the
ACX1180 software. The functions of the keys are defined in
the menu line of the ACX1180 software.
3.3.2 Input keys
The input keys can be used to enter letters, numbers and
special characters in the input boxes. If a key is pressed
several times in succession in the input box, all the
characters which can be used for this are displayed.
t Pressing the #4 key when at the main menu provides
quick access to the Language selection screen. Follow
on-screen instructions to change language.
t Pressing the #7 key when at the main menu does an
automatic Oil Drain process.

© MAHLE
Product description | ACX1180 | 11ACX1180 | 11| 11 en
3.3.3 Printer (Optional)
t Service reports can be printed out.
m Protect thermal printer paper against direct sunlight,
heat,oils, greases, tanning agents and materials
containing plasticizers (e.g. PVC folders).
t If print to flash drive is enabled (See Selectable Options
section) and a flash drive is inserted in USB port, a dupli-
cate report will be generated. Files are saved to USB as
a text file by date.
3.3.4 Service doors
t There are two service doors: One on the left side and
one on the rear of the housing.
t Tools can be placed on the upper cover.
t The service door on the side provides access to the the
internal refrigerant bottle, and the filter drier.
t The service door on the rear permits access to the
Vacuum pump oil fill/drain and used oil.
Fig. 5: Opening service door on back
To open the service door on the cover, remove the two Phil-
lips head screws and take out the service door.
Fig. 6: Removing service door
m Never attempt to operate the ACX1180 without service
doors, as this would make the working area dangerous.
The housing of the ACX1180 was designed with a built-
in ventilation fan to prevent the accumulation of poten-
tially flammable R134a refrigerant vapors.

© MAHLE
12 | ACX1180 | Product descriptionen
3.3.5 Oil bottles
The used oil bottle should be checked prior to every service
to ensure there is sufficient room for any oil that is recov-
ered during the A/C service.
Used oil bottle
t To remove the used oil bottle, twist connection counter-
clockwise and remove bottle.
Fig. 7: Removing used oil bottle
1 Connection
Sym b ol Des cr ip t ion
Used oil bottle
3.3.6 Service quick-release couplings
t The service quick-release couplings are connected to
the service connections of the vehicle air conditioning
system during A/C service. When not in use, the service
quick-release couplings can be connected to the park-
ing/flush couplers.
t To remove the service quick-release couplings from the
parking/flush coupler, (Fig. 8, Pos. 2), press the coupling
slightly towards the connection and carefully pull the
knurled section back to unfasten it from the coupler.
Fig. 8: Unfastening quick-release coupling
To connect the coupling, position the coupling on the park-
ing coupler/Flush adapter, pull back the knurled section of
the coupling element and press carefully onto the connec-
tion.

© MAHLE
Product description | ACX1180 | 13ACX1180 | 13| 13 en
3.3.7 Inline filters
The service hoses are connected to the ACX1180 by way of
the inline filters. The inline filters prevent the ingress of fine
particles into the internal hydraulic circuit of the ACX1180.
1 Adapter for connection
2 Filter element
3 Adapter for hoses
4 Sealing ring
3.3.8 Locking caster brakes
Rolling of the ACX1180 can be prevented by locking the
caster brakes (Fig. 1, Pos. 6) at the rear wheels.
3.3.9 Power supply cable and switch
The power supply cable is connected to the back of the
unit. When not in operation, the power supply cable can
be coiled up and set on the spare tank storage area on the
back of the ACX1180.
The ACX1180 is switched on by toggling the rocker switch
to the On position.
3.4 Refrigerant identification
unit (Optional)
The refrigerant identification unit permits precise determina-
tion of the type of refrigerant as to prevent cross contamina-
tion by other refrigerants.
m Only after successful identification of refrigerant, service
hoses may be connected to the vehicle.
t The refrigerant identification unit is incorporated into the
service procedure and thus always to be used for A/C
service.
3.4.1 Delivery
Fig. 9: Refrigerant identication unit—delivery
1 Refrigerant identication unit
2 White sample lter

© MAHLE
14 | ACX1180 | Product descriptionen
3.5 Functional description
The ACX1180 was designed with menu driven prompts on
the display to guide technician through the service setup.
The display shows data such as the internal cylinder weight
and prompts technician for input using the alphanumeric
keypad and various navigation buttons.
The ACX1180 can be used to perform a fully automatic A/C
service. The technician will be prompted for entry of data
such as charge amount and given options such as perform-
ing leak tests. Once necessary data has been entered, the
ACX1180 will automatically complete an A/C service and
alert the technician for interaction (if necessary) or when
complete.
The ACX1180 can be used to perform the individual
functions of an A/C service as well (Recycle, Vacuum or
Charge).
A setup routine can be used to select specific options, set
default values, perform maintenance operations and man-
age fluid capacities processed.
The refrigerant recovered from the air conditioning system
passes through the combo filter to remove suspended
particles and moisture.
The purpose of the vacuum pump is to generate a vacuum
in the air conditioning system which removes excess mois-
ture and to detect possible leaks in the vehicle air condition-
ing system.
Used oil separated from the vehicle refrigerant recovered
drains into the used oil bottle.
Oil removed from the vehicle A/C system compressor dur-
ing the recovery process should be manually injected into
the A/C system prior to recharging the system.
The vehicle air conditioning system is partly filled with UV
dye to facilitate the detection of leaks in the event of dam-
age to the vehicle air conditioning system.
The refrigerant in the internal refrigerant bottle is used for
filling the vehicle air conditioning system.
The purging unit for the non-condensable gases, consisting
of a temperature sensor, pressure sensor, coil and orifice,
always takes effect when the internal refrigerant bottle pres-
sure is higher than the saturation pressure.
Refrigerant identification is a menu-driven process imple-
mented by a refrigerant identification unit which is integrat-
ed into the ACX1180 (when option is turned on).

© MAHLE
Commissioning | ACX1180 | 15ACX1180 | 15| 15 en
4. Commissioning
t All the operations described in Section 4 must be
performed prior to first A/C service.
4.1 Removing transportation packaging
t
When removing the packaging, use care to ensure there
is no damage caused to the ACX1180 unit or any of the
included accessories.
1. Remove the cardboard box.
2. Remove screw from metal strap at front of unit.
3. Remove screws from straps at rear of unit.
4. Remove the straps from the slots at rear of unit.
5. Using a wrench, remove the nut from the bolt at front of
unit to remove metal strap.
6. Remove cardboard blocks from under ACX1180 unit.
7. Remove ACX1180 from pallet.
t Do not unplug any electrical connections and only have
internal components opened and repaired by trained
customer service personnel.
t Contact customer service in the event of any transporta-
tion damage (e.g. oil leakage).
4.2 Attaching handle
1. Remove plastic bubble wrap from handle.
2. Remove bolt from rear handle mounting hole (both sides
of ACX1180 unit).
3. Rotate handle upwards and over top of the handle
mounting spacers.
Fig. 10: Setting up handle
4. Insert the bolt on each side through handle and the
spacer and tighten.
Fig. 11: Insert bolt and tighten
5. Tighten the bolt at the front side of the handle to ensure
it does not come loose at a later time.

© MAHLE
16 | ACX1180 | Commissioningen
4.3 ACX1180
m
The ACX1180 is designed for 120 VAC ± 10 % , 50/60
Hz. Follow the information on ACX1180 rating plate.
1. Set the ACX1180 on a flat, vibration-proof surface.
2. Actuate the caster brake to stop ACX1180 from rolling.
3. Connect the power supply cable to the power supply.
4. Switch on the main switch.
@ The unit will prompt user to Select Language.
@ The fan is switched on.
t The fan runs while the ACX1180 is switched on.
WE I G H T = # #.# L B
AUTOMATI C
START?
4.3.1 Setting language
1. During first time setup, the unit will automatically prompt
user to select a language. After this, it will be necessary
touse or togettoSetup andpressYES.
1. Press YES again to enter Sel ec t ab le Opt i ons (or press
and hold #4 key from main menu).
2. Select language with   .
3. Store selection with YES.
4.3.2 Setting date and time
1. From main screen, use  or  to get to Set u p and
press YES.
2. Use or toscrolltoMaintenance Options and
press YES again.
3. Press NO until Set Dat e and Tim e is displayed.
4. Altervalueswith or.
5. Move to next value with 
.
6. Store entries and return with YES.
4.3.3 Activating / deactivating printer, buzzer
1. From main screen, use  or  to get to Set u p and
press YES.
2. Press YES again to enter Selec t abl e Opt i on s
3. Press YES button to scroll though various options.
4. Activate/deactivate by using  or  to select YES or
NO.
5. Store entries by changing selection and pressing the
YES button. Escape by pressing NO button.
4.4 Setup
4.4.1 Selectable Options
1. From main screen, use  or  to get to Set up and
press YES.
2. Press YES again to enter Sel ec t ab le Opt ion s.
3. Press YES button to scroll though various options.
4. Activate/deactivate by using  or  to select YES or
NO.
Opt ion Description
Select language Select language to be displayed on screen.
Buzzer enabled? Audible alarm additionally sounds in the
event of error messages.
Refrig ID installed? Optional accessory that can be purchased
and added at user convenience.
AC Cap DB installed? Optional accessory that can be enabled.
Printer installed? Optional accessory item.
Print to flash drive? Print results to flash drive for records.
Low voltage detect
enabled?
Only applicable to "C" version units.
Micron vacuum sen-
sor enabled?
Only applicable to "C" version units.
Password p rotection
enabled?
Optional setting if password protection pre-
ferred.
VIN entry enabled? Allows technician to enter vehicles VIN
number that is being serviced.
Operator ID entry Only applicable to "C" version units.
AC test mode ena-
bled?
Only applicable to "C" version units.
Va c u u m p u m p o i l l i f e
test enabled?
Only applicable to "C" version units.
Refrigerant liquid
flush enabled?
Only applicable to "C" version units.
Techalert demomode
enabled?
If TechALERT is puchased, the demo can be
enabled to demonstrate use.
High pressure leak
detect enabled?
Only applicable to "C" version units.
Automatic weighing
oil injection enabled?
Only applicable to "C" version units.
Automatic weighing
oil drain enabled?
Only applicable to "C" version units.
High voltage oil flush
enabled?
Only applicable to "C" version units.
Fill cylinder enabled? Allows user to fill internal cylinder from exter-
nal refrigerant tank.
Manual oil injection
enabled?
Allows user to manually inject oil between
vacuum and charge procedure.

© MAHLE
Commissioning | ACX1180 | 17ACX1180 | 17| 17 en
4.4.2 Default Values
1. From main screen, use  or  to get to Set u p and
press YES.
2. Scroll to Defaul t Values, press YES to enter.
3. Press YES button to scroll though various options.
4. Modify values by using 
 to select position of cursor
and the numeric keypad to change entered value. Press
YES to accept value.
Opt ion Descript ion
Fill Cylinder target
amount
The value set here will be the amount of re-
frigerant which will have been transferred
when the procedure stops automatically.
Initial vacuum hold Only applicable to "C" version units. This
sets value where vacuum pump will pull the
A/C system into a vacuum and then pause
for a period of 60 seconds.
Final vacuum level Only applicable to "C" version units. This
sets the target vacuum level for service.
Vacuum run time This screen prompts for the length of time
the vacuum pump will run during each cycle.
Hose overcharge
amount
A small overcharge of refrigerant is neces-
sary to compensate for refrigerant which will
remain in the hose after a charge procedure
Default minimum line
voltage
Only applicable to "C" version units. During
machine operation, the line voltage is moni-
tored to remain above a threshold to ensure
correct operation.
Elevation from sea
level
Elevation from sea level to adjust pressure
transducer calibration.
Oil life vacuum rise
level
Only applicable to "C" version units. Enter
the amount of rise in vacuum level used dur-
ing the vacuum pump oil life test
Oil drain max level Currently not applicable.
Minimum vacuum
leak level
During vacuum leak test, this value is used to
determine a pass or fail.
High voltage flush
charge amount
Used to set amount of refrigerant used in
flush routine. DO NOT REDUCE THIS VALUE
TO LESS THAN 1.6LBS; risk of residual oil
may be left in hoses!
Default vacuum leak
time
Used to set amount of time vacuum leak
process will check for potential leaks.
4.4.3 Maintenance Options
1. From main screen, use  or  to get to Set up and
press YES.
2. Use  or  to scroll to Maintenance Options and
press YES again.
3. Press YES or NO to either select or bypass the different
options.
4. Altervalueswith or.
5. Move to next value with 
.
6. Store entries and return with YES.
Opt ion Description
Perform calibration
check?
Press YES if desired. When prompted, attach
supplied steel calibration check ball to mag-
net at bottom of load cell to continue check.
Perform internal load
cell site calibration
Press YES if required, press NO otherwise.
If required, special 4KG weight required and
available for purchase (see Accessory Items).
Perform internal load
cell shop calibration.
Press YES if required, press NO otherwise. If
required, special 10KG weight required and
available for purchase (see Accessory Items).
Set date and time? Press YES key if adjustment needed, press
NO otherwise. If adjustment is needed, use
  to modify value and press YES to ac-
cept entry.
Perform Input/Output
diagnostics?
Use this to test solenoid and sensor function.
Also can monitor sensor values for trouble-
shooting purposes.
Perform combo filter
replacement
Press YES key if replacement needed. Press
NO otherwise. If YES selected, unit will
check pressure in accumulator to ensure no
refrigerant is present.
Perform vacuum
pump oil replacement
Press YES key if replacement needed, press
NO otherwise. Vacuum pump oil should be
replaced every 10 hours for best perform-
ance.
Change operator
password
If YES is selected, unit will ask for service
manager password prior to allowing operator
password change. Press NO to bypass pass-
word change.
Change service man-
ager password
Press YES if desired, press NO otherwise.
Print parameter set-
tings
Press YES if desired, press NO otherwise. If
printer not installed, file can still be printed/
saved to flash drive.
4.4.4 Total Capacities
1. From main screen, use  or  to get to Set up and
press YES.
2. Use  or  to scroll to Tot al Cap ac it i es and press
YES again.
3. Press YES to scroll through different values.
Opt ion Description
Combo Filter Life Remaining Amount of refrigerant able to be
processed until replacement of
combo filter required.
Total Refrigerant Recycled Total refrigerant recovered
throughout life of unit.
Total Refrigerant Charged Total refrigerant charged
throughout life of unit.
Vacuum Pump Oil Life Remain-
ing
Time remaining until vacuum
pump oil must be replaced.

© MAHLE
18 | ACX1180 | Commissioningen
4.6 Filling internal refrigerant bottle
Warning – Risk of frostbite from
escaping refrigerant
Refrigerant causes severe frostbite
on the skin.
h Check the service hoses for damage.
h Firmly connect the service quick-release
couplings to the service hoses.
h Wear protective goggles.
h Wear protective gloves.
t Before the ACX1180 can be used, the internal
refrigerant bottle must be filled with liquid refrigerant. Use
only R134a refrigerant.
t The refrigerant can be obtained from your gas supplier. It
can be stored normally and transported in bottles with con-
nection fittings.
t To ensure a reliable procedure, it is advisable to use the
optimum quantity of refrigerant. The optimum quantity
of refrigerant for the ACX1180 is 10lbs (4.5kg) – 18lbs
(8.16kg).
t An inadequate quantity may make efficient filling of the ve-
hicle air conditioning system impossible. Also, if there is an
insufficient quantity, the ACX1180 may not be able to oper-
ate efficiently. In the event of an excessive quantity, there
may not be sufficient space for the refrigerant recovered
from the vehicle air conditioning system.
m Generally speaking, the actual quantity of refrigerant added
exceeds the set quantity to allow a dead weight in the
tank to keep the internal refrigerant circuit wetted. Add 1lb
(454g) to the set quantity when filling with refrigerant for
the first time.
1. To fill internal bottle, push  until "FILL CYLINDER" is
displayed then press YES.
2. Follow the menu prompting.
t The current pressure inside the external refrigerant bottle is
indicated on the low-pressure gauge.
t Any amount of refrigerant between 6.6lb (3kg) and 24.2lb
(11kg) can be added.
m Do not interrupt the automatic filling process prior to auto-
matic termination by the ACX1180.
4.5 Checking type of connection of
external refrigerant bottle
t
Follow the instructions below for filling the internal
refrigerant bottle.
— Refrigerant bottle with one valve:
Always turn the external refrigerant bottle upside
down when filling the internal refrigerant bottle.
— Refrigerant bottle with two valves:
Use the adapter set to connect the service hose (LP)
to the external refrigerant bottle. In doing so, turn the
external refrigerant bottle such that the connections
are facing upwards.
m The internal refrigerant bottle should only be replaced if it
is severely damaged. The internal refrigerant bottle must
always be filled using an external refrigerant bottle.
m During filling, the external refrigerant bottle must be
firmly positioned and the operator must ensure that the
service hoses are safely routed to avoid the danger of
the external refrigerant bottle falling over.

© MAHLE
A/C service preparation | ACX1180 | 19ACX1180 | 19| 19 en
5. A/C service preparation
Warning – Risk of burns from hot engine
components
Contact with hot engine components will
cause severe burns.
h Allow the engine to cool down.
h Wear protective goggles.
h Wear protective gloves.
Warning – Risk of frostbite from
escaping refrigerant
Refrigerant causes severe frostbite on
the skin.
h Check the service hoses for damage.
h Firmly connect the service quick-release
couplings to the service hoses.
h Wear protective goggles.
h Wear protective gloves.
Perform the following preparatory work prior to vehicle A/C
service:
m Service hoses must be contructed of the proper materi-
als and have the lengths as supplied with the unit. Hoses
must have shutoff devices (quick-release couplers) at the
connection point to the A/C to minimize the introduction of
air into the ACX1180 and to minimize the amount of refrig-
erant released while disconnecting the hoses.
m Inspect hoses for signs of damage prior to performing A/C
service. Use of damaged hoses will result in the loss of
refrigerant and the possibility of refrigerant contamination.
t Follow the vehicle manufacturer's recommendations for
A/C service on vehicles with a low-pressure connection
only.
1. Set the ACX1180 on a flat, vibration-proof surface.
2. Actuate the caster brake to stop the unit from rolling.
3. Connect the power supply cable to the power supply.
4. Switch on the main switch.
t Follow the manufacturer's instructions for the
corresponding vehicle before performing A/C service.
m The ACX1180 is only to be operated with R134a refrig-
erant. Check which refrigerant is used for the vehicle
before performing A/C service.
m The ACX1180 cannot be used for air conditioning sys-
tems repaired using a chemical sealant. These sealants
may cause serious damage to the ACX1180 if they are
present. Detection devices are available to check for
chemical sealants. Non compliance will void the war-
ranty.
m Never attempt to close the valves of the internal refriger-
ant bottle while the ACX1180 is in operation.
m Only new lubricant, as specified by the system manu-
facturer, shall be installed in the MAC system. Lubricant
removed from the system and/or equipment shall be
disposed of in accordance with the applicable federal,
state, and local procedures and regulations.

© MAHLE
20 | ACX1180 | Operationen
6. Operation
m Before connecting service hoses proceed as follows:
1. Perform refrigerant identification (if equipped - see
chapter 6.3).
6.1 Service phases
y Rec o ve r y p h as e: Refrigerant is extracted from the
vehicle, cleaned and routed into the internal refrigerant
bottle.
y Vacuum phase: A vacuum is generated in the vehicle
air conditioning system and the system is checked for
leaks.
y Recharge phase:
— Refrigerant: The vehicle air conditioning system is
filled with a specified amount of R134a refrigerant.
6.2 A/C Database
t
If purchased, the A/C Database can be used to select
vehicle and determine the charge amount.
1. To enable, go to "Set up >> Sel ec t abl e Opt i on s".
2. Press YES until screen displays "AC CAP DB In-
stalled?".
3. Use  and  to scroll to Ext er n al and press YES.
4. Once enabled, the unit will ask technician if they would
like to use AC Capacity Guide to determine charge
amount.
5. If YES is selected, the unit will proceed to allow user to
select Year, Make, Model, Engine, and any other options
the vehicle may have.
t Database is updated yearly with current model year
vehicles. Updates can be purchased and downloaded
through the MAHLE Aftermarket Inc. website.
6.3 Refrigerant identification unit
6.3.1 Refrigerant analysis
m Oil contamination will damage the refrigerant identifica-
tion unit! If the refrigerant sample is supplied to the unit
from the recycling equipment directly, it must be pro-
tected from oil that comes from vehicles or accumulate
in service hoses!
m The operator must periodically examine the test hose
and white sample filter for oil contamination and stop
immediately if any oil is observed!
t If installed and enabled, Refrigerant Identification will
automatically occur anytime a Recycle or Internal Bottle
fill is performed.
t The gas pressure should be between 1.7 –16 bar.
Accurate gas analysis can be achieved with less than
1.7bar but additional time must be provided. In this
case start the flow of gas and then wait for 20 seconds
before instructing the refrigerant identification unit to
test the gas.
t After sample is completed, ID results will be displayed on
ACX1180 screen.
t If results show air percentage over 5% , check filter, hose
and coupler for any potential contamination or leaks
prior to repeating identification.