MAHLE ACX120 User manual

EN | 1 | ACX120/220 | CONTENTS
© MAHLE
1CONTENTS
1CONTENTS 1
2General instructions 3
2.1General Notes 3
2.2General instructions 3
2.3Manufacturer identification 3
3Safety conditions 3
3.1Personal safety information 3
3.1.1Definitions 3
3.1.2Personal safety
information 4
3.1.3Important information on
service equipment safety 7
3.2Safety devices 7
4Layout of the manual 7
4.1Use of the manual 7
4.2Symbols 8
4.2.1Safety 8
4.3Glossary 8
4.4Guidelines for the handling of
refrigerant 9
4.4.1Precautions for
refrigerant storage 9
4.4.2Conditions of refrigerant
and system 10
4.4.3Recycling capacity 10
5Product description 10
5.1Application 10
5.2Scope of delivery 10
5.3Description of the unit 10
5.4User interface 11
5.4.1Main menu 12
5.5E³ connect quick couplers 12
6Technical features 13
7Installation 15
7.1Equipment installation 15
7.1.1Unpacking ACX120/220
15
8Commissioning 16
8.1Connections 16
8.1.1Positioning and
connection 16
8.2Initial verification 17
9Setup 18
10A/C system charge 19
10.1Preliminary operations 19
10.2Non-condensable gas
discharge 20
10.3Quick mode and zero
tolerance charge mode 20
11Automatic cycle 21
11.1Automatic cycle data loading
21
11.1.1Database (optional) 21
11.1.2Last cycle 21
11.1.3My database 21
11.1.4Direct Input 22
11.2Automatic cycle data setting22
11.2.1Electric Compressor
Function (Optional) 22
12Manual cycle 22
12.1Recovery 22
12.2Vacuum 23
12.3Charge 23
12.4Flushing (with optional
accessories) 23
12.5Hoses drain 24
13Special test 24
13.1Ac performance test 24
13.2Refrigerant clean 24
14Maintenance 24
14.1Report exporting 25
14.2Internal cylinder fill 25
14.3Self leak test 25
14.4Cylinder pressure check 26
14.5Cylinder refrigerant view 26
14.6Air purge system 26
14.7Air purge 26
14.8Pressure zero 26
14.9Counters 26
14.10E³ pump - vacuum pump oil
change 26
14.10.1Oil pump visual check 28
14.11Dryer filter replacement 28
14.12System info 29
14.13System update 29
14.14Maintenance of printer
(optional) 29

EN | 2 | ACX120/220 | CONTENTS
© MAHLE
14.15Periodic checks 30
15Disposal 30
15.1A/c service unit disposal 30
15.2Recycled materials disposal 31
15.3Packaging disposal 31
16Spare parts 31

EN | 3 | ACX120/220 | General instructions
© MAHLE
2General
instructions
2.1 General Notes
All rights reserved.
This manual may not be reproduced, in
part or entirely, either in printed or digital
form.
It may be printed out solely for use by the
user and operators of the equipment to
which it refers.
MAHLE and resources used for the
drawing up of this manual will not be held
responsible for the incorrect use of the
manual while they guarantee that
information in the manual have been duly
checked.
The product can be subject to changes
and improvements. MAHLE reserves the
right to change without notice the
information contained in the manual.
2.2 General instructions
Pressure equipment undergoes checks
before commissioning and periodical
checks during operation, in compliance
with rules and law provisions in force in
the country where the tool is used.
The operator is responsible for operating
the equipment in conformity with local
legislation.
ACX120 is designed for recovering and
recycling R134a refrigerant fluid from
automotive A/C plant.
ACX220 is designed for recovering and
recycling R1234yf refrigerant fluid from
automotive A/C plant.
The equipments are intended to be used
by automotive and similar repair and
service workshops.
This equipment is intended solely for use
by professionally trained operators
familiar with the basics of refrigeration,
refrigeration systems, refrigerants and the
hazards associated with pressurised
equipment. Careful reading of the present
manual by the owners, the users and the
operators is required for a correct and
safe use of the tool. The user shall not be
entitled to open the product since
maintenance operations are reserved to
the authorised service centre.
2.3 Manufacturer
identification
The ACX equipment is manufactured by:
MAHLE Aftermarket GmbH
Service Solutions Europe
Pragstr. 26 - 46, 70376 Stuttgart,
Germany
Phone: [phone]
3Safety conditions
3.1 Personal safety
information
3.1.1 Definitions
DANGEROUS AREAS:
Any area within or close to the equipment
implying risk for the safety and health of
exposed persons.
EXPOSED PERSON:
Any person completely or partially
standing in a dangerous area.
OPERATOR:
The person/s charged with operating the
machine for its intended purpose.

EN | 4 | ACX120/220 | Safety conditions
© MAHLE
CLASSIFICATION OF OPERATORS
The operator can be classified according
to two main categories, which, in some
cases, refer to one single person:
The operator charged with the
equipment operation has the
duty to:
oStart up and monitor
the machine's
automatic cycle;
oCarry out simple setting
operations;
oRemove the causes of
equipment stop not
implying breakings of
members but simple
operating anomalies.
Maintenance technician a
technician trained by an
authorised MAHLE centre,
capable of working on the
machine’s mechanical and
electrical components with its
guards open to make
adjustments and to service and
repair it.
USER
Body or person legally responsible for the
equipment.
3.1.2 Personal safety information
The MAHLE ACX 120/220 A/C service
station is particularly simple and reliable
due to its adjustments and functions.
When used correctly it presents no
hazard for the operator, provided he
observes the following general safety
instructions and that the service station is
regularly serviced (incorrect
maintenance/use compromise the
equipment's safety).
Before operating the service station for
the first time, read these instructions
carefully. If any part of the instructions is
unclear, contact your reseller or MAHLE.
This service station may be used by only
one equipment operator, familiar with A/C
and refrigeration systems and the hazards
associated with refrigerants and high
pressure equipment.
WORKPLACE: ACX120 can work with
R134a. ACX220 can work with R1234yf.
Refrigerant R1234yf is defined as
flammable refrigerant.
Nonetheless, although refrigerant R134a
is not defined as flammable, mixtures of
air or oxygen with R134a may become
flammable under very particular
conditions.
The equipment must be operated
outdoor or in a well-ventilated location
(at least 1 air change per hour). The
workshop has to be equipped with
ventilation systems able to ensure air
change in every environment area or
carry out periodical ventilation by
opening the areas.
Use the equipment away from heat
sources or hot surfaces. The equipment
must not be used in explosion risk
environments (potentially explosive
atmospheres). Before using it, put the
equipment on a levelled plane and secure
position, blocking it with suitable wheel
stops.
Do not expose the tool to direct sunrays,
heat sources, rain and jets of water. Do
not smoke near the equipment and during
operations (keep at a distance of at least
1 m).
The work area must be monitored by the
operator while the equipment is operating.

EN | 5 | ACX120/220 | Safety conditions
© MAHLE
ATTENTION: R134a and/or R1234yf
refrigerant fumes/gases are heavier than
air and can gather on the floor or inside
cavities/holes and cause choke by
reducing the oxygen available for
breathing.
At high temperatures, the refrigerant
breaks down releasing toxic and
aggressive substances, harmful for the
operator and the environment.) Avoid
inhaling the system coolants and oils.
Exposure can irritate eyes and the
respiratory tract.
ELECTRICAL CONNECTION: Connect
the power cord solely to a mains supply
which conforms to the ratings on the
machine's nameplate (mounted on its
side). Make sure the mains socket is
grounded.
Maximum impedance allowed in the point
of connection to the mains shall comply
with standard EN 61000-3-11. Starting
currents can cause short voltage drops,
which may affect other equipments under
unfavourable conditions. If impedance in
the point of connection to the mains is
not compliant, this may lead to
interference so please consult the
electrical power network operator before
connecting the equipment.
Never use the service station with a
defective power cord or a different one
from that supplied with the machine. If
damaged, immediately have it replaced
with an original spare part or equivalent
by a MAHLE centre. Before opening the
service station, extract completely the
supply cable from the plug, or you can
get an electric shock.
Do not tamper with or bypass the safety
equipment and settings.
Do not leave the machine powered up
when not in use; shut off the power
supply before leaving the equipment
unused for a long time. Do not forget that
the tool (pressure tool) must always be
protected.
REFRIGERANTS AND LUBRICANTS -
PERSONAL SAFETY EQUIPMENT AND
PRECAUTIONS: The refrigerants and the
pressure cylinders have to be handled
with care, otherwise there will be possible
health risks.
The operator must wear safety glasses,
gloves and protective clothing suitable to
the work. Contact with the refrigerant can
cause blindness (eyes) and other physical
damages (freezing) to the operator. Avoid
contact with the skin; the refrigerant's low
boiling point (approx. –26 °C for R134a
and approx. -30 °C for R1234yf) can
cause freezing burns.
Further information about safety can be
obtained from the safety sheets of
lubricant and refrigerant producers.
Do not inhale refrigerant or oil vapour.
Keep away from the vent valves and
ventilation coupling, especially when non-
condensable gas is being vented.
Never direct the quick couplings (taps)
towards your face or other persons or
animals.
OTHER PROHIBITIONS AND USE
LIMITATIONS: Only use pure R134a or
R1234yf refrigerants, refrain from using
on vehicles containing other types of
refrigerants or mixtures of the two
refrigerants or other refrigerants.
Mixture with other types of refrigerant
produces serious damage to the

EN | 6 | ACX120/220 | Safety conditions
© MAHLE
conditioning and cooling systems. Mixed
refrigerants have to be disposed of
according to the current regulations.
Never use ACX equipment with systems
containing compressed air; mixtures of
R134a or R1234yf with air or oxygen may
be potentially flammable.
Do not modify calibration of safety
devices. Do not remove seals of safety
valves and of control systems. Do not use
external tanks or other storage containers
that are not type-approved or without
safety valves.
Make sure the equipment's aeration and
ventilation ports are not obstructed or
covered while the equipment is operating.
HOSE CONNECTIONS: Hoses may
contain pressurised refrigerant. Before
changing the service couplers, check the
respective pressures in the hoses
(pressure gauge). Before connection to a
car A/C system, to an external
tank/cylinder, check that the quick
couplers are closed (unscrewed HP and
LP valves). Scrupulously follow the
instructions on the equipment's display.
QUICK COUPLERS
CLOSING/OPENING:
MAINTENANCE/GENERAL CLEANING:
The equipment has to be serviced at the
intervals indicated by the equipment itself.
The service station maintenance has to
be performed according to the
procedures described in this manual and
to the current safety regulations.
Use only MAHLE original parts.
When the equipment requires the drier
filter and the vacuum pump oil to be
changed, you have to be careful in the
replacement.
A/C service station maintenance can be
carried out exclusively by a trained
operator or by a service man of a MAHLE
certified seller.
Do not use chemical agents for the
service station cleaning as they could
attack the material or the surface.
STOP FOR LONG PERIOD: Store the
equipment in a safe place, disconnected
from the mains, away from excessive
temperatures, humidity and the risk of
damaging impact.
Contact the Technical Service to run a
safety shutdown of the equipment, and if
scrapping the unit, to drain and recycle
the R134a or R1234yf refrigerant as
required by local legislation.
To resume operation, repeat the
installation (there is no need to register
the unit anew on the website) and run the
commissioning trials and regular
operational checks as required by local
legislation.
Closing (detach from
the vehicle):
counter clockwise
Opening (connect to
the vehicle):
clockwise

EN | 7 | ACX120/220 | Layout of the manual
© MAHLE
3.1.3 Important information on
service equipment safety
When using the equipment, the following
operations are not allowed as they might
cause, under certain circumstances,
danger for persons and cause permanent
damage to the equipment itself.
- Do not remove or make
unreadable labels, signs
and/or dangers signs placed
on the equipment and in the
area nearby.
- Do not disable the unit's
safety equipment.
- Use only fuses identical to
the originals as specified on
the nameplate; do not tamper
with or attempt to repair the
fuses.
If the power supply is known
or can be expected to vary
beyond the limits specified
for the service equipment,
immediately disconnect it.
- The electrical system to
which the service equipment
is connected must be
configured as provided by
local legislation.
- Only operators or qualified
staff instructed or certified for
the equipment maintenance
can open the equipment. The
equipment contains parts
which can cause
electrocution: shut off power
to the equipment before
servicing/repairing it.
3.2 Safety devices
ACX 120/220 is equipped with the
following safety devices:
SAFETY PRESSURE SWITCH:
It stops the compressor in case
of excessive pressure.
SAFETY VALVE: The safety
valve opens when the pressure
inside the system reaches a
level higher than the fixed limits.
MAIN SWITCH: Switches the
equipment off by interrupting
the power supply. It is advisable
to pull the power cord plug out
of the mains socket in any case
before starting maintenance
work.
ANY TAMPERING WITH THE
ABOVE-MENTIONED SAFETY
DEVICES IS PROHIBITED.
Failure to observe any of the above
safety instructions voids the
equipment's warranty.
4Layout of the
manual
4.1 Use of the manual

This manual is an integral part
of the equipment and must be
kept in the equipment's
immediate vicinity by the
purchaser
This manual shall accompany
the equipment in case this is
passed on to a new user.

EN | 8 | ACX120/220 | Layout of the manual
© MAHLE
The content of this manual has
been drawn up in compliance
with the guide lines of the UNI
standard 10893:2000.
Diffusion, modification or use of
this manual for own aims is
forbidden.
The manual uses symbols which
call the reader's attention to
specific points to facilitate its
use.
It includes all technical,
operating, shutdown,
maintenance, spare parts and
safety information.
In case of doubts on the correct
interpretation of the instructions,
please contact our technical
service to obtain the required
clarifications.
Operations which are
potentially hazardous for the
operator are highlighted with
this symbol.
Such operations can cause
serious injury.
Operations requiring special
attention are highlighted with
this symbol.
Such operations shall be
carried out correctly to avoid
causing damage to objects or
to the surrounding
environment. This symbol also
highlights information to which
special attention must be paid.
Operations which require
careful reading of the manual's
instructions are highlighted
with this symbol.
4.2 Symbols
This paragraph describes the safety
symbols which may be posted on the
service equipment.
4.2.1 Safety
ALTERNATING
CURRENT
SAFETY GROUNDING
CONSULT THE
INSTRUCTIONS
MANUAL
ATTENTION!
ELECTROCUTION
HAZARD
CAUTION !: DO NOT
REMOVE THE COVER
(maintenance
technicians only)
USE PROTECTIVE
GLOVES
WEAR PROTECTIVE
GOGGLES
USE ANTI-SMASH
SAFETY SHOES
4.3 Glossary
To make the reading of this manual
easier, we have prepared the list of the
most important technical terms used in
the manual.
Refrigerant: Refrigerant fluid used in
advanced motor vehicle A/C systems.
The following refrigerant fluids may be
used:
R-1234yf CH2CFCF3 2,3,3,3-
Tetrafluoropropene.
R-134a C2H2F4 - 1,1,1,2-

EN | 9 | ACX120/220 | Layout of the manual
© MAHLE
Tetrafluoroethane
A/C system: air conditioning system.
Equipment:
ACX 120/220 service
station for recovering, recycling, draining
and charging the A/C system.
External tank: Refrigerant bottle used to
fill the internal tank.
Internal cylinder: cylinder for refrigerant
storage.
Phase: Performance of a single function.
Cycle: Sequence of steps.
Recovery: Extraction of refrigerant from
the vehicle.
Recycling: Cleaning of refrigerant,
includes: separating out oils, removal of
non-condensable gas and
single/multiple pass through filters to
reduce humidity, acidity and particulate
content of the fluid.
Disposal: disposal of refrigerant for
storage followed by
destruction/scrapping by an authorised
waste management centre.
Vacuum cycle: Draining out of a motor
vehicle A/C system and separation out of
condensed matter and humidity, using
only the vacuum pump.
Oil charge: Charge of oil into an A/C
system to ensure the correct charge as
specified by the vehicle's manufacturer.
Charge: filling of refrigerant into the A/C
system in the amount specified by the
manufacturer.
System flushing: Cleaning phase for the
removal of possible polluting substances
from the A/C system or parts of it.
Non condensable gases: Refrigerant
stored in gaseous phase, including air
and nitrogen.
4.4 Guidelines for the
handling of refrigerant
4.4.1 Precautions for refrigerant
storage
The refrigerant removed from the A/C
system must be handled with care to
prevent or minimise the risk of mixing
with other refrigerants.
This machine is suitable for treating
R134a or R1234yf refrigerants,
individually (not simultaneously).
The external cylinders used to store the
refrigerants must be clearly marked to
prevent mixing different refrigerants.
Cylinders shall be free from oil or other
contaminants and clearly marked so as to
identify the refrigerant contained.
ATTENTION: when handling,
using and storing R-134a or R-
1234yf refrigerant and dealing
with emergency situations,
MAKE SURE to refer to the
product’s safety sheet.
GET THE SAFETY SHEET
FROM YOUR REFRIGERANT
SUPPLIER AND FOLLOW ITS
INSTRUCTIONS.
REFRIGERANT R1234YF IS
DEFINED AS FLAMMABLE
REFRIGERANT.

EN | 10 | ACX120/220 | Product description
© MAHLE
1
2
3
4
5
6
7
9
8
4.4.2 Conditions of refrigerant
and system
The condition of the refrigerant is critical
to the operation of the vehicle's A/C
system. Running repairs properly
following failure or damage safeguards
the quality of the refrigerant itself
(particulates, acids and water).
4.4.3 Recycling capacity
The service equipment's filtering systems
must be replaced regularly (see
maintenance messages) to ensure
effective recycling.
5Product
description
5.1 Application
ACX120/220 is suitable also for hybrid
and electric vehicles. ACX120/220
features all the functions required for
vehicle A/C service.
The following functions can be
implemented:
Refrigerant recovery and
recharging.
Vacuum generation.
Flushing.
The ACX120/220 can only be
operated with R134a. The
ACX120/220 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.
5.2 Scope of delivery
Description
Service hose (high pressure)
Service hose (low pressure)
Quick-release coupling (high pressure)
Quick-release coupling (low pressure)
Used oil bottle
New oil bottle
Original instructions
Adapter for external bottle connection
Safety goggles
Safety gloves
Dust cover
5.3 Description of the unit
Fig. 1: Left-Front view
1 Rear handle and grip
2 Tool tray and storage
3 Display and operating unit
4 ACX120/220 front housing
5 Locking caster
6 Rear wheel
7 Used oil bottle

EN | 11 | ACX120/220 | Product description
© MAHLE
8 New oil bottle
9 Service hose
DO NOT USE THE UNIT
UNLESS THE CHARGING
HOSES (HP – LP) ARE
CORRECTLY CONNECTED
Fig. 2: Rear view (detail)
1 Fan
2 Vents
Fig. 3: Right-front view (detail)
1 Power cord connector and
Power switch
2 USB type B (Device port to PC)
3 USB type A (Host port to USB
Memory Stick)
The USB type-A connector
can only be used with USB
2.0 portable memory devices
with Mass storage service for
reports export and station
update, or for connection to
MAHLE refrigerant identifier.
Do not connect other types
of devices, such as USB
keyboards or other units.
Fig. 4: Display and operating unit
1 High-pressure gauge
2 Low-pressure gauge
3 LCD Display
4 Keyboard
The pressure gauges (Fig. 4, Pos. 1, 2) of
the display and operating unit are used to
monitor the pressure during the individual
vehicle A/C service phases. The status of
the various service phases during
maintenance is displayed on the LCD
screen (Fig. 4, Pos. 3).
The menu selection and the necessary
entries are made by way of the keyboard
(Fig. 4, Pos. 4) integrated in the panel.
MAHLE supplies a USB stick for updating
the ACX120/220 software. If required, the
USB stick can be inserted in the USB
type A socket (Fig. 3, Pos. 4) to perform
updating of the firmware/software.
5.4 User interface
All settings, controls and service
functions are available in the pages
showed in the LCD display moving the
cursor and inserting the data by the
keyboard.
The LCD displays the service equipment’s
status, the progress of A/C system
1
2
2
1
3
1
2
3
4

EN | 12 | ACX120/220 | Product description
© MAHLE
service and any alarms and error
messages.
When a button is pressed, a beep sounds.
The following keys are available:
To move up in the
menu options or data
field
To move down in the
menu options or data
field
Arrows to decrease
the data value
Arrows to increase the
data value
To enter a text with
numbers and
characters
To confirm and to go
head
To interrupt the
operation in progress
To select a function in the menu select by
the up/down arrows the text name of the
function, the text name will blink, then
press the green ENTER key.
If there are descriptions that need more
space on the screen page, for example
the manual cycle list (see the screen page
below), or in case of setup, it is possible
to display the different entries pressing
the down arrow key. By up/down arrows,
the menu moves one line up or down
depending on whether it is pressed on the
arrow up or on arrow down.
If you need to enter free text, the
numerical keypad can be used. The
keyboard works like a keyboard of a
phone to compose SMS: press some
times to select one of the letters available
under that key.
5.4.1 Main menu
The Main menu of the graphical user
interface allow to select the following
functions:
Automatic cycle
Manual cycle
Special tests
Setup
Maintenance
Service
Each function will be described in the
next chapters.
5.5 E³ connect quick
couplers
E³ CONNECT is the INTELLIGENT
COUPLER, that with the suitable
automated procedure in the software
enables to:
reduce the non condensable gas
formation inside the cylinder ;

EN | 13 | ACX120/220 | Technical features
© MAHLE
avoid the refrigerant dispersion
in the air during the
disconnection (puff effect);
check possible SCHRADER
valve leaks before disconnection.
To connect the coupling, position the
coupling on the parking coupler, pull
back the knurled section of the
coupling element and press carefully
onto the connection.
6Technical
features
Cylinders
Cylinder capacity 12 l
Maximum
operating
pressure (PS)
20 bar
ACX120 PED
category
(Dir.97/23/EC)
II
ACX220 PED
category
III
(Dir.97/23/EC)
Weight of
refrigerant content
Scale
Heating band
function
E³ Fill
Safety valve
Type AIRTEK -
VS14NPT20H
NBRPED4
20bar R 1/4
NPT
Calibration
pressure
20 bar
PED category
(Dir.97/23/EC)
IV
Containers for oil and detection
dye
Recovered PAG
oil container
250 ml
New PAG oil
container
250 ml, with
OIL CARE
valve
Pneumatic circuit
Vacuum pump
flow rate
170 l/min
single stage
Vacuum level 0.02 mbar
Vacuum pump oil
life
60h –
extensible to
max 1000 h
with Pump
Monitoring
System
procedure
Refrigerant
recovery
compressor cubic
capacity
8cc
Drier filter Every 150Kg of
refrigerant
recovered
Non condensable
gases discharge
Manual, with
solenoid valve
HP and LP taps Automatic
Safety pressure switch

EN | 14 | ACX120/220 |
© MAHLE
Type 13/18bar
1/4SAE
Trip pressure 18 bar
PED category
(Dir.97/23/EC)
IV
Pneumatic fittings
Net length of
external HP and
LP hoses
3 m
ACX120 HP and
LP pressure
gauges
Analog 80
mm, pulse-
free, 1.6 class
ACX220 HP and
LP pressure
gauges
Analog 80
mm, pulse-
free, 1.0 class
User interface
Display Alphanumeric
al LCD 4x20
Keypad Membrane
Software updating USB type-A
with USB 2.0
key
USB type-B
with direct
connection to
PC.
Functions and features
Recovery,
exhausted oil
recovery, vacuum,
charge
Auto/Manual
New oil charge Timed/Manual
Recycling mode Single or
“Tank
refrigerant
internal
recycling”
Memory for
customized cycle
100 records
Recovered oil
measurement
Manual
Flushing “Regular”
function
(standard)
High intensity
flushing
available with
external
accessory
(option)
A/C Performance
Test
Visual guided
procedure
(with HP and
LP pressure
gauges)
Sound level < 70 dB (A)
Battery type for
internal Real time
clock
Lithium CR-
2032 3V
180mAh 3g.
Overall dimensions
WxDxH 1050 x 655 x
850 mm
Loadless weight about 84 kg
Power supply
Frequency 50 Hz
Voltage 230 V ~
Power 800 W
Fuses Retarder fuses
250V T10A
Installation
category
II
Environmental conditions
Operating
temperature
10-50°C
Humidity 10-90% R.H.
(non
condensing)
Ambient pressure 75 kPa until
106 kPa

EN | 15 | ACX120/220 | Installation
© MAHLE
7Installation
7.1 Equipment installation
7.1.1 Unpacking ACX120/220
RISK OF OVERTURNING
The manufacturer disclaims all
responsibility for damage to objects
and/or persons resulting from the
equipment being wrongly removed from
the pallet, or from the operation being
made by unsuitable personnel, with
improper means/protections and
without complying with the existing
laws on manual handling of loads and
with the operations described in this
manual.
Cut the strap and remove the carton.
Cut the straps securing the unit to the
pallet.
Remove the equipment from the
pallet (2 operators required)
Lift both front
wheels by
levering with the
handle and on
rear wheels (this
way the operators
must not lift the
full weight of the
unit)
Slowly lower
the unit from the
pallet by means
of the rear wheels
Keep the pallet, carton and scratch
protection film for use when returning the
unit. The unit rolls on wheels; the two
smaller wheels can be locked.
ACX120/220 is supplied with the
accumulation tank empty. This prevents
problems in shipping the unit.

EN | 16 | ACX120/220 | Commissioning
© MAHLE
REFRIGERANT SCALE SCREW
RELEASE
The tool is transported, with the scale
blocked by a locking screw to avoid the
load cell damage. The scales locking
screw is placed on the equipment
bottom/right side (see the box shown
above) and is formed by a bolt. For
commissioning, unscrew the screw.
8Commissioning
8.1 Connections
The unit has to be positioned on a
horizontal surface to ensure the correct
operation.
The unit has to be connected to the
electric mains following instructions on
the identification plate of the unit applied
next to the main switch, mainly as to
applicable voltage and power.
8.1.1 Positioning and connection
HANDLING: During handling, the
minimum devices required for
correct handling shall be ensured,
as provided for by accident
prevention provisions.
POSITIONING: Place the unit in a
stable place. The location must be
well ventilated, with a good rate of
change of air. The unit must be
located at least 10 cm from any
potential obstacles to its internal
ventilation. Keep the unit away
from rain and excessive humidity
as they can irreparably damage it.
In addition, the equipment must
never be directly exposed to the
sunrays or to excessive dust.
INSTALLATION: the unit must be
installed by a specialised
technician in scrupulous
observance of in accordance with
electrical engineering principles.
The use of the equipment in
explosive atmosphere is
forbidden.
CONNECTIONS: since the unit is
connected to the main power
supply, it must be properly
grounded with its power plug
GND pin. Failure to ground the
unit can damage it and
constitutes a risk of fatal injury to
the operator. Position the unit so
that the power plug is easy for the
operator to access.
ATTENTION: Leave the quick
coupling taps closed when the
unit is not in use and at the end of
vehicle service operations.
Power mains
connection
Vehicle A/C system
connections

EN | 17 | ACX120/220 | Commissioning
© MAHLE
8.2 Initial verification
Execute the following actions in sequence
by following the display guided procedure
and the illustrations on the screen of the
equipment:
Refrigerant weight check
First tank filling
It is possible to interrupt the initial check
and print a report with the equipment
printer in which the checking status is
reported.
The equipment cannot operate in
automatic mode until all the steps of the
initial check have been completed.
CAREFULLY ABIDE BY
THE FOLLOWING
INSTRUCTIONS TO
AVOID DANGER TO
PERSONS, THE
DISCHARGE OF
REFRIGERANT IN THE
ATMOSPHERE
Let us consider as first filling the one
carried out during the initial check with
internal tank of the equipment free of
refrigerant and containing air.
Set the quantity of refrigerant to fill (at
least 3 kg) and follow the guided
procedure shown on the display.
Check that the equipment hoses are not
connected and positioned in the hose
winder. Start the procedure that initially
implies the creation of vacuum in the
internal tank. This phase will take 15
minutes and will act on the whole
equipment.
Only when the message appears asking
to connect the charge tank, connect the
HP quick coupler (colour red) of the unit
to an external refrigerant tank using the
supplied adaptor.
When the message occurs open the
coupler by turning the knob clockwise.
Open the valve on the external tank.
Just right before reaching the planned
quantity of refrigerant, the unit will stop
and ask the user to close the external
refrigerant tank. Then, the device will
continue the recovery from the hoses and
ends when these are empty. Hence, it is
necessary to open the HP quick-coupler
and disconnect it from the external tank.
Thanks to the E³ CONNECT function, the
refrigerant - usually kept between the
cylinder fitting and the hose quick-coupler
until the end of the process - will not be
released in the environment.
There may be two types of source tanks:
with plunger and without plunger.
Tanks with plunger shall remain upright
to be able to transfer liquid refrigerant; for
this type of tanks connect to the L (liquid)
coupler.
Tanks without plunger have only one
valve, so they must be turned upside
down to transfer the liquid refrigerant.
The LP gauge indicates the pressure
inside the external tank.
After some minutes the unit will
automatically end the function.
At the end the weight of the charged
refrigerant will be displayed.

EN | 18 | ACX120/220 | Setup
© MAHLE
9Setup
From the SETUP menu it is possible to
select parameters and activations before
starting cycle:
ELECTRIC COMPRESSOR FUNCTION
by selecting this entry, one may
change the type of Oil to charge into
the A/C system. Attention: the
HYBRID KIT PRO (optional
accessory) is required in order to run
this function
E³ CONNECT
by selecting this entry, you can
enable the E³ CONNECT function.
CHARGE MODE
by selecting this entry, one may
decide whether to enable use of the
Quick Mode or Zero Tolerance
charge method
OIL CHARGE MODE
by selecting this entry, one may
decide the oil charge mode during
the charge cycle.
oAutomatic: during the
charge cycle, the user will
be prompted to enter the
quantity of oil to be charge
(ml) as well as the oil type,
PAG ( ISO-46/100/150) or
POE.
oManual: During the charge
cycle, the user will be
prompted to select YES in
case he wants to proceed
with the oil manual charge
before the refrigerant charge
phase, or NO in case he
doesn’t want to charge oil
during the charge cycle.
A/C PERFORMANCE TEST
by selecting this entry, one can
enable or disable the pressure check.
AIR PURGE SYSTEM
by selecting this entry, one can
enable or disable the AIR PURGE
SYSTEM function. If enabled, on a
weekly basis, the station, when
switched on, will suggest the user to
run the procedure. If disabled,
execution of the procedure will no
longer be suggested.
REFRIGERANT CLEAN
by selecting this entry, one may
decide whether or not to enable the
refrigerant clean function, which
enables an additional recycling,
within the station itself, started in
automatic when it is switched on but
not in use. This function ensures a
higher level of purity of the recycled
refrigerant to the advantage of the
service quality.
RECOVERED REFRIGERANT AND OIL
PRINTING (ONLY WHEN PRINTER IS
INSTALLED)
selecting this entry, you can choose
whether you want to enable
displaying and printing of the
recovered refrigerant quantity.
Setting available only with printer
installed.
REPORT SAVING MODE
by selecting this entry, you can save
the reports of the performed charges
(automatic cycle or Reg. 842/2006).

EN | 19 | ACX120/220 | A/C system charge
© MAHLE
HOSES LENGTH
by selecting this entry, it will be
possible to change the length of the
charge hoses.
UNIT OF MEASURE
selecting this entry, you can modify
the pressure unit of measurement
(switching from Bar to PSI)
CLOCK ADJUSTMENT
by selecting this entry, date and time
of the station may be changed.
GARAGE DATA
by selecting this entry, one can enter
the garage data to be printed on the
end of cycle report.
LANGUAGE
by selecting this entry, any language
present in the database may be set.
In case you choose a language with
unintelligible characters, hold down
the green ENTER button in the
starting screen-page and you will
directly return to the language setting
menu.
RIGHT / LEFT-HAND DRIVE
It allows setting the database for
operations on A/C systems of
vehicles with right-hand or left-hand
drive and return the exact value of
refrigerant and oil to be charge.
STARTUP SCREEN
By selecting this entry, you can
decide whether the startup screen of
the unit will be the databank page or
the main menu page.
DATABASE ACTIVATION
by selecting this entry, you will
receive the “database activation
request code” to be provided to your
distributor in order to be able to buy
the database activation/update and
subsequently receive the “ACX
activation key”.
DEFAULT SETUP
By selecting this entry, you can
restore the unit default settings.
MAHLE reserves the right to add
new parameters to make the
equipment increasingly versatile
and adaptable to market’s needs.
10 A/C system
charge
10.1 Preliminary operations
The recovery and charge operations have
be carried out after the car /AC system
has run for some time; however, an
excessively hot A/C system has to be
avoided since the next charge phase
could be adversely affected by high
pressures.
The vehicle must not be prepared in a
special way; connecting hoses have to be
attached by identifying their position.
Vehicle details necessary for the
performance of the charge/recovery/
vacuum cycle are the amount of
refrigerant and the type and quantity of oil.
These data are often found on the engine
compartment plate or on the technical
manuals.
As to oil quantity technical manuals of
cars, systems as well as available details
in general indicate the total quantity of oil
in the system.

EN | 20 | ACX120/220 | A/C system charge
© MAHLE
Indeed the amount of oil to be charged is
that extracted during the refrigerant
recovery phase which is very small. In the
car A/C system you have to add only the
oil amount necessary to restore the
amount set by the car manufacturer
FEATURES
Your new A/C service station is equipped
with new E³ CONNECT quick couplers.
These new couplers offer the following
functions:
1. Avoid dispersion of the refrigerant,
allowing the recovery by the tool
(thus protecting the environment and
saving refrigerant).
2. Automatic leak test of the car A/C
system valve at the end of the
service.
After connecting the quick couplers to the
(high pressure) HP and (high pressure) LP
connectors of the vehicle, screw the
valves only when required by the
messages on the tool display.
10.2 Non-condensable gas
discharge
The station is equipped with the AIR
PURGE SYSTEM function, which allows
automatically detecting and purging non-
condensable gas (mainly air) accumulated
within the tank.
Periodically, basically every week, the
station, the first time it is switched on that
day, will suggest running the AIR PURGE
SYSTEM procedure
Running this procedure is very important
to ensure the ideal working parameters
for the station operation. The presence of
non-condensable gas in the tank will
increase the pressure inside the tank and,
therefore, will slow down and reduce the
efficiency of charge cycle on the vehicle.
The procedure will take a few minutes,
and its duration may vary according to
the amount of non-condensable gas
within the tank.
WARNING: Leave the quick
coupling taps closed when the
unit is not in use and at the end of
vehicle service operations.
WARNING: For the Air Purge
System procedure to be executed
manually, the station must have
been off for at least one hour.
10.3 Quick mode and zero
tolerance charge mode
ACX120/220 can apply two different
refrigerant charge modes; the first one is
called Quick mode and features the
opening of the charge valve by charging
refrigerant through the HP port. By the
Quick Mode part of the refrigerant
remains into the hoses and is
compensated by software calculation.
NON-CONDENSABLE
GAS VENT VALVE