Valeo ClimFill Maxi User manual

ClimFill® Maxi
Service station for air conditioning systems of
vehicles with refrigerant gas R-134a.
Use and maintenance manual
Ver. 2.0

ENGLISH 2 / 74 CAP. 1 - CONTENTS
ClimFill Maxi
CAP. 1 - CONTENTS
CAP. 1 - CONTENTS .................................................................................................................. 2
CAP. 2 - GENERAL INSTRUCTIONS............................................................................................ 4
2.1 ENERAL NOTES...................................................................................................................4
2.2 ENERAL INSTRUCTIONS .....................................................................................................4
2.3 MANUFACTURER IDENTIFICATION ......................................................................................4
2.4 MARKIN ..............................................................................................................................5
CAP. 3 - SAFET CONDITIONS.................................................................................................. 6
3.1 PERSONAL SAFETY INFORMATION ......................................................................................6
3.1.1 Definitions........................................................................................................ 6
3.1.2 Personal safety information ........................................................................... 6
3.2 IMPORTANT INFORMATION ON SERVICE EQUIPMENT SAFETY .......................................11
3.3 SAFETY DEVICES..................................................................................................................11
CAP. 4 - LA OUT AND USE OF THE MANUAL ......................................................................... 12
4.1 USE OF THE MANUAL ..........................................................................................................12
4.2 SYMBOLS .............................................................................................................................12
4.2.1 Safety ............................................................................................................ 12
4.3 LOSSARY...........................................................................................................................13
4.4 UIDELINES FOR HANDLIN REFRI ERANT .....................................................................14
4.4.1 Precautions for refrigerant storage............................................................. 14
4.4.2 Refrigerant conditions.................................................................................. 14
4.4.3 Recycling capacity...................................................................................... 14
CAP. 5 - GENERAL DESCRIPTION............................................................................................ 15
5.1 FRONT VIEW (EXTERIOR).....................................................................................................16
5.2 FRONT VIEW (INTERIOR) .....................................................................................................17
5.3 REAR VIEW (EXTERIOR).......................................................................................................18
5.4 REAR VIEW (INTERIOR)........................................................................................................19
5.5 RI HT SIDE VIEW .................................................................................................................20
5.6 LEFT SIDE VIEW.....................................................................................................................21
5.7 FRONT SIDE VIEW ................................................................................................................22
5.8 TOUCHSCREEN ...................................................................................................................23
5.9 STATUS BAR..........................................................................................................................24
5.10 FUNCTION KEYS............................................................................................................26
5.11 CLIMFILL
®
-LOCK PATENTED TECHNOLO Y QUICK COUPLERS ...............................28
5.12 INCLUDED ACCESSORIES............................................................................................28
5.13 OPTIONAL ACCESSORIES............................................................................................29
CAP. 6 - TECHNICAL FEATURES .............................................................................................. 30
CAP. 7 - INSTALLATION........................................................................................................... 32
7.1 EQUIPMENT INSTALLATION ................................................................................................32
7.1.1 Unpacking limFill
®
Maxi.............................................................................. 32
CAP. 8 - COMMISSIONING .................................................................................................... 34
8.1 CONNECTIONS...................................................................................................................34
8.2 P OSITIONIN AND ELECTRIC CONNECTIONS ..............................................................................34
8.3 FIRST TANK FILLIN ..............................................................................................................36
8.4 NEW OIL BOTTLE FILLIN ....................................................................................................37
8.5 DETECTION DYE BOTTLE FILLIN ........................................................................................38
CAP. 9 - SETUP......................................................................................................................... 39
CAP. 10 - A/C S STEM RECHARGE ........................................................................................ 42
10.1 REMARKS ......................................................................................................................42
10.2 NON-CONDENSABLE AS DISCHAR E VALVE........................................................43

CAP. 1 - CONTENTS 3 / 74 ENGLISH
ClimFill Maxi
10.3 RECHAR E Q-MODE AND S-MODE...........................................................................44
CAP. 11 - AUTOMATIC C CLES.............................................................................................. 45
11.1 AUTOMATIC A/C SYSTEM SERVICE.............................................................................45
11.2 AUTOMATIC CYCLE (BUSES) .......................................................................................45
11.2.1 Last cycle ...................................................................................................... 45
11.2.2 User-defined cycles...................................................................................... 45
11.2.3 Search parameters by vehicle registration plate number........................ 45
11.3 AUTOMATIC CYCLE (OTHER VEHICLES).....................................................................45
11.3.1 Vehicle selection from database ............................................................... 45
11.3.2 Last cycle ...................................................................................................... 45
11.3.3 User-defined cycles...................................................................................... 46
11.3.4 Search parameters by vehicle registration plate number........................ 46
11.3.5 Automatic cycle parameters configuration.............................................. 46
11.3.6 OIL TYPE REPLA EMENT................................................................................ 47
CAP. 12 - MANUAL C CLES ................................................................................................... 48
12.1 PRELIMINARY OPERATIONS.........................................................................................48
12.2 RECOVERY....................................................................................................................48
12.3 VACUUM PHASE ..........................................................................................................48
12.4 INJECTION ....................................................................................................................49
12.5 OPERATION CONTROL (EXCLUDIN BUSES).............................................................50
12.6 EMPTYIN HOSES.........................................................................................................50
12.7 FLUSHIN ......................................................................................................................50
12.8 NITRO EN TEST.............................................................................................................51
CAP. 13 - MAINTENANCE....................................................................................................... 52
13.1 SELF LEAK TEST...............................................................................................................53
13.2 PUMP MONITORIN SYSTEM SPECIAL FUNCTION - VACUUM PUMP OIL CHAN E
53
13.3 DRYER FILTER CHAN E................................................................................................55
13.3.1 MESSAGE FOR FILTER ALMOST EXHAUSTED ................................................. 58
13.4 COUNTERS ....................................................................................................................58
13.5 VESSEL FILLIN (A/C SERVICE STATION TANK) ..........................................................58
13.6 NON-CONDENSABLE AS DISCHAR E ....................................................................59
13.7 TANK REFRI ERANT INTERNAL RECYCLIN ...............................................................59
13.8 SYSTEM INFORMATION ................................................................................................60
13.9 MAINTENANCE OF PRINTER ........................................................................................60
13.10 PERIODIC CHECKS.......................................................................................................60
CAP. 14 - DISPOSAL................................................................................................................ 63
14.1 A/C SERVICE UNIT DISPOSAL ......................................................................................63
14.2 RECYCLED MATERIALS DISPOSAL...............................................................................63
14.3 PACKA IN DISPOSAL ..............................................................................................63
CAP. 15 - SPARE PARTS........................................................................................................... 64
CAP. 16 - MESSAGE AND ALARM CODES.............................................................................. 65
CAP. 17 - MAINTENANCE FORMS .......................................................................................... 71

CAP. 2 - GENERAL INSTRUCTIONS 4 / 74 ENGLISH
ClimFill Maxi
CAP. 2 - GENERAL 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.
VALEO SERVICE 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. VALEO SERVICE 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 equipment is used.
The operator is responsible for operating the equipment in conformity with local
legislation.
The equipment is designed for recovering and recycling R134a refrigerant fluid from
A/C systems of buses, cars and similar vehicles.
The equipment is intended to be used by repair and service garages for buses, cars
and similar vehicles.
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 equipment.
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 ClimFill
®
Maxi equipment is manufactured by:
VALEO SERVICE
70 rue Pleyel Cedex
93285 Saint Denis (France)

ENGLISH 5 / 74 CAP. 2 - GENERAL INSTRUCTIONS
ClimFill Maxi
2.4 MARKING
The ClimFill
®
Maxi equipment has been manufactured in compliance with the European
Union directives listed in the Declaration of Conformity supplied with the pressure
equipment.
The equipment is a PED risk class III device (97/23/EC).
The characteristic data of the equipment are indicated on the specific data plate
applied onto the equipment side part.
It is prohibited to remove, damage or tamper with the equipment
“data plate”.
NAMEPLATE
CE MARKIN : The present CE declaration is enclosed to the equipment. Store correctly
and provide on request.
Fac-Simile

CAP. 3 - SAFET CONDITIONS 6 / 74 ENGLISH
ClimFill Maxi
CAP. 3 - SAFET CONDITIONS
3.1 PERSONAL SAFET INFORMATION
3.1.1 Definitions
DAN EROUS 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.
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 VALEO SERVICE
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 VALEO SERVICE ClimFill
®
Maxi 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 VALEO SERVICE. 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.

ENGLISH 7 / 74 CAP. 3 - SAFET CONDITIONS
ClimFill Maxi
WORKPLACE: 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 a 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 close to 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.
ATTENTION: the R134a 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 with 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 VALEO SERVICE 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.

CAP. 3 - SAFET CONDITIONS 8 / 74 ENGLISH
ClimFill Maxi
REFRIGERANTS AND LUBRICANTS – PERSONAL PROTECTION EQUIPMENT AND
PRECAUTIONS: The refrigerants and the pressure vessels 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
damage (freezing) to the operator. Avoid contact with the skin; the low boiling
temperature (about –26 °C for R134a) may cause 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: Use only pure R134a refrigerant, and do not
use it on vehicles containing other types of refrigerants. The mixture with other types of
refrigerant produces serious damage to the conditioning and cooling systems. Mixed
gases have to be disposed of according to current regulations. Do not use the ClimFill
®
Maxi station with compressed air systems, R134a and air mixtures can be potentially
explosive.
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.

ENGLISH 9 / 74 CAP. 3 - SAFET CONDITIONS
ClimFill Maxi
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/vessel, 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. These controls include also a leak self-test that the
equipment performs automatically.
The service station maintenance has to be performed according to the procedures
described in this manual and to the current safety regulations.
Use only VALEO SERVICE original parts.
When the equipment requires the dryer 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 VALEO SERVICE certified seller. If the maintenance is not
performed according to the expected schedule, the equipment will be blocked.
Do not use chemical agents for the service station cleaning, as they could attack the
material or the surface.
Closing (detach from the
vehicle):
counter clockwise
Opening (connect to the
vehicle):
clockwise

CAP. 3 - SAFET CONDITIONS 10 / 74 ENGLISH
ClimFill Maxi
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 gas 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.
TRANSPORT: If the equipment has to be transported, you have to screw the safety screw
in order to fix the equipment scale. The safety device for transport is on the back of the
equipment and it consists of a bolt with wing-nut. Commissioning: Slacken the wing-nut,
unscrew the screw for about 4 mm. and fix it again with the wing-nut. Transport: slacken
the wing-nut, screw the screw by hand and then fix it again with the wing-nut. For the
transport of the R134a refrigerant, specific regulations are in force in every country.
Therefore, refer to your reseller or your authorised service centre for information.