yellow jacket 800 Series User manual

Automatic Refrigerant Recovery/Recycling/Recharge System
Model 39800
Operation Manual
For Automotive Applications
YELLOW JACKET
®

2
Refrigerants: All Models: R-134a
Compressor: 1/2 HP Hermetic Compressor
Power Source: 120V AC 60Hz for US Models/ 230V AC 50Hz for CE Models
Amperage: RLA: 9.3 RLA:
FLA:11.0 FLA:
LRA: 30.0 LRA: 19.0
Size: 800 Series
Height: 45 in
Width: 19.5 in
Depth: 29 in
Weight: Maximum is deluxe unit at 225 lb. w/ Tank
Before operating this unit, please read this man-
ual thoroughly. You must understand the proce-
dures outlined in this manual. Failure to follow
these procedures could void all warranties.
Before handling refrigerants, read the material
safety data sheet (MSDS) from the refrigerant
manufacturer.
Inhalation of high concentration of refrigerant
vapors is harmful and may cause heart
irregularities, unconsciousness, or death.
Deliberate inhalation of refrigerants is
extremely dangerous. Death can occur without
warning. Vapors reduce oxygen available for
breathing and are heavier than air. Decomposi-
tion products are hazardous. Liquid contact
can cause frostbite. All refrigerant containers,
equipment, and hoses are under pressure.
Model 800 Series Refrigerant Management System
Section Page Section Page
Specifications 2 MODE 6: Tank Refill 9
Safety Instructions 3 MODE 7: Refrigerant Management System 9
Component Diagram 4 Purging Non-Condensable Gases 10
Control Panel Overview 5 Maintenance Reminders 10
Setup/Check List/User Options 6 Filter change/compressor oil/vacuum oil
MODE 1: Recovery Only 7 Troubleshooting Information 11
MODE 2: Vacuum 7 Common Problems 12
MODE 3: Charge Only 8 LCD Error Messages 13
MODE 4: Full Cycle 8 Repair Parts List 14
MODE 5: Oil Inject 9 Warranty Information 14
Table of Contents
Specifications

3
Know your equipment. Read and understand the
operation manual and labels affixed to the unit. Learn
it’s application and limitations as well as the specific
potential hazards of your equipment.
ALWAYS WEAR SAFETY GOGGLES.
Ground all equipment. This unit is equipped with an
approved 3 prong grounding-type plug. The green
ground wire should never be connected to a live
terminal.
Use the Proper Extension Cords. Use the following
guide for choosing the proper extension cord:
Wire Maximum Length
18 Ga. 10 feet
16 Ga. 25 feet
14 Ga. 50 feet
12 Ga. 100 feet
Avoid Dangerous Environments. Do not use this
unit in damp locations or expose it to rain. This
equipment should be used in a location with
mechanical ventilation that provides at least four air
changes per hour. This equipment should not be used
near open containers of flammable liquids.
Disconnect Unit from Power Supply Before
Servicing. An electrical shock hazard is present
when the unit is disassembled or the cowling is
removed.
Repair Damaged Parts. Do not operate the unit with
a defective part. Repair unit to proper operating
conditions.
Use Recommended Accessories. Follow the
instructions that accompany all accessories.
Improper use of accessories may damage equipment
or create a hazard.
Use Caution When Connecting or Disconnecting.
Improper usage may result in refrigerant burns ( frost-
bite). If a major refrigerant leak occurs, proceed
immediately to a well ventilated area. The hoses
included with this unit are supplied with couplers that,
when closed, prevent refrigerant vapors from venting
when disconnecting from the automobile.
Only Use the Model 800 Series with the Correct
Refrigerants. See the specifications for a list of
compatible refrigerants.
Operate the Unit within the Design Environment.
The Model 800 series was designed to operate in a
temperature range from 40°F to 120°F. The unit
should also not be operated in a wet location.
WARNING! Refrigerant, in liquid and vapor form, is a
potentially hazardous material. Please consult the
manufacturer’s Material Safety Data Sheet for
additional information and adhere to the following
safety guidelines:
• Avoid breathing high concentrations of vapors.
• Use with sufficient ventilation to keep operator
exposure below recommended limits, especially in
enclosed and low lying areas.
• Avoid contact of liquid refrigerant with the eyes
and prolonged skin exposure.
• Wear goggles and protective gloves.
• Do not attempt to operate this unit above 120°F
ambient temperature.
• Do not allow refrigerants to contact open flame.
Refrigerant decomposition in a flame results in
phosgene gas. Breathing phosgene gas can be
fatal.
FIRST AID: If high concentrations of refrigerant are
inhaled, immediately remove the victim to fresh air.
Call a physician or emergency medical technician.
Keep calm. If not breathing, give artificial respiration.
If breathing is difficult, give oxygen. Do not give
epinephrine or similar drugs.
• EYE: In case of liquid contact, immediately flush
eyes with plenty of water. Call a physician.
• SKIN: Flush with water. Treat for frostbite, if
necessary, by gently warming the effected area.
CAUTION! All refrigerant hoses, recovery tanks,
refrigerant lines, the Model 800 series, and other
vessels containing refrigerants should be handled as
if under high pressure.
General Safety Instructions

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Component Location and Description
1. Touch Pad (Control Panel)
2. High Gauge
3. Low Gauge
4. Auto High Side Hose (Red)
5. Auto Low Side Hose (Blue)
6. Tank Liquid Hose (Red)
7. Tank Vapor Hose (Blue)
8. Oil Drain Bottle
9. Oil Inject Bottle
10. Tool Tray
11. Main Power Switch
12. Oil Inject Switch
13. Storage Tank
14. Vacuum Pump
11.
4.
1.
2.
8.
5.
9.
3.
12.
10.
13.
7.
6.
14.

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LCD Display
The Liquid Crystal Display (LCD) display provides the
unit operator with continual updates of the status of
the Model 800. In addition, the display will prompt the
technician for the user input needed to continue
operation. The LCD shows error codes for rapid
diagnosis of abnormal conditions.
The display is divided into five fields which aid the
technician in rapidly reading information.
1. Weight - Shows the weight of refrigerant being
processed in each mode.
2. Time (MINS) - Shows the time set for either Flush
or Vacuum. Timer will count down to display the
time left.
3. Purge - A “Y” in this field indicates non-
condensable gases such as air are present in the
storage tank. The unit will purge automatically
next time the unit is turned on when the “Y” is
displayed. An “N” indicates non-condensable
gases are below the set limit. An “E” indicates the
unit purged for thirty (30) seconds and non-
condensable gases are still present. This is a
safety feature which prevents excess purging
when a malfunction occurs somewhere in the
system. See the Purging Non-Condensable Gas
section for further details.
4. Mode - Displays the Mode number of the current
operation.
5. Status Line - Displays programming commands
and informs the user of current status of the unit.
Mode Selection Keys
The Mode Selection Keys allow the technician to
select a specific operation. Six Mode keys are
located on the left side of the control panel. One key,
the Refrigerant Management System Key, is located
on the right side.
1. MODE 1 - Recover Only, is used to recover and
recycle refrigerant from an automobile A/C
system. This mode is most often used prior to
opening an A/C system to atmosphere to replace
a system component.
2. MODE 2 - Vacuum is used to vacuum air from a
system previously opened to the atmosphere.
This mode will then proceed to recharge the A/C
system. This mode also allows the technician to
verify the A/C system will hold a vacuum for a
certain length of time.
3. MODE 3 - Charge Only, adds refrigerant to an A/C
system and is most commonly used to “top off” the
system.
4. MODE 4 - Full Cycle, performs a complete recov-
ery, recycling, evacuating and charging of an
automobile A/C system.
5. MODE 5 - Oil inject, injects the oil into the system.
6. MODE 6 - Tank Refill, is used to add new refriger-
ant to the storage tank.
7. MODE 7 - Refrigerant Management System, gives
the technician access to information about
refrigerant use to date.
Function Keys
The Function Keys are used to enter data into the
system in a variety of modes.
FUNCTION A - INCREASE. Press INCREASE to
raise values on the display for user-input information.
Holding the button depressed will increase the rate of
change.
FUNCTION B - DECREASE. Press DECREASE to
lower values on the display for user-input information.
Holding the button depressed will increase the rate of
change.
FUNCTION C - WEIGHT CONVERSION. Press
WEIGHT CONVERSION to change the displayed
units of weight. The choices are: pounds/ounces,
pounds, ounces, and kilograms.
ENTER - Press ENTER to accept the value on the
LCD after using the INCREASE or DECREASE keys.
Operation Keys
START- Press START to begin a selected operational
mode.
RESET- Press RESET to cancel the current opera-
tion. The RESET may have to be pushed more than
once to return to “Select Mode” screen.
Control Panel Features
WEIGHT
TIME
(MIN) PURGE
MODE STATUS LINE
2LB 4OZ 15MIN N
3 CHARGING

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Initial Setup
To ensure quick, successful integration of the Model
800 series into your shop, please follow these set-up
procedures before the first use of the unit.
Step 1: FILL VACUUM PUMP WITH OIL
1. Remove thumbscrews located under the vacuum
pump shelf.
2. Rotate the front of the vacuum pump out to
expose the oil fill port.
3. Remove the red protective cap from the oil fill port
and discard it.
4. Remove the fill cap located on top of the vacuum
pump.
5. Using a funnel, insert oil to the oil level line using
the provided YELLOW JACKET vacuum pump oil.
6. Replace the oil fill cap.
7. Rotate the vacuum pump back into its original
position and replace the thumbscrews.
Step 2: FILL SOURCE TANK WITH REFRIGERANT
(also see page 11)
1. Attach the tank refill adapter (Part No. 19153) to
the R-134a virgin cylinder.
2. Plug unit into a grounded 110V outlet.
3. Turn on the main power switch.
4. When the display reads “SELECT MODE” press
the TANK REFILL key.
5. Follow the user prompts to complete the tank refill
process.
6. When the display reads “SUPPLY TANK EMPTY”
disconnect blue hose.
7. Remove the tank refill adapter from empty R134a
virgin cylinder and place it in the tool tray located
on top of the unit.
The unit is now ready for operation.
The Recovery Only mode should be used to fully
recovery and recycle all refrigerant from an air
conditioning system. For instance, if the system
needs to be opened to atmosphere to replace a part,
all refrigerant must be removed before opening the
system.
MODE 1 Operational Steps
1. Refer to Pre-Operation Check List.
2. Verify the automobile air conditioning system
is off.
3. Press MODE 1 for recovery operations. The
LCD should read “CONNECT HOSES ENTER
TO CONTINUE.”
NOTE: If desired, the gauges of the 800 SERIES
can now be used to aid investigation of an A/C
system problem. Ensure the automobile A/C
system is turned off prior to selecting a mode on
the 800 SERIES.
2. Connect the high and low side auto service
hoses to the respective high and low side
service ports on the automobile A/C system.
Open the service hose valves.
3. Press ENTER to begin recovery operations.
WARNING: DO NOT RECOVER
CONTAMINATED REFRIGERANT WITH THIS
UNIT. RECOVERING CONTAMINATED
REFRIGERANT WILL VOID ALL WARRANTIES
AND MAY CAUSE DAMAGE TO OTHER
AUTOMOBILES SERVICED IN THE FUTURE.
During the recovery operation, refrigerant is removed
from both the high and low side of the automobile air
conditioning system. The LCD will display the amount
of refrigerant being recovered and the status line will
read “RECOVERING REFRIG.”
Note: If “RECOVERY HOLD” Option is selected
The unit will stop at 6” of mercury and hold for five
min as required by EPA Per SAE J2211. If the
pressure rises to 0 psi the compressor will restart and
the unit will pull down to the required 6” of mercury
and hold for two minutes. The unit will repeat this
process until the system pressure remains stable at
vacuum for two minutes or until it fails this process
five times. If the process fails five times the status line
will read “ LEAK CHECK FAILED.” This may mean
that the automobile A/C system has a gross leak and
it will not hold a vacuum.
If this occurs take the appropriate steps to locate the
leak and properly repair it.
If the “RECOVERY HOLD” option is not selected the
unit will shut off at the required level of vacuum and
the operator must insure that the EPA standard (SAE
J2211) is met..
After the system turns off, the unit will beep to alert
the technician the job is complete. The oil removed
from the auto will drain into the oil drain bottle on the
side of the unit. Because a small amount of gas will
be released as the oil drains, a small hissing sound
may come from the bottle.
Mode 1– Recovery Only

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6. Verify the message on the LCD reads
“RECOVERY COMPLETE.”
7. Press the RESET button. The LCD should read
“CHECK OIL LEVELS.”
8. Shut the service valves and disconnect the high
and low side auto service hoses from the
automobile.
9. Measure the oil in the oil drain bottle. Dispose of
recovered oil in a proper manner.
10. Use the oil injection switch to add new oil back
into the automobile A/C low side port in
accordance with the automobile manufacturer’s
recommendations. Add an amount of new oil
equal to the amount collected in the oil drain
bottle.
Mode 1– Recovery Only, cont.
Mode 2– Vacuum
The vacuum function of the 800 SERIES is designed to
remove moisture from the automobile A/C system by pull-
ing a deep vacuum. This mode is most often used after
completing a repair that required opening the A/C system to
the atmosphere. Moisture in an A/C system can cause er-
ratic operation and must be removed before recharging the
system with refrigerant.
MODE 2 Operational Steps
1. Refer to the Pre-Operation Check List.
NOTE: If desired, the gauges of the 800 SERIES can
now be used to aid investigation of an A/C system
problem. Ensure the automobile A/C system is turned
off prior to selecting a mode on the 800 SERIES.
2. Verify the auto air conditioning system is off.
3. Press MODE 2 for Vacuum.
4. The LCD will read “CONNECT HOSES PRESS
ENTER TO CONTINUE”
5. Connect the high and low side auto service hoses
to the respective high and low side service ports
on the automobile A/C system. Open the service
hose valves.
6. Press the ENTER key.
7. When the LCD reads “SET VACUUM TIME,” set
the vacuum time by pressing and holding
INCREASE or DECREASE until the desired time
is shown. Release the button and press ENTER
to accept the vacuum time shown on the LCD. By-
pass vacuum time by setting time to zero.
8. When the LCD reads “SET VACUUM HOLD
TIME,” set the vacuum hold time by pressing and
holding INCREASE or DECREASE until the
desired time is shown. Release the button and
press ENTER to accept the vacuum hold time
shown on the LCD. Vacuum hold time can be
bypassed if the time is set to zero. Answer
Question: OIL INJECT PAUSE ? “Y” for “Yes.”
Press the increase or decrease key to switch
between Y and N.
9. The LCD should read “PUSH START.”
10. Press START key to begin vacuum and charg-
ing operations.
Note: If the automobile A/C system has pressure on it, the
unit will automatically begin a recovery cycle to insure that
no refrigerant is released into the atmosphere.
12. The 800 SERIES will begin to evacuate the A/C
system and will beep to indicate the end of the
vacuum time.
13. When the unit prompts you to “INJECT OIL
NOW” press and hold the OIL INJECT button until
the desired amount of oil has been injected into
the system.
14. Press the ENTER key to continue
15. Record the vacuum level shown on the low
pressure gauge and press START to begin the
vacuum hold time. The hold time will count down
on the LCD and the unit will beep at the end of the
hold time.
16. Record the final vacuum level shown on the low
pressure gauge. If the two recorded vacuum lev-
els are different, the A/C system may have a leak
and might not retain refrigerant when charged.
17. Verify the message on the LCD reads “VAC
COMPLETE.”
18. Press the RESET button. The LCD should read
“CHECK OIL LEVELS.” Unit will force a hose
clearing routine (see full cycle).
19. Shut the service valves and disconnect the high
and low side auto service hoses from the
automobile.
Press the RESET button to return to the “SELECT
MODE” status.

8
Mode 3 – Charge Only
The Charge Only function is designed to add a
precise amount of refrigerant when the A/C system is
low on refrigerant. This mode is most often used
when the A/C system is working but does not produce
sufficiently cold air.
MODE 3 Operational Steps:
1. Refer to the Pre-Operation Check List.
NOTE: If desired, the gauges of the Model 800
can now be used to aid investigation of an A/C
system problem. Ensure the automobile A/C
system is turned off prior to selecting a mode on
the Model 800.
2. Verify the auto air conditioning system is off.
3. Press MODE 3 for Charge Only.
4. The LCD will read CONNECT HOSES ENTER TO
CONTINUE. Press the ENTER key.
5. Connect the high and low side auto service hoses
to the respective high and low side service ports
on the automobile A/C system. Open the service
hose valves.
6. When the LCD reads “SET CHARGE AMOUNT,”
set the amount of refrigerant to be charged into
the A/C system by pressing and holding the
INCREASE or DECREASE key until the desired
amount is shown. Release the key and press
ENTER to set the charge amount on the LCD.
7. The LCD should read “PUSH START.”
8. Press START key to begin charging operations.
The 800 Series will start the charge cycle.
The LCD will display the charging process progress.
The unit will beep when the desired charge amount
has been transferred to the A/C system.
9. Verify the message on the LCD reads “CHRG
ONLY COMPLETE.” Unit will force a hose
clearing routine (See Full cycle).
10. Shut the service valves and disconnect the high
and low side auto service hoses from the auto.
11. Press the RESET key to return to the “SELECT
MODE” status.
Mode 4 – Full Cycle
The Full Cycle function of the Model 800 is designed
to remove and recycle all refrigerant in an A/C system
by transferring the refrigerant to the storage tank,
remove moisture in the system by pulling a vacuum,
and charging the system with a precise amount of
refrigerant.
MODE 4 Operational Steps
1. Refer to the Pre-Operation Check List.
NOTE: If desired, the gauges of the Model 800
can now be used to aid investigation of an A/C
system problem. Ensure the automobile A/C
system is turned off prior to selecting a mode on
the Model 800.
2. Verify the auto air conditioning system is off.
3. Press MODE 4 for Full Cycle. The LCD will read
“CONNECT HOSES”
4. Connect the high and low side auto service hoses
to the respective high and low side service ports
on the automobile A/C system. Open the service
hose valves. Press the ENTER key to continue.
5. When the LCD reads “SET VACUUM TIME,” set
the vacuum hold time by pressing and holding
INCREASE or DECREASE until the desired time
is shown. Release the button and press ENTER
to accept the vacuum hold time on the LCD.
NOTE: Vacuum hold time can be bypassed if the
time is set to zero.
6. When the LCD reads “SET VAC HOLD TIME,”
set the vacuum time by pressing and holding
INCREASE or DECREASE until the desired time
is shown. Release the button and press ENTER to
accept the vacuum hold time shown on the LCD.
NOTE: Vacuum hold time can be bypassed if the
time is set to zero.
7. When the LCD reads “SET CHARGE AMOUNT,”
set the amount of refrigerant to be charged into
the A/C system by pressing and holding
INCREASE or DECREASE until the desired
amount is shown. Release the button and press
ENTER to accept the charge amount on the LCD.
8. The LCD should read “PUSH START.”
9. Press START KEY to begin full cycle operations.
10. The unit will begin to recover as outlined for the
Recovery Only cycle, and then evacuate the A/C
system and will beep to indicate the end of the
vacuum time— if Vacuum Hold is used.

9
7. Record the vacuum level shown on the low
pressure gauge and press START to begin the
vacuum hold time. The hold time will count down
on the LCD and the unit will beep at the end of the
hold time. If vacuum hold time was set to zero, the
unit will transition into charge mode.
8. Record the final vacuum level shown on the low
pressure gauge. If the two recorded levels are dif-
ferent, the A/C system may have a leak and may
not retain refrigerant when charged. The Model
800 will automatically start the charge cycle.
The unit will prompt you to “INJECT OIL NOW” press
and hold the oil inject key until the desired amount of
oil is injected into the A/C system.
The LCD will display the progress of the charging
process. When the desired charge amount has been
transferred to the A/C system, the unit will beep.
13. Verify the message on the LCD reads “FULL
CYCLE COMPLETE.”
14. Press the RESET button. The LCD should read
“CHECK OIL LEVELS.” The LCD will read
“HOSES NEED CLEARING”
15. Press the Enter Key. The unit will then prompt
you to “DISCONNECT VEHICLE.”
16. Shut the service valves and disconnect the high
and low side auto service hoses from the auto.
17. Press the ENTER key; the LCD will read
“CLEARING HOSES.”
18. Measure the oil in the oil drain bottle. Dispose of
recovered oil in a proper manner.
19. Press the RESET button to return to the
“SELECT MODE” status.
Mode 4 – Full Cycle, cont.
Mode 5– Oil Inject
When prompted, press this key and watch the oil
inject bottle until the correct amount of oil has been
injected. Release the key when the correct amount of
oil has been added to the system.
Mode 6– Tank Refill
In order to use the charging mode, you must have at
least six (6) pounds of refrigerant in the storage tank.
Follow this procedure to add refrigerant to the storage
tank. When adding R-134a to the tank of either a
Model 800, you will need to use the tank refill adapter
supplied in the accessory kit. This adapter connects
the low side auto service coupling to the tank of new
R-134a refrigerant. It should be stored in the tool tray
on the top of the unit.
1. Refer to the Pre-Operation Check List.
2. Select MODE 6– Tank Refill.
3. Connect the blue low side auto service hose to the
new refrigerant source tank and open the tank
valve. Turn the source tank upside down to
ensure all of the refrigerant is transferred to the
storage tank on the unit.
4. Press the ENTER button. Refrigerant will transfer
to the storage tank. The unit will shut off auto-
matically when either the supply tank is empty or
the storage tank is full.
Press the RESET key to return to the “SELECT
MODE” status.
Mode 7– Refrigerant Management System
The Refrigerant Management System (RMM) built into
the Model 800 tracks all aspects of refrigeration
usage. The information can significantly help you
manage your automobile A/C repair business. In
addition, new federal regulation require strict records
of your refrigerant usage. The software in this system
is designed to ensure the highest possible accuracy in
managing refrigerant usage. Refrigerant measure-
ment during charging is extremely accurate. In
recovery mode, however, accuracy is plus or minus
three ounces based on variations in air temperature
and pressure.
Uses of the refrigerant data include:
• Improved record keeping
• Accurate determination of net profits
• Reduced billing errors
• Minimized refrigerant loss from leaks and theft
• Reduced operator errors

10
Purging Non-Condensable Gases
The Model 800 is designed to automatically purge
non-condesable gases such as air present in the
storage tank. When the pressure in the tank exceeds
a threshold value, the unit will automatically purge the
excess pressure. The unit will only purge when it is
first turned on. The current purge status is displayed
in the upper right corner of the LCD when in Select
Mode.
The purge status in the LCD should be either “Y”,
“N”, or “E.” A “Y” indicates air is present in the tank.
The unit will purge the next time it is turned off and on.
An “N” in the window indicates a purge is not needed.
An “E” will display on the LCD if the previous purge
was insufficient to lower the non-condensable gas
value below the limit. The purge time is set to 30
seconds to minimize refrigerant loss. If the LCD
continues to display an “E” after several purge
cycles, there may be an error in the system. Check
the pressure in the tank to determine if the system is
purging unnecessarily.
If the unit continues to display “Y” or an “E” and the
tank pressure is near the value in the table below,
contact Ritchie Engineering Customer Service at
[phone].
Mode 7– Refrigerant Management System, cont.
The refrigerant management information is stored in
nine registers. To access the information, press
Mode 7, REFRIGERANT MANAGEMENT SYSTEM.
Press INCREASE or DECREASE to cycle through the
registers. The registers are:
Register 1: Total number of jobs to date.
Register 2: Cumulative run time in minutes.
Register 3: Refrigerant recovered during last job.
Register 4: Refrigerant charged in last job.
Register 5: Run time of last job.
Register 6: Total amount of refrigerant recovered to
date.
Register 7: Total amount of refrigerant charged to
date.
Register 8: Total of all new refrigerant added to the
storage tank to date.
Maintenance Reminders
Approximate Pressure (psig)
Temp (ºF) R-12 R-134a
65 74 74
70 80 81
75 87 88
80 96 97
85 102 115
Temp (ºF) R-12 R-134a
90 110 120
95 118 126
100 127 135
105 136 145
110 146 155
FILTER - “MAINT-FILTER CHG DUE”
The Model 800 has a unique filter system which
ensures the refrigerant transferred to the storage
cylinder is clean and moisture-free. The filters must be
changed periodically to ensure the system is working
properly. A maintenance reminder prompts you when
to change your filters. All refrigerant must be removed
from the old filters before they are removed. Follow
the filter change procedures carefully to minimize
refrigerant loss and ensure only clean, moisture-free
refrigerant is transferred into the storage cylinder.
Pressing the ENTER key will turn the reminder off
until the next time you start the unit. Pressing the
RESET key will reset the reminder until the next
scheduled maintenance.
Filter Change Steps:
1. Turn on system power
2. Run recovery cycle
3. Remove filter drier
4. Replace filter drier

11
Maintenance Reminders, cont.
Maintenance—Compressor Oil
The oil should be checked for contamination and
proper oil level when the compressor oil maintenance
reminder is displayed. Pressing the ENTER key will
turn the reminder off until the next time you start the
unit. Pressing the RESET key will reset the reminder
until the next scheduled maintenance.
Instructions for Oil Maintenance
Oil Level Check
1. Place unit on a level surface and run a recovery
cycle with the unit.
2. Unplug unit.
3. Remove front cover of unit.
4. Slowly remove oil port cap on compressor.
Note: High pressure may be present, remove cap
slowly.
5. Place rear wheels of unit on a 2 x 4.
6. Oil should drip out of oil drain port.
7. If oil runs out of port rapidly, allow to drain.
8. Replace oil port cap and cover.
9. Dispose of oil properly.
Oil Replacement Procedure
1. Follow steps 1 thru 4 in the oil level check.
2. Tilt unit at 45° angle towards oil drain. port until all
oil has been drained.
3. Refill with proper amount and type of oil. The
proper oil charge is 8.0 ounces or 225 cc’s of
Artic 22 Castrol SW 22 POE oil.
4. Replace oil port cap and front cover.
5. Dispose of oil properly.
Note: Failure to perform oil maintenance can cause
the compressor to overfill with oil and severely
damage the compressor.
Oil
Drain
Port
Maintenance— Vacuum Pump Oil
Pressing the ENTER key will turn the reminder off un-
til the next time you start the unit. Pressing the RE-
SET key will reset the reminder until the next sched-
uled maintenance.
Check oil level when pump is running.
When pump is running, oil level should be 1/2 to 5/8
up in the sight glass. This level is necessary for
proper operation.
This Maintenance is Best Performed when the oil
is warm.
1. Remove thumb screws under vacuum pump.
2. Rotate the front of the vacuum pump towards the
rear of the unit.
3. Place a container under the oil drain plug and
remove the oil drain plug.
4. Drain oil into the container.
5. Dispose of the oil properly.
6. Refill the vacuum pump with YELLOW JACKET
(Quart Part no.
93192) vacuum
pump oil to the cor-
rect level.
7. Reverse Steps 1-2.
Oil drain plug
Oil fill port
Oil sight glass
Troubleshooting Information
The Model 800 has a number of sophisticated
features which make it by far the most user friendly
A/C service system in the world. The unit was
designed for easy operation, service and trouble-
shooting. Although the Model 800 was manufactured
with high quality components, a component failure
could cause it to operate incorrectly.
The following section is designed to provide you with
additional information to help diagnose a system. If a
problem occurs, please read this section thoroughly
prior to calling technical support. This will reduce the
time needed to restore your system to normal
operation. Technical support can be reached at
[phone].

12
Common Problems and Potential Solution
Problem Possible Causes Possible Solutions
Model 800 cannot pull
automobile A/C system
into a vacuum
• Service valves on hoses not properly installed
on A/C system.
• Service ball valve seals are worn.
• Hoses on unit are loose or leak.
• Automobile A/C system has a leak.
• Check valve seals and threads and replace if needed.
• Replace valve seals and Schrader core depressor.
• Tighten or replace hoses on unit.
• Find and repair leak in A/C system.
High side gauge
readings above normal
• Restriction in A/C system or Schrader core.
• Service hose ball valve closed.
• Incorrect charge amount entered in unit.
• Check hose connection and fix restriction. Replace
Schrader core.
• Open valve.
• Recover, check scale calibration, and recharge
system.
Refrigerant not being
transferred during Tank
Refill.
• Valve on supply tank closed.
• Ball valve on blue service hose closed or
hose is constricted.
• Wrong hose installed on new refrigerant tank.
• Storage tank is full.
• Open Valve.
• Open valve or straighten hose.
• Install blue service hose on refrigerant tank.
• Close valve on new supply. Disconnect service hose.
Touch Pad will not
accept commands
• Button on touch pad is stuck.
• Bad Touch Pad.
• Wire disconnected between touch pad and
microprocessor.
• Microprocessor malfunction.
• Feel for non-responsive button. If not responding, call
Technical Support.
• Call Technical Support.
• Call Technical Support.
• Call Technical Support.
Fan not running in any
cycle
• Loose power wire to fan.
• Microprocessor malfunction.
• Fan malfunction.
• Locate loose fitting and reconnect.
• Call Technical Support.
• Call Technical Support.
Machine will not turn on • Power cord is not plugged into a 120 Volt
outlet.
• Circuit breaker tripped on shop power panel.
• Bad Main Power switch.
• Loose wire.
• Bad Transformer on microprocessor board.
• Plug into outlet.
• Reset circuit breaker. If circuit breaker immediately
trips, do not reset. Consult a qualified electrician.
• Call Technical Support.
• Repair loose wire.
• Call Technical Support.
Unit will not recover
refrigerant from A/C
system
• Valves on service hoses shut.
• Service hose is constricted.
• Unit storage tank valve is closed.
• Open valves.
• Straighten hose.
• Open tank valves.
• Compressor not operating. • Call Technical Support.
Unit will not charge
refrigerant into vehicle
• Valves on service hoses shut
• Service hose is constricted
• Unit storage tank valve is closed
• Open valves
• Straighten hose
• Open tank valves
• Compressor not operating • Call Technical Support.
Refrigerant leaking
during charging
• Service valves on hoses not properly installed
on A/C system.
• Check valve seals and threads and replace if needed.
• Service ball valve seals are worn. • Replace valve seals and Schrader core depressor
• Hoses on unit are loose or leak. • Tighten or replace hoses on unit
• Automobile A/C system has a leak • Find leak in A/C system and repair.

13
LCD Error Messages and Potential Solution
Error Possible Causes Possible Solutions
Hi Pressure Limit • Service valves on hoses closed • Open valves
• Schrader core on A/C system not depressing • Replace Schrader core
Tank Empty • No refrigerant in storage tank • Refill storage tank using Mode 6, Tank Refill
• Tank not properly on scale • Reposition scale
• Scale cord not properly connected • Check scale cord connection
• Scale is out of calibration • Re-calibrate scale using Utility Mode
Supply Tank Empty • Tank of new refrigerant is empty • Close supply tank valve and disconnect hoses. If
tank is not empty, see “Refrigerant not being trans-
ferred during Tank Refill.”
Tank Full • Tank is 80% full • Charge some refrigerant or transfer to another tank.
• Scale is out of calibration • Re-calibrate scale using Utility Mode
• Tank not properly on scale • Reposition tank
Time Limit (during
charging cycles)
• Tank on unit is closed
• Default time limit is too short
• Open tank valve
• Use default time of 10 minutes unless A/C system
• Compressor not running • Call Technical Services
• Tank or scale misaligned • Reposition tank and scale
Time Limit (during
recovery cycle)
• A/C system has a leak • Locate and repair leak
• Valves on service hoses shut • Open valves
• Service hose is constricted • Straighten hose
• Unit storage tank valve is closed • Open tank valves
• Compressor not operating • Call Technical Services
No Scale • Scale cord not connected • Properly connect cord
• Scale cord damaged • Call Technical Services
• Microprocessor malfunction • Call Technical Services
No Tank • Tank is not on scale • Place tank on scale
• Scale out of calibration • Calibrate scale using Utility Mode
Possible Overcharge • Tank was disturbed during charging cycle • Re-start Full Cycle
• Internal failure of unit • Call Technical Services
Accum Time Limit • Internal failure of unit • Call Technical Services
Accum Hi Pressure • Internal failure of unit • Call Technical Services
Purge “Y” • Non-condensable gases are present in
storage tank
• Turn unit off and on to start purge cycle
Purge “N” • Non-condensable gases are NOT present in
storage tank
• Normal condition
Purge “E” • Time limit was reached before purge cycle
was complete.
• Turn unit off/on to start purge cycle. If “E” remains
after three on-off cycles, contact Technical Support.

14
Model 800 Repair Parts List
Part # Description
95173 High Pressure Switch
38023 Vacuum Switch
Capacitor
Relay
38026 Differential Switch
Membrane Touch Pad
Microprocessor
95157 Circuit Breaker, 15 Amp
Automatic Scale Assembly
Part # Description
27296 R-134a Auto Low Side Blue Hose (10ft)
27696 R-134a Auto High Side Red Hose (10ft)
00849 R-134a Tank Vapor Blue Hose (30in)
00853 R-134a Tank Liquid Red Hose (30in)
19153 R-134a Tank Refill Adapter
95006 50lb Refrigerant Tank
Filter-Dryer (2 per unit)
38019 Oil Bottle
38053 Service Compressor
Recovery Division
6701 W. 110th St.
Bloomington, MN 55438 USA
Phone: [phone]
Toll Free: 800-769-8370
Fax: [phone]
Toll Free: 800-322-8685
E-mail: [e-mail]
Web Site: www.yellowjacket.com
Warranty Information
LIMITED WARRANTY
Ritchie Engineering guarantees YELLOW JACKET®products to be free of defective material and workmanship which would affect the
life of the product under normal use for the purpose for which it was designed.
This warranty does not cover items that have been altered, abused, misused, improperly maintained, or returned solely in need of field
service maintenance. This warranty expressly excludes Vacuum Pump damage and failures caused by failure to maintain clean,
uncontaminated oil in the pump – the major reason for pump returns. Therefore, problems related to non-maintained oil will void this
warranty on that part of the product.
This warranty does not cover abuse, damage from over tightening valves, or broken gauges. “Series 41” Manifold valves can be re-
conditioned using replacement seating cylinder 41133. There will be a reconditioning charge for manifolds returned to the factory for
repair.
If found defective, we will upon compliance with the return instructions either credit, replace, or repair, at our option, the defective
product provided it is returned within one year of the date of factory shipment (90 days for tubing tools). Note: Hoses are Date Coded
to help determine age of hose. See recommended hose safety inspection procedure. Leak detectors have date of manufacture label
on product.
Correction in the manner provided above shall constitute a fulfillment of all liabilities with respect to the quality, material and workman-
ship of the product. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUALITY,
WHETHER WRITTEN, ORAL OR IMPLIED.
WARRANTY RETURNS - For HVAC&R Recovery Units and for Automotive Recovery, Recycle, Recharge equipment, call 1-
800-769-8370 for instructions for service, repair, or return. Our automatic series (Models 39870, 39750, 39751, 39770, 39771,
39800, 39830, 39832, 39833, 39840, 39841, 39842, 39843) has a two year full parts and labor warranty, the semi– automatics
(Models 39710, 39711, 39730, 39731, 39732, and 39733) and hand held machines (Models 39702 and 39704) have a full one years
parts and labor warranty. For all other products, please return warranty items to the main factory in Bloomington, MN, prepaid for
credit, replacement, or repair, at our option. No authorization is required. All returns must be PREPAID. On direct drive pumps, many
of the problems can be solved over the telephone. Call 952-943-1333.
NON-WARRANTY RETURNS - Prior authorization must be obtained from home office for non-warranty returns. All returns must
be PREPAID. Minimum restocking charge 20% on standard items of current date coding and manufacture. Special production items
will have a higher restocking charge. Many items shown in our price list are custom-fabricated to customer’s order.
Printed in U.S.A 06-06 FK P/N 380496