yellow jacket 39830 User manual

For Automotive Applications
Model 39830
Operation Manual
YELLOW JACKET
®
Automatic Refrigerant
Recovery/Recycling/Recharging & Flushing System

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: 830 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
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,
Model 830 Series Refrigerant Management Systems
Section Page Section Page
Specifications 2 MODE 6: Tank Refill 11
Safety Instructions 3 MODE 7: Refrigerant Management System 11-12
Component Diagram 4 Purging Non-Condensable Gases 12
Control Panel Overview 5 Maintenance Reminders 13-14
Setup/Check List/User Options 6 Compressor oil/vacuum oil/filter change
MODE1: Recovery Only 7-8 Troubleshooting Information 14
MODE 2: Vacuum & Charge 8 Common Problems 15
MODE 3: Charge Only 9 LCD Error Messages 16
MODE 4: Full Cycle 9-10 Repair Parts List 17
MODE 5: Oil Flush 10-11 Warranty Information 18
Table of Contents
Specifications
2

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 follow-
ing 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 me-
chanical ventilation that provides at least 4 air
changes per hour. This equipment should not be
used near open containers of flammable liquids.
Disconnect Unit from Power Supply Before Ser-
vicing. 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 operat-
ing conditions.
Use Recommended Accessories. Follow the in-
structions that accompany all accessories. Im-
proper use of accessories may damage equipment
or create a hazard.
Use Caution When Connecting or Disconnect-
ing. Improper usage may result in refrigerant burns
( frostbite). 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 830 Series with the Correct
Refrigerants. See the specifications for a list of
compatible refrigerants.
Operate the Unit within the Design Environment.
The Model 830 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 addi-
tion 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 respira-
tion. 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 830 series, and other
vessels containing refrigerants should be handled
as if under high pressure.
General Safety Instructions
3

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. Circuit Breaker
14. Storage Tank
15. Charge Selector Switch
16. Vacuum Pump
4
11.
4.
1.
2.
8.
5.
9.
3.
12.
10.
14.
7.
6.
13.
15.
16.

LCD Display
The Liquid Crystal Display (LCD) display provides
the unit operator with continual updates of the Model
830’s status. In addition, the display will prompt the
technician for the user input needed to continue
operation. The LCD shows error codes for rapid di-
agnosis 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 dis-
play 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 automati-
cally 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 lo-
cated 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 sys-
tem. This mode is most often used prior to
opening an A/C system to atmosphere to replace
a system component.
2. MODE 2 -Vacuum & Charge, 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 Flush, removes oil and refrigerant
from an A/C system.
6. MODE 6 - Tank Refill, is used to add new refrig-
erant 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 informa-
tion. Holding the button depressed will increase the
rate of change.
FUNCTION B - DECREASE. Press DECREASE to
lower values on the display for user-input informa-
tion. 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 opera-
tional 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
5

1. Open tank valves on storage tank. Turn valves
counter clockwise to open.
2. Empty the oil drain bottle.
3. Place charge selector valve in desired position.
The unit can charge either on the high side of
the automobiles A/C system or the low side.
Note: Charging directly on the A/C compressors low
side may damage the compressor. Please follow the
OEM recommended charging procedure. YELLOW
JACKET® is not responsible for any damage that
occurs from not following the recommended service
procedure.
Pre-Operation Check List
6
Initial Setup
To ensure quick, successful integration of the Model
830 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, fill with oil to the oil level line
with 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 R134a 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.
Changing User Options
The user can change the settings of some automatic
options that this unit offers. To change these options
do the following:
AUTO RECOVERY HOLD TIME
The unit comes pre-set from the factory to perform
the Recovery Hold Time. The Recovery Hold Time
automatically performs the hold times that are
recommended in the SAE J 2211 standard to insure
that all of the refrigerant is recovered from the auto-
mobiles A/C system. This process ensures that all
the refrigerant is removed from the A/C system and
also prevents overcharging the A/C system when
you recharge it.
To turn this feature off, perform the following steps:
1. Turn the unit off.
2. Hold the ENTER key down and turn on the main
power switch.
3. When the display reads “PRESS START FOR OP”
release the ENTER key.
4. Press the START key.
5. Press and release the START key until the display
reads “RECOVERY HOLD TIME”.
6. Press the ENTER key.
7. Press the INCREASE key until the display reads
“N”.
8. Press the ENTER key to set change.
9. Turn the unit off to exit the control function.
There are several other user defined options that are
preset from the factory and should not be changed
unless instructed to do so by a factory service tech-
nician or an authorized YELLOW JACKET® service
center.
Here is a list of options and the default settings.
MAX RECOVERY TIME 45 MIN
MAX CHARGE TIME 10 MIN
MAINTENANCE REMINDERS Y

The Recovery Only mode should be used to fully
evacuate 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 830 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 830 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.
(Models with the optional refrigerant
identifier)
The unit will display “ID REFRIGERANT Y/N.” To
make your selection use the increase and decrease
keys to toggle from Y to N. Press the enter key to
enter your selection, If yes is selected the unit will
begin the refrigerant identification process.
If the refrigerant does not pass the identification
process (98% pure) the unit will clear itself and
display an error message “REFRIG ID FAILED.” If
this occurs run the identification process again to
insure that the proper identification of the refrigerant
purity level.
If it fails a second time, disconnect hoses from the
automobile and take the appropriate measures to
recover the refrigerant from the automobile with a
separate unit designated to recover contaminated
refrigerant and have the refrigerant properly
disposed of.
WARNING: DO NOT RECOVER
CONTAMINATED REFRIGERANT WITH THIS
UNIT. RECOVERING CONTAMINATED
REFRIGERANT WILL VOID ALL
WARRANTIES AND MAY CAUSE DAMAGE
TO OTHER AUTOMOBILES THAT YOU
SERVICE 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.
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
Mode 1– Recovery Only
7

The Vacuum & Charge function of the 830 SERIES is
designed to remove moisture from the automobile A/C
system by pulling a deep vacuum and charging the
system with a precise amount of refrigerant. 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 erratic 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 830 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 830
SERIES.
2. Verify the automobile air conditioning system is
off.
3. Press MODE 2 for Vacuum & Charge.
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 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
shown on the LCD.
7. When the LCD reads “SET VACUUM TIME,”
set the vacuum time by pressing and holding IN-
CREASE or DECREASE until the desired time is
shown. Release the button and press ENTER to
accept the vacuum time shown on the LCD. Vac-
uum time can be bypassed if the time is set 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 Ques-
tion: OIL INJECT PAUSE ? Y
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 830 SERIES will begin to evacuate the A/C
system and will beep to indicate the end of the
vacuum time.
13. The unit will prompt you to “INJECT OIL NOW”
press and hold the OIL INJECT switch 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. If vacuum hold time was
set to zero, the unit will transition into charge
mode.
16. Record the final vacuum level shown on the low
pressure gauge. If the two recorded vacuum
levels are different, the A/C system may have a
leak and might not retain refrigerant when
charged. The 830 SERIES will automatically
start the charge cycle.
The unit will begin the charge process using the vacuum
charge method. If the charge amount is not charged in 2
minutes time the unit will begin a power charge cycle to
insure that an accurate charge is achieved.
17. Verify the message on the LCD reads “VAC &
CHRG 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 auto-
mobile.
Press the RESET button to return to the “SELECT
MODE” status.
Mode 2– Vacuum & Charge
recommendations. Add an amount of new oil
equal to the amount collected in the oil drain
bottle.
8

Mode 3– Charge Only
The Charge Only function of the Model 830 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 830
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 830.
2. Verify the automobile 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 INCREASE or DECREASE key until the
desired amount is shown. Release the key and
press ENTER to set the charge amount shown
on the LCD.
7. The LCD should read “PUSH START.”
8. Press START key to begin charging operations.
The 830 Series will start the charge cycle.
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.
9. Verify the message on the LCD reads “CHRG
ONLY COMPLETE.” Unit will force a hose clear-
ing routine (See Full cycle).
10. Shut the service valves and disconnect the high
and low side auto service hoses from the auto-
mobile.
11. Press the RESET key to return to the “SELECT
MODE” status.
The Full Cycle function of the Model 830 is designed
to remove and recycle all refrigerant in an A/C sys-
tem 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 830
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 830.
2. Verify the automobile 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.
5. When the LCD reads “SET VACUUM TIME,”
set the vacuum hold time by pressing and hold-
ing 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.
6. When the LCD reads “SET VAC HOLD TIME,”
set the vacuum time by pressing and holding IN-
CREASE 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 de-
Mode 4– Full Cycle
9

sired amount is shown. Release the button and
press ENTER to accept the charge amount
shown 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.
11. 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.
12. Record the final vacuum level shown on the low
pressure gauge. If the two recorded vacuum
levels are different, the A/C system may have a
leak and may not retain refrigerant when
charged. The Model 830 will automatically start
the charge cycle.
The unit will prompt you to “INJECT OIL NOW”
press and hold the oil inject switch 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-
mobile.
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.
10
Mode 5– Oil Flush
The Oil Flush mode is designed to remove oil from
an automobile A/C system so new oil can be added.
In this mode refrigerant is circulated through the A/C
system and the Model 830. An oil separator in
Model 830 removes the oil and returns oil-free re-
frigerant back into the A/C system. At the end of the
cycle, the refrigerant is completely removed from
the A/C system. The Oil Flush mode is not de-
signed to flush dirt or debris from the A/C system.
This mode can take up to 1 ½ hours to complete.
Because of the variety of A/C system configurations
currently in service, the flush may bypass certain
sections of the A/C system. To ensure the complete
system is flushed, you may need to ”pinch off” cer-
tain hoses to force the refrigerant flush throughout
the system.
MODE 5 Operational Steps
1. Refer to the Pre-Operation Check List.
2. Connect the high and low side auto service
hoses to the respective high and low side ser-
vice ports on the automobile A/C system. Open
the service hose valves.
3. Press MODE 5 for Oil Flush
4. When the LCD reads “SET FLUSH AMOUNT,”
set the flush amount by pressing and holding
INCREASE or DECREASE until the desired
amount is shown. Release the button and press
ENTER to accept the flush amount shown on
the LCD. Testing has shown the ideal flush
amount is three (3) times the normal charge
amount. For instance, if the correct charge
amount for the A/C system being services is two
(2) pounds, the ideal flush amount is four (4)
pounds.
5. When the LCD reads “SET FLUSH TIME,” set
the flush time by pressing and holding IN-
CREASE or DECREASE until the desired time is
shown. Release the button and press ENTER to
accept the flush time shown on the LCD. A
minimum flush time of thirty (30) minutes is rec-
ommended.

Mode 6– Tank Refill
In order to use the charging and flushing modes,
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 830, you will need
to use the tank refill adapter supplied in the acces-
sory kit. This adapter connects the low side auto
service coupling to the tank of new R-134a refriger-
ant. 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.
The LCD will read “BLUE HOSE===> CYLINDER”
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 trans-
fer to the storage tank. The unit will shut off
automatically 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 830 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 sys-
tem is designed to ensure the highest possible accu-
racy in managing refrigerant usage. Refrigerant
measurement during charging is extremely accurate.
In recovery mode, however, accuracy is plus or mi-
nus three ounces based on variations in air tempera-
ture and pressure.
Uses of the refrigerant data include:
• Improved record keeping
• Accurate determination of net profits for your
business
• Reduced billing errors
• Minimized refrigerant loss from leaks and theft
• Reduced operator errors
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.
Register 9: Send data to the optional printer. Press
ENTER to print the refrigerant management data.
11
6. The LCD should read “PUSH START.”
7. Press START to begin flushing operations. The
Model 830 will recover any refrigerant in the A/C
system and charge the system with the selected
flush amount of refrigerant. The refrigerant will
circulate throughout the A/C system and the
Model 830. The unit’s oil separator will remove
the oil from the refrigerant and return the clean
refrigerant to the A/C system. At the end of the
cycle, all refrigerant and oil will be recovered
from the automobile system.
8. The unit will beep to indicate the cycle is com-
plete and the LCD will read “FLUSH CYCLE
COMPLETE.”

12
Purging Non-Condensable Gases
The Model 830 is designed to purge
automatically 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 either be
“Y”, “N”, or “E.” A “Y” indicates air is present
in the tank. The unit will purge next time it is
turned off and on. An “N” in the windows
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.
To check the tank pressure, let the unit sit
undisturbed for at least three hours. Connect
the high side service hose to the auxiliary port
on the storage tank. Read the value on the
high pressure gauge. The reading should be
close to those in the following table.
If the unit continues to display “Y” or an “E”
and the tank pressure is near the value in the
table below, contact technical services at 1-
800-769-8370.
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

13
Maintenance Reminders
Maintenance—Compressor Oil
The oil should be checked for contamination and
proper oil level when the compressor oil mainte-
nance 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 by 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
until the next time you start the unit. Pressing the
RESET key will reset the reminder until the next
scheduled 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 correct level.
7. Reverse Steps 1-2.
Oil drain plug
Oil fill port
Oil sight glass

Filter Maintenance
“MAINT-FILTER CHG DUE”
The Model 830 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 care-
fully 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 off the Main Power.
2. Press and hold the DECREASE button and turn
on the power. This starts the unit in a special
Filter Change Mode.
3. The LCD will display “CLOSE LIQUID VALVE
ON TANK, PUSH START.”
4. Close the liquid valve on the storage cylinder.
Normally this valve has a red handle.
5. Press START and the LCD will display
“CONNECT HIGH SIDE SERVICE HOSE.”
6. Connect the red, high side auto service hose to
the service port located on the “T” fitting
connected to the tank vapor port. This port may
have a brass or red plastic cap which must be
removed before attaching the service hose. Do
not disconnect the short hose from the tank!
7. Press START to begin filter evacuation. The
LCD will display “PLEASE WAIT-
EVACUATING FILTERS.”
The unit will completely evacuate all refrigerant from
the two filters and the internal components of the
unit. The red service hose will be the only
component containing refrigerant when the cycle is
complete. The outside of the filters will develop
frost during evacuation. This is normal and
indicates liquid refrigerant is being removed from
the filters. This operation takes about twenty (20)
minutes.
8. When the cycle is complete, the unit will beep
and the LCD will display “EVACUATION
COMPLETE.”
9. Remove the front cover of the unit.
10. Make note of the flow direction arrows on the old
filters.
11. Loosen the filter bracket. Remove the filters and
discard them. Replace with new filters ensuring
the flow direction arrow is the same as it was on
the old filters.
12. Check all fittings for leaks to ensure no
refrigerant is lost during subsequent system
operation.
13. Remove the red high side auto service hose
from the “T” fitting and replace the service port
cap. Open the liquid valve on the storage tank.
The 830 series is ready for operation.
14
Troubleshooting Information
The Model 830 has a number of sophisticated
features which makes it by far the most user friendly
A/C service system in the world. The unit was
designed to be extremely easy to operate, service
and troubleshoot. Although the Model 830 was
manufactured with high quality components, a
component failure could cause the 830 to operate
incorrectly. YELLOW JACKET® recognizes the
importance of keeping your equipment operational
and rapidly restore it to service when a problem
occurs.
Whenever a problem occurs, please read this
section. It is designed to provide you with additional
information to help diagnose a system problem.
Read this section thoroughly prior to calling technical
services. This will reduce the time needed to restore
your system to normal operation. Technical support
can be reached at 1-800-769-8370.

15
Common Problems and Potential Solution
Problem Possible Causes Possible Solutions
Model 830 cannot pull auto-
mobile 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 depres-
sor.
• Tighten or replace hoses on unit.
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. Re-
place schrader core.
• Open valve.
• Recover, check scale calibration, and recharge
system.
Refrigerant not being trans-
ferred 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 respond-
ing, call Technical Services.
• Call Technical Services.
• Call Technical Services.
• Call Technical Services.
Fan not running in any cycle • Loose power wire to fan.
• Microprocessor malfunction.
• Fan malfunction.
• Locate loose fitting and reconnect.
• Call Technical Services.
• Call Technical Services.
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 immedi-
ately trips, do not reset. Consult a qualified
electrician.
• Call Technical Services.
• Repair loose wire.
• Call Technical Services.
Unit will not recover refriger-
ant 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 Services.
Unit will not charge refriger-
ant 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 Services
Refrigerant leaking during
charge operations
• 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 de-
• 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.

16
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 transferred during Tank Refill.”
Tank Full • Tank is 80% full • Charge some refrigerant or transfer to an-
other 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 cy-
cle was complete.
• Turn unit off and on to start purge cycle. If
“E” remains after three on-off cycles, contact
Technical Services.

17
Model 830 Repair Parts List
Part # Description
95173 High Pressure Switch
38023 Vacuum Switch
Capacitor
Relay
38026 Differential Switch
380401 Membrane Touch Pad
38007 Microprocessor
95157 Circuit Breaker, 15 Amp
95257 6” Fan Motor 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
38003 Filter-Dryer (2 per unit)
38019 Oil Bottle
38053 Service Compressor
68836 Automatic Scale Assembly

18
Ritchie Engineering Co., Inc.
Recovery Division
6701 W. 110th St.
Bloomington, MN 55438 USA
Phone: [phone] or 800-769-8370
Fax: [phone] or 800-322-8684
E-mail: [email protected]
Web Site: www.yellowjacket.com
Printed in U.S.A 06/07 FK P/N 380466 REV B
LIMITED WARRANTY
We guarantee Ritchie 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 re-
turned 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 reconditioned using replacement seating cylinder 41133. There will be a recondition-
ing 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 qual-
ity, material and workmanship of the product.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF QUAL-
ITY, WHETHER WRITTEN, ORAL OR IMPLIED.
Returns (Warranty)
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, 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 ma-
chines (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 re-
pair, 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.
Returns (Non-Warranty)
Prior authorization must be obtained from home office for non-warranty returns. All returns must be PRE-
PAID. 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.
Warranty Information