16. Hose Replacement. Disconnect power supply to the AR400.

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1 16. Hose Replacement The AR400 is equipment with external hoses such as R-12 Low and High Service hoses, R-134 Low and High Service hoses, Tank hoses and vacuum pump hose. The unit also utilizes internal refrigerant hoses between the manifold block and solenoid blocks, the discharge block and purge gauge, the discharge block and DOA chamber and finally between the oil separator and DOA chamber. CPS uses premium refrigerant hose for these hoses. It is not expected that these hoses will degrade during the life of the equipment. The Low and High Service hoses will need replaced periodically do to constant usage when connecting to a mobile a/c system. If a hose needs replace, please read the following: Disconnect power supply to the AR400. Danger: Only a qualified service technician should service this equipment. An Electrical Shock hazard is present which could lead to severe injury or even death. Use either Low Side Refrigerant removal (for Low Side Service hose, High Side Service hose, Manifold to Solenoid Block hoses, Oil Drain hose and Compressor Suction hose) or Complete Refrigerant removal (for all other hoses) procedures in SECTION 3 to remove refrigerant from AR400. Once refrigerant is removed from the hose to be replaced, loosen the fittings on both ends. Replace with new hose. Follow the loosening and tightening procedures in SECTION 3. Check for leaks after installation is complete. 18 S2-18

2 17. Teflon Valve Replacement The AR400 uses four Teflon disc type valves. The valves are used only for the manifold assembly valves and can be easily replaced without removing this assembly from the unit. Use CPS Teflon valve repair kit M2XRK. Use either Low Side Refrigerant removal procedures in SECTION 3 to remove refrigerant from the manifold assembly. Peel the label on the valve knob back to expose a Phillips head screw. Remove the screw. Use a 1 socket wrench to remove brass valve body. Remove and discard the Mylar disc, Teflon disc, brass pin and spring from valve cavity. Install new valve parts. Tighten the brass valve body as follows: Hand tighten, then use the 1 socket wrench until snug. Turn 1/8 of a turn. Do not over tighten. Check for leaks. Secure valve knob on valve stem. 18. Oil Injection Bottle Assembly Replacement The Oil Injection bottle is used to add new oil to an a/c system while under a vacuum. The Oil injection bottle assembly is located on the back of the AR400. It is attached directly to the solenoid block via a check valve. This check valve must be pointing towards the unit. A quick way to check for proper operation is to remove the bottle and start the unit in the Evacuation mode. Once a vacuum is shown on the manifold gauge, open the injection valve. Place your finger over the end of the dip tube. You should feel suction. If no suction, the check valve or the injection valve may be defective. Use the Low Side Refrigerant removal procedure in SECTION 3. Remove the bottle and dip tube from the Oil Injection assembly. Use a ½ inch wrench to loosen the check valve/valve body assembly from the solenoid block. Install new assembly. S

3 A small amount of sealant (use CPS recommended sealant) should be applied to the male pipe thread end of the check valve coming out of the valve body. Be careful not to apply the sealant inside the fitting. The sealant could plug up the check valve. Remove the bottle and dip tube. Hand-tighten the 1/8 male pipe thread fitting into the solenoid block pipefitting. Once hand tight, use a ½ inch wrench until resistance is felt. Align the assembly so the bottle will hang straight down. Do not over-tighten. Over tightening can deform check valves. Place dip tube and bottle back on assembly. Check for leaks. 19. DOA Chamber Assembly Replacement The DOA Chamber is used to separate oil from the incoming refrigerant. It has two non-serviceable devices; 1. distillation coil and 2. coalescent filter media. If for some reason the DOA Chamber was not working, it will have to be replaced. Use the Complete Refrigerant removal procedure in SECTION 3. Disconnect the 5 refrigeration connections going to the DOA Chamber. Remove the two #8 screws on the back of the unit that hold the DOA Chamber in place. Remove and replace with new DOA Chamber assembly. Loosen and tighten all refrigeration fittings as per SECTION 3. S

4 20. Compressor Oil Return System Replacement The Compressor Oil Return System is used to separate oil from the high pressure refrigerant leaving the compressor discharge. When the compressor shuts down, the oil is then automatically returned to the compressor. Use the Complete Refrigerant removal procedure in SECTION 3. Disconnect the 3 refrigeration connections going to the Compressor Oil Return System. Remove the two #8 screws on the back of the unit that hold this assembly in place. Remove and replace with new assembly. Loosen and tighten all refrigeration fittings as per SECTION Condenser Coil Replacement The Condenser coil is used to sub-cool the refrigerant. This will improve AR400 operation in high ambient conditions. It will be very rare to replace this part. Use the Complete Refrigerant removal procedure in SECTION 3. Disconnect the 2 refrigeration connections that come from the condenser coil tubing. Remove the four #8 screws that hold the two condenser coils onto the fan shroud. Remove and replace with new assembly. Loosen and tighten all refrigeration fittings as per SECTION 3. S

5 22. Wheel Service and Replacement The AR400 is equipped with two 10 pneumatic tires and two swivel casters. One of the casters has a brake. The pneumatic tires should be inflated to 24 psig. The pneumatic wheels are held in place by a cotter pin. The casters are secured by a /12-13 lock nut. Cotter Pin 23. Vacuum Pump Service and Replacement The AR400 is equipped with a vacuum pump. It will be necessary to periodically add oil. The oil level is shown through the sight glass provided on the vacuum pump. The oil should be filled to the oil level mark. If the vacuum pump oil is discolored, drain all the oil. Add new oil until sight glass is at the proper level. To remove the vacuum pump, remove the 2 mounting screws that come from the under side of the vacuum pump shelf. Disconnect vacuum pump hose. Disconnect power cord from vacuum pump. Install new vacuum pump. Reconnect vacuum pump hose and power cord. Check oil level in new vacuum pump. Make use the power switch on the vacuum pump is in the ON position. Power Switch 22 S2-22

6 24. Tank Micro-Switch Service and Replacement The AR400 is equipped with two micro-switches. These switches are used to determine which Storage tank is on the Scale. To check proper operation of the switch, remove wires from micro-switch. With the Storage tank resting on the micro-switch, terminal points 1 (COM) - 2 (NC) should be open. Use an ohmmeter to check continuity. If these points are still closed, adjust the lever (by hand bending) on the micro-switch until the switch closes when the Storage tank pushes it down. If switch cannot be adjusted, replace. Replace the micro-switch by removing the two #6-32 screw and nuts. A ¼ long nylon spacer is used to properly position the micro-switch from the side of the Vacuum Pump Shelf. Mount new micro-switch by reusing screws, nuts, and nylon spacers. Place a Storage Tank on the micro-switch lever. Check for continuity between 1 (COM)-2 (NC). This contact should be open. Adjust micro-switch lever if necessary. Transfer wires from defective switch to new switch. 25. PC Board Microprocessor Replacement The AR400 is equipped with a replaceable microprocessor. The software contained in the microprocessor can be updated with new features. The only way to introduce them into the AR400 is to replace the older version microprocessor with a new one. Danger: Only a qualified service technician should service this equipment. An Electrical Shock hazard is present which could lead to severe injury or even death. Disconnect power supply to the AR400. Open the front cover of the AR400. Locate the PC Board. Find the microprocessor on the PC Board. The microprocessor is marked with a version code such as VER Use CPS recommended chip puller to remove the old chip. Place the new version chip in the socket. Take great care when handling the new chip. Static electricity can and will permanently damage the chip. Make sure the chip beveled corner matches the socket beveled corner. Push chip until flat. Do not force. Turn on unit and check for proper operation. PC Board Microprocessor Chip Beveled Corner 23 S2-23