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Agramkow Manual Da Máquina
Agramkow Manual Da Máquina
Augustenborg Landevej 19
DK-6400 Sønderborg
Tel +45 74 12 36 36
Fax +45 74 43 36 46
agramkow@agramkow.com
www.agramkow.com
Instructions
Caterpillar do Brazil
Contents
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6. Specifications ................................................................................................................ 30
1. Safety instructions
The design of the Line-side charging equipment is based upon the most recent technique
mainly concentrated on safety and functional ability.
However, the equipment may be dangerous or not workable if the operator or the maintenance
dept. have not received a satisfactory training.
The equipment is designed to work with refrigerant R134a according to the following
sequences:
• Pressure test
• Vacuum test
• PAG Oil Filling
• Charging
AGRAMKOW cannot be held responsible for any other application than described in this
instruction manual.
Service or maintenance must not be carried out while the equipment is working.
Service or maintenance must only be carried out by skilled personnel having received the
necessary training.
Installation
The equipment must only be placed or moved on horizontal (plane) floors. If the equipment
has to be transported on not horizontal floors (rake > 3°C), a fork-lift truck or other suitable
equipment must be used.
Connection
1. Connect the equipment to the power supply, see label on control panel. The supply has to
be in accordance with IEC 294-1 or EN 60204-1, clause 4.3.
4. Connect He-supply
6. Press CONTROL ON
Please note:
• If any fault is indicated, correct the fault and press RESET. If EMERGENCY STOP has been
actuated, press RESET EMERGENCY STOP followed by START/RESET.
3.1.1 Pneuadapter HP
310-110083B
3_Service and maintenance instructions\Filling head HP\310-110083B-01.pdf
315-010132A
3_Service and maintenance instructions\Filling head HP\315-010132A-00.pdf
Item number Quantity Unit Position Item name Make Drawing No.
310-011094A 1,00 Pcs Pneuadapter charge, Staubli HP AGRAMKOW
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Filling head complete HP 24330 315-010132A mkl 04-03-2008 00 00022805 MKL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01
062-0002169 1,00 Pcs 14 Air hose connector for pneuadapter AGRAMKOW 596-100252A
062-0002169 1,00 Pcs 15 Air hose connector for pneuadapter AGRAMKOW 596-100252A
062-0002169 1,00 Pcs 16 Air hose connector for pneuadapter AGRAMKOW 596-100252A
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Pneuadapter charge, Staubli HP 310-011094A tcl 17-09-2007 01 00005382 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
031-2244020 1,00 Pcs 25 Heater ACIM JOUANIN
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Pneuadapter charge, Staubli HP 310-011094A tcl 17-09-2007 01 00005382 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 4
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 5
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 6
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 7
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
087-7886011 1,00 Pcs 40 O-ring ø7,65 x ø1,78 HNBR BUSAK+SHAMBAN
062-0002137 1,00 Pcs 47 Valve body evac. valve 3/8" AGRAMKOW 596-100069A-06
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. slide valves 062-0002200 mkl 24-08-2006 01 00010557 MKL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 8
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
310-110059C 1,00 Pcs Remote control AGRAMKOW 310-110059C-01
052-3100181 1,00 Pcs 12 Mounting plate for push buttons AGRAMKOW 310-100181A-02
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mech. remote control 310-010870A bd 04-03-2008 02 00020830 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 9
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
062-0005690-Y 1,00 Pcs Beskyttelse 60mm AGRAMKOW
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Protection 062-0005690 tcl 06-12-2007 00 00020829 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 10
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
310-110059C 1,00 Pcs Remote control AGRAMKOW 310-110059C-01
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
El remote control 310-010871B tcl 10-03-2008 02 00022867 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 11
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01
081-3100066 1,00 Pcs 18 Evac. hose 3/8" PEX, L=8m AGRAMOW 310-140066A-00
081-3100067 1,00 Pcs 19 Charging hose 1/4" PEX, L=8m AGRANKOW 310-140067A-01
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Hose packet 7/8m 310-010888A tcl 22-11-2005 01 00012283 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 12
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
062-0002140 1,00 Pcs Hose connector evac. valve 3/8" AGRAMKOW 596-100070A-02
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. hose 3/8" PEX, L=8m 081-3100066 bd 21-01-2004 Evak slange 3/8" PEX L=8 m 00003022 BD 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 13
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
062-0002138 1,00 Pcs Hose connector 1/4" straight A'GRAMKOW 596-100072A-03
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Charging hose 1/4" PEX, L=8m 081-3100067 bd 21-01-2004 Fyldeslange 1/4" PEX, L=8m 00003021 BD 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 14
14-03-2008
Parts List 12:18:50
Item number Quantity Unit Position Item name Make Drawing No.
310-200010B 0,00 Pcs El-diagram Eplan A/C Pneuadapter AGRAMKOW
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Harting connection straight 310-011224A tcl 05-10-2005 03 00011761 TCL 24330 Caterpillar Bra 24
Line-side AC charging equipment
310-110083B
3_Service and maintenance instructions\Filling head HP\310-110083B-01.pdf
310-011094A
3_Service and maintenance instructions\Filling head HP\310-011094A-01.pdf
Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01
062-0002169 1,00 Pcs 14 Air hose connector for pneuadapter AGRAMKOW 596-100252A
062-0002169 1,00 Pcs 15 Air hose connector for pneuadapter AGRAMKOW 596-100252A
062-0002169 1,00 Pcs 16 Air hose connector for pneuadapter AGRAMKOW 596-100252A
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Pneuadapter charge, Staubli HP 310-011094A tcl 17-09-2007 01 00005382 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:20:36
Item number Quantity Unit Position Item name Make Drawing No.
042-2970000 1,00 Pcs 25 Cable w. plug AGRAMKOW
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Pneuadapter charge, Staubli HP 310-011094A tcl 17-09-2007 01 00005382 ZVM 24330 Caterpillar Bra 24
Line-side AC charging equipment
310-110059C
3_Service and maintenance instructions\Filling head HP\310-110059C-01.pdf
310-010870A
3_Service and maintenance instructions\Filling head HP\310-010870A-02.pdf
Item number Quantity Unit Position Item name Make Drawing No.
310-110059C 1,00 Pcs Remote control AGRAMKOW 310-110059C-01
052-3100181 1,00 Pcs 12 Mounting plate for push buttons AGRAMKOW 310-100181A-02
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mech. remote control 310-010870A bd 04-03-2008 02 00020830 TCL 24330 Caterpillar Bra 24
Line-side AC charging equipment
310-110059C
3_Service and maintenance instructions\Filling head HP\310-110059C-01.pdf
310-010871B
3_Service and maintenance instructions\Filling head HP\310-010871B-02.pdf
Item number Quantity Unit Position Item name Make Drawing No.
310-110059C 1,00 Pcs Remote control AGRAMKOW 310-110059C-01
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
El remote control 310-010871B tcl 10-03-2008 02 00022867 TCL 24330 Caterpillar Bra 24
Line-side AC charging equipment
3.1.1.5 Hoses
310-110083B
3_Service and maintenance instructions\Filling head HP\310-110083B-01.pdf
310-010888A
3_Service and maintenance instructions\Filling head HP\310-010888A-01.pdf
Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01
081-3100066 1,00 Pcs 18 Evac. hose 3/8" PEX, L=8m AGRAMOW 310-140066A-00
081-3100067 1,00 Pcs 19 Charging hose 1/4" PEX, L=8m AGRANKOW 310-140067A-01
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Hose packet 7/8m 310-010888A tcl 22-11-2005 01 00012283 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:22:50
Item number Quantity Unit Position Item name Make Drawing No.
062-0002140 1,00 Pcs Hose connector evac. valve 3/8" AGRAMKOW 596-100070A-02
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. hose 3/8" PEX, L=8m 081-3100066 bd 21-01-2004 Evak slange 3/8" PEX L=8 m 00003022 BD 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:22:50
Item number Quantity Unit Position Item name Make Drawing No.
062-0002138 1,00 Pcs Hose connector 1/4" straight A'GRAMKOW 596-100072A-03
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Charging hose 1/4" PEX, L=8m 081-3100067 bd 21-01-2004 Fyldeslange 1/4" PEX, L=8m 00003021 BD 24330 Caterpillar Bra 24
Line-side AC charging equipment
3.1.2 Pneuadapter LP
310-110083B
3_Service and maintenance instructions\Filling head LP\310-110083B-01.pdf
315-010133A
3_Service and maintenance instructions\Filling head LP\315-010133A-00.pdf
Item number Quantity Unit Position Item name Make Drawing No.
310-011096A 1,00 Pcs Mekanisk pneudapter charge AGRAMKOW
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Filling head complete LP 24330 315-010133A bd 04-03-2008 00 00022806 MKL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:23:38
Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01
062-0002169 1,00 Pcs 14 Air hose connector for pneuadapter AGRAMKOW 596-100252A
062-0002169 1,00 Pcs 15 Air hose connector for pneuadapter AGRAMKOW 596-100252A
062-0002169 1,00 Pcs 16 Air hose connector for pneuadapter AGRAMKOW 596-100252A
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mekanisk pneudapter charge 310-011096A tcl 18-10-2007 Mekanisk pneudapter charge 00010902 AH 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:23:38
Item number Quantity Unit Position Item name Make Drawing No.
066-7100152 1,00 Pcs 24 Male connector, 2-K16-118 HANSEN COUPLING
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mekanisk pneudapter charge 310-011096A tcl 18-10-2007 Mekanisk pneudapter charge 00010902 AH 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 4
14-03-2008
Parts List 12:23:38
Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 5
14-03-2008
Parts List 12:23:38
Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 6
14-03-2008
Parts List 12:23:38
Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 7
14-03-2008
Parts List 12:23:38
Item number Quantity Unit Position Item name Make Drawing No.
087-7886011 1,00 Pcs 40 O-ring ø7,65 x ø1,78 HNBR BUSAK+SHAMBAN
062-0002137 1,00 Pcs 47 Valve body evac. valve 3/8" AGRAMKOW 596-100069A-06
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. slide valves 062-0002200 mkl 24-08-2006 01 00010557 MKL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 8
14-03-2008
Parts List 12:23:38
Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01
081-3100066 1,00 Pcs 18 Evac. hose 3/8" PEX, L=8m AGRAMOW 310-140066A-00
081-3100067 1,00 Pcs 19 Charging hose 1/4" PEX, L=8m AGRANKOW 310-140067A-01
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Hose packet 7/8m 310-010888A tcl 22-11-2005 01 00012283 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 9
14-03-2008
Parts List 12:23:38
Item number Quantity Unit Position Item name Make Drawing No.
062-0002140 1,00 Pcs Hose connector evac. valve 3/8" AGRAMKOW 596-100070A-02
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. hose 3/8" PEX, L=8m 081-3100066 bd 21-01-2004 Evak slange 3/8" PEX L=8 m 00003022 BD 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 10
14-03-2008
Parts List 12:23:38
Item number Quantity Unit Position Item name Make Drawing No.
062-0002138 1,00 Pcs Hose connector 1/4" straight A'GRAMKOW 596-100072A-03
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Charging hose 1/4" PEX, L=8m 081-3100067 bd 21-01-2004 Fyldeslange 1/4" PEX, L=8m 00003021 BD 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 11
14-03-2008
Parts List 12:23:38
Item number Quantity Unit Position Item name Make Drawing No.
310-200010B 0,00 Pcs El-diagram Eplan A/C Pneuadapter AGRAMKOW
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Harting plug for oil pneuadapt 310-011499A tcl 27-09-2007 00 00019896 TCL 24330 Caterpillar Bra 24
Line-side AC charging equipment
310-110083B
3_Service and maintenance instructions\Filling head LP\310-110083B-01.pdf
310-011096A
3_Service and maintenance instructions\Filling head LP\310-011096A-00.pdf
Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01
062-0002169 1,00 Pcs 14 Air hose connector for pneuadapter AGRAMKOW 596-100252A
062-0002169 1,00 Pcs 15 Air hose connector for pneuadapter AGRAMKOW 596-100252A
062-0002169 1,00 Pcs 16 Air hose connector for pneuadapter AGRAMKOW 596-100252A
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mekanisk pneudapter charge 310-011096A tcl 18-10-2007 Mekanisk pneudapter charge 00010902 AH 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:24:35
Item number Quantity Unit Position Item name Make Drawing No.
066-7100152 1,00 Pcs 24 Male connector, 2-K16-118 HANSEN COUPLING
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mekanisk pneudapter charge 310-011096A tcl 18-10-2007 Mekanisk pneudapter charge 00010902 AH 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:24:35
Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 4
14-03-2008
Parts List 12:24:35
Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 5
14-03-2008
Parts List 12:24:35
Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 6
14-03-2008
Parts List 12:24:35
Item number Quantity Unit Position Item name Make Drawing No.
087-7886011 1,00 Pcs 40 O-ring ø7,65 x ø1,78 HNBR BUSAK+SHAMBAN
062-0002137 1,00 Pcs 47 Valve body evac. valve 3/8" AGRAMKOW 596-100069A-06
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. slide valves 062-0002200 mkl 24-08-2006 01 00010557 MKL 24330 Caterpillar Bra EUR
Line-side AC charging equipment
3.1.2.3 Hoses
310-110083B
3_Service and maintenance instructions\Filling head LP\310-110083B-01.pdf
310-010888A
3_Service and maintenance instructions\Filling head LP\310-010888A-01.pdf
Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01
081-3100066 1,00 Pcs 18 Evac. hose 3/8" PEX, L=8m AGRAMOW 310-140066A-00
081-3100067 1,00 Pcs 19 Charging hose 1/4" PEX, L=8m AGRANKOW 310-140067A-01
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Hose packet 7/8m 310-010888A tcl 22-11-2005 01 00012283 TCL 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:25:33
Item number Quantity Unit Position Item name Make Drawing No.
062-0002140 1,00 Pcs Hose connector evac. valve 3/8" AGRAMKOW 596-100070A-02
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. hose 3/8" PEX, L=8m 081-3100066 bd 21-01-2004 Evak slange 3/8" PEX L=8 m 00003022 BD 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:25:33
Item number Quantity Unit Position Item name Make Drawing No.
062-0002138 1,00 Pcs Hose connector 1/4" straight A'GRAMKOW 596-100072A-03
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Charging hose 1/4" PEX, L=8m 081-3100067 bd 21-01-2004 Fyldeslange 1/4" PEX, L=8m 00003021 BD 24330 Caterpillar Bra EUR
Line-side AC charging equipment
AC Pneuadapter
Service
Service of pneuadapter
In the following you will find a description of how to service the A/C pneuadapter, and which
spare parts to be used. Read this description carefully before starting the service to obtain
the best service result and to avoid accident due to the refrigerant pressure in the filling
hoses.
Warning
Before maintenance make sure, that the filling head is without any pressure
and that the pneumatic and the fluid supply are disconnected.
See the assembly drawings and parts lists for the pneuadapters:
Evacuation/charging pneuadapter 310-110083B
Evacuation pneuadapter 310-110084C
T:\Master Pistoldok
AC Pneuadapter
• Turn off the station (no voltage), turn off the compressed air supply
• Disengage the pneuadapter from the filling equipment
• Demount the HK2 coupling for the refrigerant supply
• Demount the Harting plug. Demount the holder of the hose control
• The pneuadapter can now be taken down
Important!!
Before the adapter is used, the filling hose must be emptied of refrigerant.
This must be made with suitable recovery equipment.
Important!!
Before the refrigerant supply is connected, the air supply for the pneuadapter must
be connected, so that the internal valves will be positioned correctly (Harting plug).
If not, the internal valves might be damaged, and refrigerant might be
let out in the surroundings.
T:\Master Pistoldok
AC Pneuadapter
Demounting
Loosen the 2 Allen screws, pos. 3 (310-110083B) at the adapter.
Now the valve housing can be pulled out of the cap.
(The housing can be screwed on the safety hose in order to improve the access).
Mounting
Pull the cap surrounding the valve housing, and turn it until the threaded holes in
the housing fit the cap.
Note:
This manual uncoupling mechanism is omitted on some types of adapters.
T:\Master Pistoldok
AC Pneuadapter
Demounting
Important!
Before the adapter is demounted, the filling hose must be emptied of refrigerant
(and recovered). Demount the adapter housing (see 3).
Remove the safety screw, pos. 13 (310-110083B). Now the filling hose can be pulled out of
the valve housing (straight direction).
Mounting
Check that the O-rings are OK. Put in the filling hose carefully, and press it until it reaches
the bottom. Put in the safety screw.
T:\Master Pistoldok
AC Pneuadapter
Demounting
Mounting
• See ‘Mounting of filling hose’.
The filling hose and the evacuation hose cannot be mixed up, as the diameters are different.
T:\Master Pistoldok
AC Pneuadapter
Demounting
• Demount the electrical connection in the pushbutton housing.
• Lead colour (standard): violet/black.
• For more information see encl. „Standard connection Harting combined plug“
incl. photo and description: Harting plug A-C.doc
• Demount the housing of the valve housing, see 3
• The heater device can be demounted by means of a spanner, 13 mm
(right-hand thread).
Important!
When mounting, use compound; code No 100-7720191.
Place the cable in a loop before installation to avoid it from being pulled out of the sensor
during operation
T:\Master Pistoldok
MM Filling head Coolant fluid
Important!
The control air hoses must always be filled with 10 cm PAG oil
(measured from the coupling). If the oil level is not high enough,
the lifetime of the adapter will be shorter.
When filling, no air bubbles may be visible at the adapter.
When mounting, the control air hose must be led as much as possible into the fitting.
T:\Master Pistoldok
AC Pneuadapter
Important!!
Demounting must only be made on a clean mat free of dirt and dust.
Evacuation valve
See drawing No 310-110083B or 310-110084C
Demount the vacuum hose, see 5 (photo 4).
The valve slide can now be taken out by means of the tool delivered with the adapter
(please check that the tool catches hold of the inside of the valve slide correctly).
Damaged valve slides must never be used. Only assembled valve slides must be used,
which should be taken out of the original wrapping immediately before the mounting.
Demonting
Mounting
T:\Master Pistoldok
AC Pneuadapter
Filling valve
See drawing 310-110083B
Demount the filling, hose; see 4.
The same procedure as for the evacuation valve.
Change of parts
The change of parts must be treated hygienically.
Service intervals
The valves must be changed every 40,000 couplings.
T:\Master Pistoldok
AC Pneuadapter
Push-button box
To prevent unintended start, place item no. 062-0005690 between hoses and push buttons
(see photo).
T:\Master Pistoldok 10
Line-side AC charging equipment
Intervals Main-
Carried out by
Components / Aggregate / tenance Operational Safety references,
Pos No Remedy Division ON / OFF
Function period tools Safety equipment
d w m 1/4y 1/2y 1y (Employee)
[min]
Filling head, mech. Drawing 310-
110083B-01
28-16 O-ring in 134a-coupling Lubricate x 1 Vacuum oil Maintenance OFF
department
28-16 O-ring in 134a-coupling Replace x 10 Vacuum oil Maintenance OFF Rubber gloves
department
40-48 Valve Replace after 40.000 chargings x Vacuum oil Maintenance OFF Rubber gloves
department
50-56 Valve Replace after 40.000 chargings x Vacuum oil Maintenance OFF Rubber gloves
department
30 in all
Note!
Sediments from the liquid, cuttings sucked up into the gun and sharp edges, where
the main gasket(s) grasp(s) will shorten the lifetime of the gasket and thereby also
the service intervals.
Intervals Main-
8 h/day operation Carried out by
Pos Components / Aggregate / tenance Operational Safety references,
No
Remedy Division ON / OFF
Function period tools Safety equipment
d w m 1/4y 1/2y 1y (Employee)
[min]
The positon numbers refer to PI-diagram 315-120046A and layout 315-110078A
15 Compressed air filter, Ultrafilter Replace filter x 15 Tools OFF Rubber gloves
19 Compressed air filter, Festo Replace filter element x 10 Tools OFF Rubber glovese
42 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
54 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
61 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
62 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
70 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
81 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
92 Massflow, Rheonik Check that the displayed weight (gram) is the x 7 ON without PAG
same as the weight of the content in the oil filling
external test tank
85 Pressure accumulator Check pre pressure setting and adjust if x 10 Tools OFF Rubber gloves
necessary
102 Vacuum sensor, Leybold DI 201 Check by means of test nipple pos. 106 x 10 ON
Calibration: See supplier's instructions
(Calibration only by maintenance
departm.)
100 Pressure sensor, IFM Check that the displayed pressure is the x 7 Manual mode
same at the pressure in the external test tank
(Calibration in the PLC only by trained
personnnel)
108 Exhaust filter, vacuum pump, SMC Replace filter element, see supplier's x 15 Tools OFF Rubber gloves
instructions
109 Vacuum pump, Leybold D16B Check oil level, see supplier's instructions x 5 Tools OFF Rubber gloves
109 Vacuum pump, Leybold Change oil, see supplier's instructions x 15 Tools OFF Rubber gloves
113 PAG oil filter Replace filter element x 15 Tools OFF Rubber gloves
117 Compressed air filter, Ultrafilter Replace filter x 15 Tools OFF, pos 12 dis- Rubber gloves
mantled
121 Sika Flow meter See supplier's instructions x 10 Tools OFF Rubber gloves
Clean filter
Intervals Main-
8 h/day operation Carried out by
Pos Components / Aggregate / tenance Operational Safety references,
No
Remedy Division ON / OFF
Function period tools Safety equipment
d w m 1/4y 1/2y 1y (Employee)
[min]
121 The
Sika positon numbers refer to PI-diagram
Flow meter Check315-120046A and layout
that the displayed 315-110078A
volume is the same x 10 Tools Manual mode Rubber gloves
at the volume in the external measuring
meaker
(Calibration in the PLC only by trained
personnel)
131 Exhaust filter, vacuum pump, Replace filter element, see supplier's x 15 Tools OFF Rubber gloves
Leybold AMC 610-10 instructions
133 Vacuum pump, Leybold D16B Check oil level, see supplier's instructions x 5 Tools OFF Rubber gloves
133 Vakuum pump, Leybold Change oil, see supplier's instructions x 15 Tools OFF Rubber gloves
140 Photo sensor, Sensick WT 150 HGA Clean optics with a soft lint-free cloth x 1 OFF
141
Check and retighten all x 20 Tools OFF
Bosch screwed connections
Warning
Components in the A/C system are NOT to be removed till the A/C system is OFF and emptied
This is because of the safety of persons and because of the environment. Use the drain nipples pos. 67 and pos. 78
and drain manifold pos. 106
No service and maintenance is necessary concerning the electrical part of the equipment
AGRAMKOW
Fluid Systems A/S
Augustenborg Landevej 19
DK-6400 Sønderborg
Denmark
Tel.: +45 74 12 36 36
Fax: +45 74 43 36 46
www.agramkow.com
agramkow@agramkow.dk
xxxxxxxx
yyyyy
4. Function description
Recovery:
4_Function description\LS AC Recovery Operator Instruction .doc
Contents
Text Description
Starting the system Handling Check the following:
- Compressed air supply is connected
- Refrigerant supply is connected
- Main switch on control cabinet is switched ON
- EMERGENCY STOP is not activated
1. Press CONTROL ON
- CONTROL ON lamp lights up
Text Description
Manuel operation Handling Check the following:
• MAN/AUTO switch must be in MAN mode
• Process selection is set to CHARGING ON
• Charging head is in parking position
• The READY / IN PROCESS lamp is flashing
Text Description
Automatic operation Handling Check the following:
without charging • MAN/AUTO switch must be in AUTO mode
• Process selection is set to CHARGING OFF
• Charging and vacuum head is placed in parking position
Text Description
Automatic operation with Handling Check the following:
charging • MAN/AUTO switch must be in AUTO mode
• Process selection is set to CHARGING ON
• Charging and vacuum head is placed in each parking
position
Content
Operation .................................................................................................................................... 3
Text Description
Start of the equipment Handling 1. Check the following :
• Compressed air supply connected
• Refrigerant bottle supply is connected
• Main switch for control cabinet is ON
• EMERGENCY STOP is not activated
Text Description
Operation Handling To recovery the A/C system of the vehicle please check the
following:
2. Fasten the recovery hoses for high and low pressure side
to the A/C system on the vehicle.
8. Please note: When the green lamp “drain the P.A.G. oil
(manually) “OK“ lights, it is possible to bleed the P.A.G.
oil from the recovery process.
Content
Operation .................................................................................................................................... 3
Text Description
Start of the equipment Handling 1. Check the following :
• Compressed air supply connected
• Refrigerant bottle supply is connected
• Main switch for control cabinet is ON
• EMERGENCY STOP is not activated
Text Description
Operation Handling To recovery the A/C system of the vehicle please check the
following:
2. Fasten the recovery hoses for high and low pressure side
to the A/C system on the vehicle.
8. Please note: When the green lamp “drain the P.A.G. oil
(manually) “OK“ lights, it is possible to bleed the P.A.G.
oil from the recovery process.
Recovery:
4_Function description\LS AC Recovery Process description .doc
Contents
Atm.
t(s)
82 Sniffing Process In this process step the operator can find the
P (bar) leakage in the A/C system with a helium sniffer.
Fault None
Measurement P1: The pressure level from the pressure sensor
M100
PSet2
Settings PSet2: Inlet level [bar]
Atm.
83,8 Venting Process This process step will equalize the pressure in
4 P (bar) the A/C system of the vehicle. When the
pressure drops below the venting level PSet1 for
SF101_T 2 sec. the process will jump to the next step
”Process end”.
Fault SF101: Venting fault
If the pressure drops to a level below PSet1
before the timer SF101_T has elapses, the
PSet1 station fault SF101 is issued.
Atm. Measurement P1: Pressure level from the pressure sensor
M100
Settings
t (s) SF101_T: Venting fault time [sec.]
T=2s PSet1: Venting level [bar]
Contents
Recovery process
Step Text Description
00 Stop Process This process step is active when the equipment is out of
the process mode and one of the following situations has
occurred:
Critical fault (e.g.: emergency stop activation)
Control OFF selected
Recovery process switched off
Fault None
Measurement None
Settings None
01 Ready Process This process step is active when the
equipment is ready to perform recovery
(recovery process is selected) when no critical
station faults are active and control is ON.
Fault None
Measurement None
Settings None
02 Empty? Process In this process step the equipment tests the
A/C system in the vehicle if it’s empty or full
with refrigerant. When the A/C system is full
a recovery process restarts. If the A/C system
is empty “Process end“ is indicated.
Fault None
Measurement None
Settings Step02_T = 180 [Sec.]
03 Recovering Process This process step emptying the A/C system of
the vehicle.
Fault None
Measurement None
Settings Step03_T = 10 [Sec.]
04 Empty? Process This process step tests the A/C system of the
vehicle if it’s really empty or still full. When
the A/C system is full a new emptying process
is performed. If the A/C system is empty
“Process end“is indicated.
Fault None
Measurement None
Settings Step04_T =30[Sec.]
05 Process end Process In this process step the recovering of the A/C
system of the vehicle has been performed and
finished.
Fault None
Measurement None
Settings None
Recovery:
4_Function description\LS AC Recovery Sub description EN.doc
Content
Sub102 Heating filling head: Function This Subroutine is performed outside the charging
process.
50 sec. OFF and 3 sec. ON
I/O None
Settings TOff = 50 sec.
TOn = 3 sec.
Fault None
Sub103 Heating filling head: Function When a charging of the A/C system is performed the
Disabled
filling head must be extra heated.
Charging + 25 sec. (max. 60 sec.)
I/O None
Settings TRunning time = 25 sec. (max. 60 sec. incl. charging)
Fault None
Sub104 Air/N2/Helium supply Function When the pressure drops below PSet2 the valve M99
Disabled
will open to ensure that there is enough
Air/N2/helium pressure in the A/C system of the
vehicle.
I/O None
Settings PSet2
Fault None
Sub105 Filling PAG supply tank Function When the tank is under setpoint level then the tank is
Enable
refilled
I/O Level switch
Settings None
Fault None
Content
Sub01 .......................................................................................................................................... 2
Sub02 .......................................................................................................................................... 2
Sub03 .......................................................................................................................................... 2
Sub04 .......................................................................................................................................... 2
Sub05 .......................................................................................................................................... 3
Sub06 .......................................................................................................................................... 3
Sub07 .......................................................................................................................................... 3
Sub05 Control of the compressor Function The compressor operates only when the pressure of
the pressure switch (mech. pos. no. 52) is above the
limit value of 0.3 bars and the safety pressure switch
(mech. pos. no. 59) has not reached a value above 15
bars.
The compressor stops when the pressure of the
pressure switch (mech. pos. no. 52) is below -0.1 bar
in a delay time of TOff seconds. The compressor also
stops immediately when the safety pressure switch
(mech. pos. no. 59) has reached 15 bars.
I/O Mech. pos. no. 58
Mech. pos. no. 59
Settings TOff = 3 min.
Fault SF102 = Pressure level in compressor too high
Common, SF003 = Motor protection(s) not okay
Sub06 Release valve for control of return Function The valve opens, if the process is not in
oil to the compressor RUNMODE, and close again after the delay time
TReturn time.
I/O Mech. pos. no. 69
Settings TReturn time = 5 - 10 sec.
Fault None
Sub07 Control the draining of the buffer Function The valve opens when the GTL pump is switched on
tank O1. and the level in the tank O1 is above the limit value
“Lo”. In this case the valve M45 closes to avoid
double supply.
I/O Mech. pos. no. 77
Settings None
Fault None
Seq02, Ready.............................................................................................................................. 3
Seq02
Ready
Seq02.TrPas 3
Seq03
Seq03.TrRes+.TrErr
Seq03.TrSnif Pressure test
Seq03.TrPas4
Seq04
Seq04.TrSnif Seq04.TrRes+.TrErr
Vacuum
Seq04.TrPas5
Seq05
Seq05.TrSnif Seq05.TrRes+.TrErr
Filling PAG oil
Seq05.TrPas6
Seq08 Seq06
Sniffing Seq06.TrRes+.TrErr
Charging R134a
(Disabled)
Seq06.TrPas10
Seq08.TrPas10+
Seq08.TrErr+
Seq08.TrRes
Seq10
Process end
Seq10.TrPas+.TrRes
ResetSEQ Init
Step20 + Step 21
Step 00
Stop
not in process
(Not "Auto" *
"StepOns")+
("Auto" * Step21
Step21T_Dn) "StopOp"
Abort/Venting
Control:
Auto: Automatic mode
StepOns: Step oneshot
StopOp: Stop sequence (operator)
StopSF: Stopp sequence (station fault)
Parked: Filling head in parking position
Mode1: Charging mode
Mode2: Calibrate R134a filling head mode
Mode3: Calibrate massflow mode
Mode4: Calibrate PAG oil filling head mode
Interlock1: Release charging mode (mode1)
Interlock2: Release calibrate R134a filling head mode (mode2)
Interlock3: Release calibrate massflow mode (mode3)
Interlock4: Release calibrate PAG oil filling head mode (mode4)
Process fault:
PF21: Car already charged
ResetSEQ Init
Not "ResetSEQ" *
"Start" Not "Parked" *
Step 60 "StopOp" + "StopSF"
Not ”Mode2”
Charging R134a
FillState_4H Step 61
Stop
FillState_1H+ Charging R134a
"Parked" * FillState_2H+
Not ”Mode2" + FillState_3H+
Not "Parked" FillState_9H
* ”Mode2" + ResetSEQ
"Parked" +
ResetSEQ
Enable:
ChargR134a: Release Seq06 block (charging R134a)
Control:
StepOns: Step oneshot
StopOp: Stop sequence (operator)
StopSF: Stop sequence (station fault)
Parked: Filling head in parking position
FillState:
_1H: No charging flow
_2H: Charging amount too small
_3H: Charging amount too large
_4H: Charging done
_9H: Massflow calibration fault
Process fault:
PF60: No charging flow (FillState_1H)
Station fault:
SF103: Timeout at charging R134a
ResetSEQ Init
Not parked *
Interlock 2 *
Step60 + Step61 +
Mode 2
Step70 + Step71 +
Step72 + Step73 Step70
Charging R134a
Step05 500 g
Stop
Charging R134a
FillState_1H + FillState_2H +
FillState_9H FillState_3H + Step71T_DN
SA103 + FillState_4H (T[2s])
Not "ResetSEQ" SA104
* "Start" Step71
Charging
Done
Not "Mode2"
FillState._6H FillState._5H * Parked
Step73 Step72
Calibration Calibration
Failed Done
TrRes Seq7.TrPas2
Control:
Mode2: Calibration of R134a filling head
FillState:
_1H: No filling flow
_2H: Deviation min
_3H: Deviation max
_4H: Filling OK
_5H: Calibration of R134a filling head OK
_6H: Calibration of R134a filling head NOK
_7H: Charging too slow
_8H: Charging too fast
_9H: Massflow reset fault
ResetSEQ Init
"Mode3" *
Interlock 3
Step 90
Not "Mode3"
Init calibration
Step 00
Stop Step 90T_DN
Not in Process T[10s]
Step91
Reset massflow
Step 91T_DN
T[20s]
Step92
Calibration done
Not "Mode3"
TrRes Seq9.TrPas2
Jump:
TrPas: Block OK
TrRes: Block NOK (reset sequence)
Control:
Mode3: Calibration of massflow
Start: Start sequence
ResetSEQ: Reset sequence
ResetSEQ Init
Not "ResetSEQ" *
"Start" *
("Parked" * Step 112
Not ”Mode4") + Not "Mode4"
Filling Done
(Not "Parked"
* ”Mode4")
Step 111C_DN
Step 113
Calibration
done
Not "Mode4"
TrRes Seq11.Trpas20
Control:
Mode4: Calibration of PAG oil filling head mode
Start: Start sequence
ResetSEQ: Reset sequence
Jump:
TrPas: Block OK
TrRes: Block NOK (reset sequence)
Start screen
START
Screen No: 1
Hardware diagnostics
HW_DIAG
Screen No: 42
Password
level 9
Force valves & pumps
FORCE
Screen No: 43
Password
level 9
Service (TPM)
SERVICE
Screen No: 6
Information
INFO
Screen No: 9
4.5 PT-diagram
Recovery:
4_Function description\PT-Diagram\LS AC Recovery Process.PT.doc
Content:
Seq02, Ready
PF30_T
Seq03, Pressure test Atm.
P2Set3
t (s)
Step30_T
Atm.
t(s)
Seq04, Vacuum
Step40 Step41
Symbolic Output Text
1. evacuation Vacuum test
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check Xsub_M103
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Calibration Massflow
Seq04, Vacuum
M (g)
PF50_T
Seq05, Filling Pag VSet3
SA106
VSet2
VSet1
SA105
dVSet1
PF50
t (s)
Step 50 Step 51
Symbolic Output Text
Filling Pag 3. evacuation
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil Sub 105
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil Sub 105
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105
Q43.2 R_Mass Calibration Massflow
MSet2
SA101
MSet1
SF103
t (s)
Step 60 Step 61
Symbolic Output Text
Charging R134a Stop at charging R134a
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub103 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Calibration Massflow
500
MSet2
t (s)
f (g/s)
FSet2
FSet3
t (s)
Step 72,73
Step 70 Step 71
Symbolic Output Text Calibration, fault or
Charging R134a (4x 500 g) Charging, Done
done
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub103 Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105 Sub105
Q43.2 R_Mass Calibration Massflow
P (bar)
Seq08, Sniffing helium
PF81_T
PSet3
PF81
Atm.
t(s)
T=2s
Step80 Step 81
Symbolic Output Text
Snif on leak? Inlet helium
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Calibration Massflow
Seq09, Calibration
massflow
Seq00 Recovery
SF101 Level too high in buffer tank O1 Sub01 Control of inlet valve for refrigerant
SF102 Too high pressure from high pressure side of the compressor Sub02 Control of inlet valve for refrigerant in buffer tank O1
SA101 High level in buffer tank O1 Sub03 Control of condenser
SA102 Pressure too high in buffer tank O1 Sub04 Control of air for P.A.G. oil release valve
SA103 Recovery Bottle full (Pos144) Sub05 Control of compressor
Sub06 Control of return oil for compressor release valve
Sub07 Control of emptying refrigerant buffer tank O1
4.6 Settings
Seq02. Ready
Step 20 Step 21
Settings Ready Venting
Default FAT SAT Default FAT SAT
Process time [s]
Step21_T [s] 5.0 5.0
PF21_T [s] 1.0 2.0
PSet1 [bar] 0.20 0.20 0.20
PF31_T PF32_T
PF32
P1Set3
PF31 dP1Set1
P1Set2
Atm.
PF32
Atm.
t(s)
Step31_T t (s)
Step32_T
Seq04, Vacuum
Step 60
Settings Filling R134a
Default FAT SAT
Process time [s]
MSet2 [g] +1.0% of MSet1 +1.0% of MSet1 +1.0% of MSet1
MSet3 [g] -1.0% of MSet1 -1.0% of MSet1 -1.0% of MSet1
FSet1 [g/s] 20.0 20.0 20.0
FSet2 [g/s] 70.0 70.0 70.0
FSet3 [g/s] 130.0 130.0 130.0
MSet2 *) [g] 650
SF103_T *) [s] 15.0
2
500 - 3000 g
Project no.: Customer: Equipment: Date: Init.: Page:
A/C, Online 07-01-2008 HLU 5/8
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\AC Settings.EN.doc Rev. 00
Settings
Step 60
Settings Filling R134a
Default FAT SAT
Process time [s]
MSet2 [g] +1.0% of MSet1 +1.0% of MSet1 +1.0% of MSet1
MSet3 [g] -1.0% of MSet1 -1.0% of MSet1 -1.0% of MSet1
FSet1 [g/s] 20.0 20.0 20.0
FSet2 [g/s] 70.0 70.0 70.0
FSet3 [g/s] 130.0 130.0 130.0
MSet3 *) [g] 650
SF103_T *) [s] 15.0
3
500 - 3000 g
Project no.: Customer: Equipment: Date: Init.: Page:
A/C, Online 07-01-2008 HLU 6/8
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\AC Settings.EN.doc Rev. 00
Settings
Step 90
Settings Filling R134a
Default FAT SAT
FSet4 [g/s] 80.0
FSet5 [g/s] 120.0
5. Fault description
Contents
6. Specifications
Date: 16-04-2008
Rev: 00
Customer: Caterpillar do Brazil
Project: 24330
General data:
Placing: The equipment must be placed indoors
Ambient air temperature: 5-40°C
Atmospheric humidity: 30-90% (not condensing)
Transportation and storage: -25 to +55°C
Colour: RAL 7035
Electrical performance: According to IEC 204-1 or EN 60204-1
Article no.: 315-000037A
Power supply:
Power consumption Abt. 3,0 kVA
Supply voltage See marking on cabinet
Frequency See marking on cabinet
Dimensions: 800x1400x1650 mm
Weight: Ca. 290 kg
Massflow: Rheonik
Pos 92
Type RHM4-GNT
Range 0,3-10 kg/min
Temperature range -20 - +120o
Max pressure 150 Bar
Connection NDC
Power 24VDC
Float: Wema
Pos 116
Type SS-F
Connection DIG/PLC, HAN 6E
Power 24VDC
Thermostat Danfoss
Pos 47
Type RT 270
Temperature range -30-+40°C
Power consumption 24V
Connection DIG/PLC
Ventilation connection: 1”
Please note:
Supply voltage and frequency in accordance with IEC 204-1 or EN 60204-1
7.1 Layout
A A
B B
C C
D D
E E
F F
Item No.:
Drawing number:
315-110078A -
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
C C
D D
E E
F F
Drawing number:
315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
C C
D D
E E
F F
Drawing number:
315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
C C
D D
E E
F F
Drawing number:
315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
C C
D D
E E
F F
Drawing number:
315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
C C
D D
E E
F F
Drawing number:
315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
C C
D D
E E
F F
Drawing number:
315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
C C
D D
E E
F F
Drawing number:
315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
C C
D D
E E
F F
Drawing number:
315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
C C
D D
E E
F F
Drawing number:
315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
C C
D D
E E
F F
Drawing number:
315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
Line-side AC charging equipment
Item number Quantity Unit Position Item name Make Drawing No.
313-020123A 1,00 Pcs Option 4 helium / N2 tryktest 15 bar AGRAMKOW
068-5981251 1,00 Pcs 002 Sound absorber G1" MANNESMANN REXROTH A/S
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mech.Parts LS AC 24330 Caterpi 315-020070A mkl 29-01-2008 00021529 NJN 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:26:35
Item number Quantity Unit Position Item name Make Drawing No.
036-2110045 1,00 Pcs 091 Solenoid valve EVR 10 DANFOSS A/S
066-7101042 1,00 Pcs 098 Coupling nipple B3 T21-3/8 FPT HANSEN COUPLING
036-0902870 1,00 Pcs 101 Angle-seat valve 1/2" type 2002 BÜRKERT
036-0902870 1,00 Pcs 103 Angle-seat valve 1/2" type 2002 BÜRKERT
036-0902870 1,00 Pcs 104 Angle-seat valve 1/2" type 2002 BÜRKERT
068-5981610 1,00 Pcs 108 Exhaust filter AMC 610-10 SMC PNEUMATIC A/S
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mech.Parts LS AC 24330 Caterpi 315-020070A mkl 29-01-2008 00021529 NJN 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:26:35
Item number Quantity Unit Position Item name Make Drawing No.
038-7740300 1,00 Pcs 141 Sensor Sick WT150-P460 SICK A/S
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mech.Parts LS AC 24330 Caterpi 315-020070A mkl 29-01-2008 00021529 NJN 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 4
14-03-2008
Parts List 12:26:35
Item number Quantity Unit Position Item name Make Drawing No.
315-120003A 1,00 Pcs PI-diagram AGRAMKOW
036-0902870 1,00 Pcs 099 Angle-seat valve 1/2" type 2002 BÜRKERT
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Option 4 helium / N2 tryktest 313-020123A mkl 20-12-2007 01 00013469 SJU 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 5
14-03-2008
Parts List 12:26:35
Item number Quantity Unit Position Item name Make Drawing No.
068-3212468 1,00 Pcs 022 Pressure regulator 0-7 bar FESTO
067-2111030 1,00 Pcs 040 Exp. valve TN2 -134a 068-3346 DANFOSS A/S
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Option 2 GTL Supply pump 313-020119A SJU 16-06-2006 01 00012320 SJU 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 6
14-03-2008
Parts List 12:26:35
Item number Quantity Unit Position Item name Make Drawing No.
276-5000197 1,00 Pcs 046 Manifold AGRAMKOW 500-100197A-03
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Option 2 GTL Supply pump 313-020119A SJU 16-06-2006 01 00012320 SJU 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 7
14-03-2008
Parts List 12:26:35
Item number Quantity Unit Position Item name Make Drawing No.
066-7100153 1,00 Pcs 028 Male connector, 3-K21-118 HANSEN COUPLING
067-3253907 1,00 Pcs 032 Ball valve 3-way 3/4" return BEE
Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Option 6, R134a changeover 313-020125A SJU 16-06-2006 01 00013195 BLP 24330 Caterpillar Bra EUR
Line-side AC charging equipment
7.3 PI-diagram
7.4 Installation
A A
B B
C C
D D
E E
F F
Drawing number:
315-340009A 00
H H
DK-6400 Sonderborg, Denmark File and pathname:
CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
Line-side AC charging equipment
315-200022A
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9. Trouble shooting
Caution
Out of consideration for the safety as well as the environment, no component in the station
must be demounted before all circuits are without pressure and have been emptied. The
station is equipped with draining nipples marked XH.
After the mounting, air bubbles must be eliminated from the circuit by repeated charging,
normally 5,000 g.
Contents
H2: Connect the vacuum gauge to the pneuadapter. Do the evacuation step in manual
position. The pressure gauge must indicate < 1 mbar.
R2: If the pressure gauge indicates 1 mbar or more, check the vacuum pump when the
pressure gauge is placed directly onto the pump, without any other connection. If the
pressure gauge does still not indicate < 1 mbar, the vacuum oil must be changed. If this
does not solve the problem either, the whole vacuum pump must be replaced.
H3: Run the process in automatic mode with a pressure gauge placed onto the pneuadapter,
and switch to manual mode in the step ‘Vacuum test’. Now wait 10-15 seconds, and
then the pressure gauge and the electronic vacuum gauge must show the same value (if
the symptom corresponds to R3 b, see below, the pressure gauge is not necessary).
R3: a) The pressure gauge and the electronic vacuum gauge do not indicate the same
value. Replace the electronic vacuum gauge. Please note the vacuum sensor and
the electronics have been calibrated together, which means both the sensor and
the electronics must be replaced.
b) The vacuum level increases slowly. The reasons could be:
1. The charging valve in the pneuadapter does not close correctly. This can be
checked as follows: Let the station remain in the position ‘READY’ for five
minutes and then open the SAE coupling manually. The pneuadapter must not
activate the end switch in the parking position! If there is a ‘puf’ due to
overpressure, the valve does not close easily. Demount the valve and replace the
valve, see spare parts.
2. The vacuum system is not completely tight. This fault occurs normally only when
components are being replaced. Check all connections and, if necessary, tighten
up.
Please note the test bottle is evacuated before the charging process, and the weight when
empty (tare) must be inserted.