Table of Contents - Snap
Contents
1. Connect power cord to properly grounded outlet Do not remove or bypass the grounding pin Electric shock and fire can cause injury Safety Information Refrigerant Risk of expelling refrigerant under pressure Wear safety goggles and protective gloves user and bystander If any refrigerant gets into eyes flush with water and seek a doctor s aid immediately even though irritation may cease Do not remove master filter while under pressure Perform maintenance procedure for removing master filter in Chapter 3 Changing the Master Filter Prevent refrigerant from contacting the skin Expelled refrigerate can cause injury Risk of explosion Do not use compressed shop air for leak detection or to pressure test a system containing refrigerant Refrigerant can form combustible mixtures at pressures above atmospheric and with air concentrations greater than 6096 by volume Do not heat a container of refrigerant above 125 F 52 C Explosion can cause injury Risk of fire Do not use this equipment in the vicinity of spilled or opened containers of gasoline Do not use Dual 3412 or leak detector equipment if R 12 substitutes are suspected R 12 refrigerant substitutes may be flammable Fire can cause injury Risk of poison Avoid breathing air conditioning refrigerant and lubricant vapor or mist Do not allow refrigerant to contact open flame or be drawn into a running engine This can ca2. Some vehicles using OZ 12 can be identified by a label that may be placed in the engine compartment but many cannot be identified Studies are currently being conducted to develop a procedure to identify the type of refrigerant in a refrigeration system State agencies and the Environmental Protection Agency EPA are moving to ban flammable substitutes If it is suspected that a refrigerant system contains a product of this type Question customers about previous service Be aware of any unfamiliar odor from the system Do not use a leak detector Do not use recycling equipment and Contact your state fire marshall or local EPA office 1 4 Introduction Functional Description Typical Front View Figure 1 1 Typical Front View A Gauge Set High and low pressure gauge manifold set for monitoring air conditioning system pressures Right hand valve opens and closes the high side service hose passage to Dual 3412 Left hand valve opens and closes the low side service hose passage to Dual 3412 Control Panel Houses display screen and control buttons Mode Button Toggles LCD display between gross weight of recovery tank and tare weight which zeroes the display for indication of charged or recycled amount 1 5 Introduction Control Knob Use to select Vacuum Off or Recycle Compressor Power Switch Turns recovery compressor on and off Must be on I for unit operation Unit On Indicato
3. Oil cup J Recovery tank is temperature monitored to maintain accurate purging of non condensable gases under all conditions 1 1 Introduction Refrigerant Gases Halogens are any of the five elements fluorine chlorine bromine iodine and astatine that form part of group 7a of the Periodic Table of Elements The fluorine and chlorine elements of this family are used to create a methane organic compound used to form dichlorodifluoromethane CCL F a halogenated hydrocarbon called CFC 12 chlorofluorocarbon 12 This refrigerant gas is commonly known as Refrigerant 12 or R 12 and has been used as a refrigerant in mobile air conditioning systems for many years The new refrigerant in the halogenated hydrocarbon family HFC 134a CH FCF or R 134a is now being incorporated in mobile air conditioning systems HFC stands for hydrofluorocarbon The environmental impact of mobile air conditioning refrigerant containing chlorine R 12 has caused regulatory action that will eventually eliminate the use of such products Regulatory action is necessary because when the chlorine content in R 12 is exposed to the atmosphere It depletes the protective ozone layer in the atmosphere It has relatively high global warming potential and Its long atmospheric lifetime is approximately 120 years R 134a has been developed for new vehicle production but does not replace or directly substitute for R 12 in existing vehicles R
4. Open the following Red service hose hand valve or coupler Blue service hose hand valve or coupler High side manifold hand valve and Low side manifold hand valve 2 Turn Compressor switch ON 3 Turn vacuum recycle valve to VACUUM Low side manifold gauge shows vacuum increasing 4 Follow manufacturer recommendations for evacuation time usually at least 30 minutes 4 Close manifold hand valves when desired vacuum and duration have been reached 5 Turn Vacuum Recycle valve OFF 6 Turn compressor switch OFF COMPRESSOR ON indicator goes out and compressor stops running 7 Monitor low side pressure for 5 minutes Any rise in vacuum indicates a leak in vehicle system 4 If source of leak cannot be determined partially charge system and perform leak test using electronic leak detector 8 When leak is identified repeat Recover Recycle proceedure repair leak and attempt Evacuation proceedure again Evacuation is complete Installation and Operation Charging A C Sy 2 stem Close the yellow service hose hand valve Remove yellow hose with anti blowback valve from the recycle port and connect it to the charge port Open blue liquid tank valve Press Mode Button so a tare weight of 0 0 is displayed Connect service hoses to vehicle Open hand valves or couplers Open yellow service hose hand valve Refrigerant flows from tank into vehicle Monitor tank weight When desi
5. 134a does not contain chlorine does not deplete the ozone layer in the atmosphere and has an atmospheric lifetime of about 15 5 years Environmental Protection Agency EPA and state regulations specify that Provisions be made to certify all air conditioning service installation and repair personnel Refrigerant be recovered recycled or reclaimed from automotive air conditioning systems instead of allowing vapors to be expelled or vented into the atmosphere and Refrigerant be recycled and reused or properly disposed of instead of allowing vapors to be expelled or vented into the atmosphere Mobile air conditioning service installation and repair technicians must be qualified and certified 1 2 Introduction Refrigerant Handling Refrigerant Safety pe IMPORTANT Mobile air conditioning systems contain chemical mixtures that require special handling to avoid injury and to avoid venting refrigerant into the atmosphere Do not discharge any refrigerant gas vapor or liquid from a refrigeration system into the atmosphere If service is required that involves opening the refrigerant system use a certified recovery system Wear safety goggles and protective gloves user and bystander If any refrigerant gets into eyes flush with water and seek a doctor s aid immediately even though irritation may cease Do not remove master filter while under pressure Follow instructions for removing master fi
6. For service or to order replacement parts or optional accessories contact your Snap on Sun Representative or call 1 800 CALL SUN 1 800 225 5786 Maintenance 3 12
7. gas in this chapter Compare the recovery tank pressure temperature relationship with the chart and bleed off any non condensables air by pressing the Purge valve button 12 Hold graduated cup under the Oil Drain valve 13 Slowly open oil drain valve Any accumulated oil expels into cup 14 Close valve immediately when all oil is expelled Amount indicated on cup is amount to add back into vehicle system when recharging 4 Discard refrigerant oil in accordance with laws in your area Purging Non condensable Gas J Be sure to purge non condensable gases immediately after each recovery and before each charge 1 Using the pressure temperature chart located on the front panel of the unit find the temperature that is the same as the reading on the temperature gauge Next to the temperature is a pressure reading That pressure reading should be what the pressure gauge indicates 2 f the pressure is higher press the purge button on the front of the unit until the pressure on the gauge is the same as what is on the chart 3 Wait a minute and monitor temperature and pressure again If they do not correspond to the chart purge again until they do Installation and Operation Evacuating A C System Use this procedure to remove air and moisture from vehicle A C system J If gauges indicate pressure recover refrigerant from service hoses before proceeding Refer to Evacuating Service Hoses in this Chapter 1
8. hazardously situation which if not avoided will result in death or serious injury to the operator or to bystanders Indicates a potential hazard which if not avoided could result in death or serious injury to the operator or to bystanders Indicates a potential hazard which if not avoided may result in minor or moderate injury to the operator or to bystanders Some safety messages contain visual symbols with signal words Example Engine systems can malfunction expelling fuel oil vapors hot steam hot toxic exhaust gases acid refrigerant and other debris Wear safety goggles and protective gloves user and bystander Engine systems that malfunction can cause injury vi Using this Manual Terms Use the following definitions as a foundation to help understand Dual 3412 processes and or components Virgin Tank A refrigerant tank disposable or refillable that contains new refrigerant When empty disposable virgin tank must be evacuated and cannot be refilled Dispose of evacuated tank in accordance with local state and federal regulations that apply in your area A refillable virgin tank should be returned to your supplier Recovery Tank A refrigerant tank designed to store refrigerant recovered from a vehicle or transferred from a virgin tank Recover The process of removing refrigerant from a system to prevent release of refrigerant into the atmosphere On Dual 3412 this process is part of recy
9. in the first filter change interval but considered the starting point Refer to the Moisture Indicator Chart below Complete the Master Filter Maintenance Schedule on the following two pages to track when to change master filter Moisture Indicator Moisture Indicator Chart Indicator Color Model Temperature 75 F 24 C 100 F 38 C 125 F 52 C Purple Very Dry Violet Dry Caution Pink Caution Wet Orange Very Wet Figure 3 1 Moisture Indicator Chart 3 2 Maintenance Master Filter Maintenance Schedule R12 Hour Meter Reading Next Change Starting Point Meter Reading 3 3 Maintenance 3 4 Maintenance Master Filter Maintenance Schedule R134a Hour Meter Heading Next Change Starting Point Meter Reading 3 5 Maintenance Changing the Master Filter Use the procedure in this section to change the master filter AWARNING AWARNING Wear safety goggles and protective gloves user and bystander If any refrigerant gets into eyes flush with water and seek a doctor s aid immediately even though irritation may cease Do not remove master filter while under pressure Perform maintenance procedure for removing master filter in this section Prevent refrigerant from contacting the skin Read understand and follow Safety Information in the front of this manual 1 Evacuate service hoses For additional informatio
10. number EAA0157CO00A for R 12 or EAA0158C00A for R 134a These tanks are D O T certified for refilling D O T certified tanks are marked D O T 4BA 350 or D O T 4BA 400 Read understand and follow Safety Information in the front of this manual IMPORTANT Vent and evacuate tanks before first use Unprepared tank can cause compressor burnout J The recovery tanks must have a minimum of 25 inHg vacuum when evacuation is complete If there is not 25 inHg vacuum check connections and repeat the procedure Tank Preparation Follow this procedure to install new recovery tanks in Dual 3412 New tanks are charged with dry air which must be vented before using tank This procedure may be used for both tanks at the same time AWARNING Wear safety goggles user and bystander Cover blue hand valve port with shop towel to help prevent debris from becoming projectile 1 Vent dry air by slowly opening blue hand valve on tank 2 Gently set tank on scale with hand valves up facing the respective front of the unit 2 3 Installation and Operation Place elastic strap around each tank so that bottom of strap is 2 above tank center weld Refer to Figure 2 2 Slide temperature probe extending from the cabinet between tank and strap Refer to Figure 2 2 Connect end of blue service hose leading from bottom of manifold gauge assembly to blue liquid tank port J For R134a install supplied tank adapter part n
11. temperature relationship with the chart and bleed off any non condensables air by pressing PURGE button Refer to Purging non condensable gas in this chapter 2 5 Installation and Operation Operation Figure 2 2 Recovery Tank and Temperature Probe J Use only the 30 pound capacity recovery tank supplied with Dual 3412 or one indicated by the warning label Using any other type or capacity tank could create the danger of explosion and potential for personal injury Inaccurate refrigerant amount may display if the correct tank is not used This section contains Procedures for connecting service hoses to the vehicle and Procedures to Recycle vehicle refrigerant Create a vacuum in the A C system before recharging and Recharge the A C system with recycled refrigerant After performing all installation procedures follow these recommended vehicle service procedures before using Dual 3412 for A C work 2 6 Installation and Operation Preliminary Checks Successful use of Dual 3412 depends on several external factors The following information explains these Precondition Vehicle Refrigerant in vehicle A C system is recovered more completely when components are warm To efficiently recover refrigerant the vehicle should be at normal operating temperature Run engine until normal operating temperature is reached with A C system off and Hood closed 4 Sometimes a small amou
12. times Heat A C system by running engine with A C OFF and keep hood closed as much as practical to hold in heat System being recycled is cold and has components that hold a substantial amount of liquid refrigerant 3 10 Maintenance Replacement Parts For R 12 Part Number 0647 0196 01 0647 0197 01 0647 0199 01 0647 0200 01 EAA0157C00A EAHO0013C00A 4719 0055 01 For R 134a Part Number 0647 0287 08 0647 0287 07 EAA0158C00A EAHOO14CO1A 4719 0055 02 Optional Accessories For R 12 Part Number EAK0095C01AB EAH0013C21A EAH0013C22A 0647 281 01 ACT 111B For R 134a Part Number EAK0095C02AB EAK0027C00AS EAH0014C12A 1 15080 1091 0301 01 Both Models Part Number EAK0029C01AB Description GM Adaptor high side GM Ford Adaptor Quick Disconnect Large GM Adaptor Quick Disconnect Ford Adaptor Recovery Tank 30 pound Gauge Assembly with hoses USA R 12 Anti blowback Valve Description Service Fitting low side Service Fitting high side Recovery Tank 30 pound Gauge Assembly with hoses USA Japan 134a Anti blowback Valve Description Master Drier Kit Gauge Assembly with hoses Europe Gauge Assembly with hoses Japan GM Adaptor for A F U and W Bodies 2 oz Oil Charge Kit for R 12 Description Master Drier Kit Vehicle Adaptor Repair Kit O rings Gauge Assembly with hoses Europe Low Side Adapter Fitting 2 oz Oil Charge Kit for 134a Description Oil Change Kit
13. yellow hoses with hand valve to ports on side panels Attach end of blue hoses without hand valve R 12 to low side left port of manifold gauge assembly Attach end of red hoses without hand valve R 12 to high side right port of manifold gauge assembly 134a refrigerant only connect high red and low blue couplers to their respective hoses Rotate coupler knobs fully CCW closed 2 1 Installation and Operation Figure 2 1 Service Hoses and Gauge Sets R 134a A Low Side Blue Hose Coupler with valve B Blue Hose C High Side Red Hose Coupler with valve D Red Hose E Yellow Hose F Hand Valve G Service Port Fitting Q Anti Blowback Valve R 12 H Low Side Blue Hose Fitting Blue Hose J Hand Valve K High Side Red Hose Fitting L Red Hose M Hand Valve N Yellow Hose O Hand Valve P Service Port Fitting Q Anti Blowback Valve 2 2 Installation and Operation Preparing and Installing Recovery Tank The recovery tanks are shipped with a dry air charge The charge must be vented and the tanks evacuated before use Use the following procedure to evacuate the dry air from the recovery tanks and install a tank for each refrigerant in Dual 3412 Do not use any tank with this equipment other than part
14. Table of Contents v ll A loi lc 1 1 Retigerant Gases E 1 2 Reingeranr su mee nm 1 3 Retrigerant Safety 15 ede e n beg redet ted teda na esu eu su Eurus dtu da RT AA 1 3 Refrigerant Substitute Warning sssssssssssssessseeeenee e nennen nennen nnns 1 4 Functional DESCMOUON REPERTUS 1 5 Typical Front VION 1 2 ibo oap Dobis eter T 1 5 acd ACCOSSOMOS ve c 1 8 Ra ACCES SONOS E T EE 1 9 SPSCIHICATIOMS o NN U N NN 1 10 General emersi aaas 1 10 rune DE 1 10 Rie M EES 1 11 erri p E EEA 1 11 Installation and Operation sssssssssssssssssesseenee meme mener 2 1 Connecting Service Hoses To Dual 3412 sse 2 1 Gomponent Identification tiri rra tede tea orptun aaa aa Ec Era PE a 2 2 Preparing and Installing Recovery Tank ssssss He 2 3 Ie EOD D LN TT ILIUM 2 6 Preliminary CHECKS RT 2 7 Connecting Service Hoses To Vehicle ssssssssssssse enne 2 9 Recover Recycle Refrigerant From Vehicle ssss 2 10 Purging Non condensable Gas sssssssssssssssssssse eene enne nennen nnne nns 2 11 Teuubdep desir uM 2 12 Ghatging A C Systelm 2er tenete epa btt eth edet d be kid e E
15. able for charging Messages display when the recovery tank is full or empty J The unit may only be used to charge an A C system when recovery tank is full J The unit may be used to recycle or evacuate an A C system when recovery tank is empty J Tank Empty is displayed when the Gross weight of the recovery tank is approximately less than 19 Ibs J Tank Full is displayed when the Gross weight of the recovery tank is 40 lbs Removing Recovery Tank 1 Close both valves on recovery tank 2 Disconnect hoses from recovery tank 3 Remove elastic band and temperature probe from tank 4 Gently remove tank from scale Evacuating Service Hoses Evacuate the service hoses before removing them from the manifold gauge assembly and whenever contamination is suspected Service hoses are not connected to a vehicle during this procedure 1 Close red and blue service hose hand valves 2 Open manifold valves Installation and Operation 3 Plug power cord into properly grounded supply line See ID plate for proper supply voltage 4 Turn compressor switch on 5 Turn vacuum recycle valve to RECYCLE 6 Monitor manifold gauges Hose evacuation is complete when 15 Hg of vacuum is reached 7 Turn vacuum recycle valve to OFF 8 Turn compressor switch to OFF Hose evacuation is complete Adding Refrigerant to Dual 3412 Follow this procedure to add virgin refrigerant to Dual 3412 4 Recovery tank s
16. alities Contact your Snap on Sun representative before operating if unsure of condition Operating Dual 3412 with the following conditions may reduce its functionality Visible evidence of damage Has been subjected to prolonged storage under unfavorable conditions or Has been subjected to severe transportation stresses Installation and Operation Connecting Service Hoses to Vehicle Figure 2 3 Service Hose Connections to Vehicle B Manifold Gauge Set C Yellow Hose D Blue Hose E Low Side Blue Hose Coupler F High Side Red Hose Coupler G Red Hose H Low Side Blue Hose Fitting High Side Red Hose Fitting Follow this procedure to connect the service hoses to the vehicle 1 Connect red high side hose with service fitting adaptor if applicable from manifold gauge set to high side service port on vehicle 2 Connect blue low side hose with service fitting adaptor if applicable from manifold gauge set to low side service port on vehicle J If the vehicle has more than one low side service port use the service port closest to the evaporator 2 9 Installation and Operation 3 Open hose hand valves or service couplers Refer to the vehicle manufacturer s service manual for proper diagnostic procedures and specifications Recover Recycle Refrigerant from Vehicle J Be sure vehicle is at operating temperature before recovering refrigera
17. assage to Dual 3412 B Service Hoses Red blue and yellow hoses for connecting gauge set to vehicle and Dual 3412 For additional information refer to Chapter 2 Connecting Service Hoses to Dual 3412 and Chapter 2 Connecting Service Hoses to Vehicle C GM Adaptor Connects to high side service port on GM vehicles D Ford Adaptor Connects to high side service port on Ford vehicles 1 8 Introduction R 134a Accessories Figure 1 4 R 134a Accessories A Gauge Set High and low pressure gauge manifold set monitors air conditioning system pressures Right hand valve opens and closes the high side service hose passage to Dual 3412 Left hand valve opens and closes the low side service hose passage to Dual 3412 B Service Hoses Red blue and yellow hoses for connecting gauge set to vehicle and Dual 3412 For additional information refer to Chapter 2 Connecting Service Hoses to Dual 3412 and Chapter 2 Connecting Service Hoses to Vehicle C Shut off Adaptors Connects to high side and low side service ports of vehicle 1 9 Introduction Specifications General Operating Power 120 VAC 50 60 Hz 12 amps maximum Shipping Weight 260 pounds Dimensions Depth 26 Height 48 Width 21 Operating Temperature Range 50 120 F ambient Maximum Operating Pressure High 300 psig Low 85 psig Pressure Range 30 inHg 300 psi Refrigerant Cha
18. cle Recycle On Dual 3412 the process of removing refrigerant from a system filtering drying and storing it in the recovery tank 4 Recycle is the only process that removes refrigerant There is not a separate recovery process 4 Dual 3412 is a single pass unit This means refrigerant is filtered and dried before reaching the recovery tank Once in the recovery tank it is ready for reuse after manual purging if necessary There is no separate recycle process to perform Evacuate The process of drawing a vacuum on a refrigerant system to remove air and moisture On Dual 3412 this process is known as vacuum Charge The process of filling an air conditioning system with refrigerant Purging The process of bleeding off non condensable gases from the recovery tank Vii Using this Manual Stable Scale Situation where reading from refrigerant weight measuring device is steady Moving Dual 3412 causes liquid refrigerant to slosh in recovery tank resulting in unsteady scale reading Avoid moving Dual 3412 before taking scale readings viii Safety Information Safety Notice For your safety read this manual thoroughly before operating Dual 3412 Dual 3412 is intended for use by properly trained skilled professional automotive technicians The safety messages presented below and throughout this user s manual are reminders to the operator to exercise care when using this unit There are many variat
19. der Refrigerant may cause injury Safety Information A test vehicle may move if not properly prepared Block the drive wheels before performing a test with the engine running Unless instructed otherwise set the parking brake and put the gear selector in neutral manual transmission or park automatic transmission If the vehicle has an automatic parking brake release disconnect the release mechanism for testing and reconnect when testing is completed Do not leave a running engine unattended A moving vehicle can cause injury Risk of injury This equipment should be operated by qualified personnel Operation of Dual 3412 by anyone other than qualified personnel may result in injury Hose couplings are not self closing Always close the valves on the gauge set before disconnecting a hose Loosened hose couplings can leak refrigerant to the atmosphere Misdiagnosis may lead to incorrect or improper repair and or adjustment Do not rely on erratic questionable or obviously erroneous test information or results If test information or results are erratic questionable or obviously erroneous make sure that all connections are correct and that the test procedure was performed correctly Refer also to the Maintenance Troubleshooting section and perform tests and make repairs as required If test information or results are still suspicious do not use them for diagnosis Contact your Snap on Sun Representativ
20. e Improper repair and or adjustment may cause vehicle or equipment damage or unsafe operation SAVE THESE INSTRUCTIONS Safety Information VI Introduction Use Dual 3412 on automotive air conditioning systems to Recover Remove refrigerant from vehicle Recycle Filter dry and store recovered refrigerant in a refillable tank Evacuate Remove air and moisture from air conditioning system using a vacuum pump to draw the system into a deep vacuum and Recharge Refill the air conditioning system with a specified amount of refrigerant Dual 3412 is a single pass design This means recovered refrigerant is filtered and dried before entering the recovery tank Refrigerant in the tank is always ready for use after manual purging if necessary See Chapter 2 Recovering Refrigerant From Vehicle There is no need to perform a separate recycle function Recover evacuate and recharge functions are performed manually This manual applies to the following Dual 3412 model Name Model Refrigerant Type Voltage Dual 3412 EEAC112A R 12 R 134a 120 VAC References in text to Dual 3412 apply to both refrigerants When a difference exists the difference is specified Dual 3412 includes one for each refrigerant A Liquid Crystal Display LCD Standard gauge set with service hoses fittings and adaptors 30 pound capacity recovery tank and electronic scale Master filter and
21. e the front cover 3 7 Maintenance pe 6 7 8 9 10 12 13 14 15 16 17 Wear safety goggles and protective gloves user and bystander Read understand and follow Safety Information in the front of this manual Disconnect all tubing and electrical connections from pump Taking note of their locations 4 Discard the O rings from hose tube ends Remove the four bolts holding the pump to the base Remove the pump through the top opening of the unit Tilt pump over an oil drain pan so the process port is straight down Oil drains from this port Approximately 9 oz of oil should be recovered If approximately 9 oz of oil is not recovered repeat step Use plastic bottle supplied with oil change kit to pour 9 3 oz 275 cc of 3GS compressor oil part number 681 0179 2 into input port of pump top port Reinstall pump and four bolts at base Install new O rings on ends of the tubing and hose assemblies Place a small amount of compressor oil on O rings and reinstall tubing assemblies Torque to 65 in Ibs Reinstall electrical connections Replace top cover Replace front cover 3 8 Maintenance Storing Dual 3412 Follow this procedure when storing Dual 3412 for prolonged periods 3 months or more 1 Change pump oil using Maintaining the Pump procedure in this chapter 2 Close all hand valves on both recovery tanks 3 Close service hose co
22. ences in text to opening and closing manifold hand valves assume Clockwise closes valves and Counterclockwise opens valves References in text to opening and closing service hose valves assume Valve is open with lever parallel to hose and Valve is closed with lever perpendicular to hose References in text to opening and closing 134a couplers assume Counterclockwise closes valves and Clockwise opens valves Check Note A check note provides additional information about the subject in the preceding paragraph Example 4 For additional information refer to Chapter 2 Connecting Service Hoses to Dual 3412 Equipment Tips Equipment tips provide information that applies to specific equipment Each tip is introduced by this icon 7 for easy identification Example Never attempt to change the recovery tank during unit operation For additional information refer to Chapter 2 Removing Recovery Tank Using this Manual Equipment Damage IMPORTANT Situations arise during testing that could damage the vehicle or the test equipment The word IMPORTANT signals these situations Example Failure to follow these instructions could damage compressor Safety Messages wd Safety messages are provided to help prevent personal injury and equipment damage All safety messages are introduced by a signal word indicating the hazard level The types of safety messages are Indicates an imminently
23. hould have at least six pounds of refrigerant or charge procedure may not be completed 1 Refer to Preparing and Installing Recovery Tank in this chapter 2 Open red vapor valve on recovery tank 3 Connect blue service hose from manifold gauge assembly to tank of virgin refrigerant J For R134a install supplied tank adapter between tank valve and blue hose Virgin tank should be upright valve up 4 Open the Virgin tank valve Blue service hose hand valve Blue manifold hand valve and 5 Turn compressor switch ON COMPRESSOR ON indicator illuminates and compressor activates 6 Turn vacuum recycle valve to RECYCLE Refrigerant flows from virgin tank through Dual 3412 and into prepared recovery tank J Monitor weight on LCD display until desired amount of virgin refrigerant has been transferred Refer to Tank Full Empty in this Chapter Installation and Operation 7 When desired amount of refrigerant has been transferred into recovery tank close Virgin tank hand valve and 8 Allow recycler to run until 15 Hg vacuum is reached Then close Blue service hose valve 9 Turn vacuum recycle valve OFF 10 Turn compressor switch OFF J Compare recovery tank pressure temperature relationship with the chart and bleed off any non condensables air by pressing PURGE button Refer to Purging Non condensable Gas in this chapter Equipment Tips Maintenance Use this chapter t
24. ions in procedures techniques tools and parts for servicing vehicles as well as in the skill of the individual doing the work Because of the vast number of test applications and variations in the products that can be tested with this instrument Snap on cannot possibly anticipate or provide advice or safety messages to cover every situation It is the automotive technician s responsibility to be knowledgeable of the system that is to be tested It is essential to use proper service methods and test procedures and to perform tests in an appropriate and acceptable manner that does not endanger your safety the safety of others in the work area or the vehicle or equipment being tested It is assumed that the operator has a thorough understanding of vehicle air conditioning systems before using Dual 3412 This understanding of principles and operating theories is necessary for competent safe and accurate use of this instrument Before using Dual 3412 always refer to and follow safety messages and applicable test procedures provided by the manufacturer of the vehicle or equipment being tested Read All Instructions Read understand and follow all safety messages and instructions in this manual and on the test equipment Safety messages in this section of the manual contain a signal word with a three part message and in some instances an icon Safety Information Power The signal word indicates the level of hazard in a situatio
25. lowing Blue liquid tank hand valve and Blue service hose hand valve or coupler CCW Identify blue hose leading from bottom of unit Connect hose end with anti blowback valve to blue liquid tank port Position this hose end at 3 o clock at the tank Remove blue service hose from tank Remove tank adapter 1 15080 if used Open red and blue valves on recovery tank Connect blue service hose from manifold gauge assembly to tank of virgin refrigerant J For R134a install supplied tank adapter between tank 25 26 27 valve and blue hose Open the Virgin tank valve Blue service hose hand valve or coupler CW Blue manifold hand valve and Turn compressor switch ON COMPRESSOR ON indicator illuminates and compressor activates Turn vacuum recycle valve to RECYCLE Refrigerant flows from virgin tank through ProLine 600 and into prepared recovery tank J Press mode button until Tare Weight is displayed 28 29 30 31 32 Monitor weight on LCD display until desired amount of virgin refrigerant has been transferred Refer to Tank Full Empty in this Chapter When desired amount of refrigerant has been transferred into recovery tank close Virgin tank hand valve and Allow recycler to run until 15 Hg vacuum is reached Then close Blue service hose valve or coupler Turn vacuum recycle valve OFF Turn compressor switch OFF Compare recovery tank pressure
26. lter For additional information refer to Chapter 3 Changing the Master Filter Prevent refrigerant from contacting the skin Read understand and follow Safety Information in the front of this manual Use Dual 3412 in locations with mechanical ventilation providing at least four air changes per hour Avoid breathing air conditioning refrigerant and lubricant vapor or mist Do not allow refrigerant to contact open flame or be drawn into a running engine This can cause refrigerant to become poisonous phosgene gas Use Dual 3412 to remove refrigerant from air conditioning systems Read understand and follow Safety Information in the front of this manual Tighten all tubing connections properly Insufficient or excessive torque can result in loose joints or deformed parts Either condition can result in refrigerant leakage 1 3 Introduction Refrigerant Substitute Warning AWARNING Do not use Dual 3412 or leak detector equipment if R 12 substitutes are suspected R 12 refrigerant substitutes may be flammable Read understand and follow Safety Information in the front of this manual Aftermarket R 12 refrigerant substitutes are being sold that are dangerous or potentially flammable gases These products contain a blend of butane isobutane and propane and have the potential for explosion Some of these products are OZ 12 Refrigerant 1 76 Arctic Chill R 176 and GHG Refrigerant 12
27. n DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury to the operator or bystanders WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury to the operator or bystanders CAUTION indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury to the operator or bystanders Safety messages in this section contain three different type styles Normal type states the hazard Bold type states how to avoid the hazard Italic type states the possible consequences of not avoiding the hazard An icon when present gives a graphical description of the potential hazard IMPORTANT SAFETY INSTRUCTIONS Risk of suffocation Vehicle exhaust gases contain carbon monoxide Refrigerant gas can displace air in work area Use Dual 3412 in locations with mechanical ventilation providing at least four air changes per hour Suffocation will cause injury Risk of electric shock and fire To avoid electric shock the power cord protective grounding conductor must be connected to a properly grounded AC outlet Use proper A C outlet for unit to operate correctly See unit ID plate on back of unit Extension cords are not recommended If an extension cord must be used use 16 AWG for cords up to 50 and 14 AWG for cords greater than 50 but less than 100
28. n refer to Chapter 2 Evacuating Service Hoses 2 Remove power cord from wall outlet 3 Release hook and loop strap securing master filter Filter Dryer Design Pressure 500 psig 3450 kPa Eos FLOW D Figure 3 3 Master Filter 4 Unscrew two hose fittings from master filter 5 Remove master filter 4 Dispose of the filter according to local state and federal regulations that apply in your area 6 Install new master filter matching direction of FLOW on filter with flow decal on cabinet 7 Attach fittings hand tight 8 Mount master filter securely by tightening hook and loop strap 3 6 Maintenance 8 Check for leaks Pump The oil in the pump assembly must be changed quarterly to prolong pump life The optional oil change kit is recommended For additional information refer to Replacement Parts in this chapter All parts necessary to change the pump oil are included in this kit Maintaining the Pump 1 Perform a Recycle on the service hoses if necessary For additional information refer to Chapter 2 Evacuating Service Hoses Unplug Dual 3412 from electrical outlet Remove screws holding top cover Remove top cover Figure 3 4 Pump A Outlet Line Connection at Pump B Input Line Connection at Pump C Outlet Line Tube D Process Line Tube E Input Line Hose F Process Line Connection at Pump 5 Remove the screws holding the front cover and remov
29. nt 1 Open red vapor recovery tank valve 2 Connect service hoses to vehicle For additional information refer to Connecting Service Hoses to Vehicle in this chapter 3 Open High red side service hose valve or coupler Low blue side service hose valve or coupler High red manifold hand valve Low blue manifold hand valve 4 Turn compressor ON COMPRESSOR ON indicator illuminates and compressor activates 5 Turn vacuum recycle valve to RECYCLE Refrigerant flows from vehicle through Dual 3412 and into recovery tank As refrigerant is recovered the low side manifold gauge shows increasing vacuum Continue recovering until low side manifold gauge indicates 15 inHg 6 Close High side manifold hand valve and Low side manifold hand valve 7 Turn vacuum recycle valve to OFF 8 Turn compressor switch OFF 9 Monitor low side manifold pressure gauge for about 2 minutes No change indicates recovery is complete Continue with system repair and or evacuation Pressure increase indicates more recovery time required or vehicle A C system has leak Repeat steps 3 through 9 If gauge reading still increases add partial charge to system and leak test with electronic leak detector to find leak Installation and Operation 10 Close red and blue service hose hand valves or couplers 11 Purge noncondensables 4 For additional information refer to Purging Non condensable
30. nt of refrigerant is left in the vehicle A C system that is not practical to recover If recovery time is too short or if vehicle components are cold this parasitic refrigerant can expand during a vacuum hold test reducing the vacuum in vehicle A C system This could be interpreted as a leak yet none exists Allow Adequate Evacuation Time Evacuate the vehicle system for a minimum of 30 minutes This helps ensure vehicle A C system is free of non condensable gas mostly air and moisture Follow Vehicle Manufacturer s A C Service Procedures When charging a slow charge condition may occur due to pressure equalization between Dual 3412 and vehicle A C system Finish charging by Closing high side manifold valve Starting engine and Turning A C system ON J It is the technician s responsibility to be familiar with vehicle manufacturer recommended service procedures 2 7 Installation and Operation AWARNING AWARNING Keep the service hoses away from moving or hot engine parts Service hoses can not withstand high temperatures or severe mechanical stress IMPORTANT Close tank valves when not using Dual 3412 Leaving tank valves open may result in refrigerant loss from tank Do not use Dual 3412 outside of the following limits Warmer than 49 C 120 F Colder than 10 C 50 F and or Relative humidity greater than 80 Stabilize Dual 3412 to a moderate temperature and inspect for abnorm
31. o maintain Dual 3412 Master filter Pump and When stored for prolonged periods Troubleshooting information and a list of parts and accessories are also included CIA stable scale weight reading with the refrigerant not moving around in the recovery tank is needed at the beginning and end of a recycle or charge program Do not lean on or move the unit at these times INever attempt to change the recovery tank during unit operation Always evacuate service hoses before disconnecting from Dual 3412 or manifold gauge set For additional information refer to Chapter 2 Evacuating Service Hoses TNever drop a recovery tank onto scale This may damage scale assembly JAlways oil seals before connection to any tank filter or fitting A leaky connection or no flow condition may result if connection is assembled dry Always close all tank valves clockwise on both recovery tanks when Dual 3412 is not in use INon condensable gasses must be purged from the recovery tank For additional information refer to Chapter 2 Purging Non condensable Gas 3 1 Maintenance Master Filter Change the master filter when the moisture indicator is violet or when the hour meter has accumulated 20 additional hours since the last master filter change Any hours already showing on the meter when unit is originally un boxed and setup should be noted on the next page as the first entry These should not be included
32. on and Operation Figure 2 1 Service Hoses and Gauge Sets sss 2 2 Figure 2 2 Recovery Tank and Temperature Probe 22 eee 2 6 Figure 2 3 Service Hose Connections to Vehicle sesss 2 9 Maintenance Figure 3 1 Moisture Indicator Chart ssssssssssssssssssseeeeeeneennn enne 3 2 Figure 3 3 Master Filter 1e tte Da n e cvs e e Rx EE EN t e Deae Reus 3 6 FIgure 3 4 Pump xXsssn meet dt dI UE 3 7 iii Trademark and Copyright information Trademark Acknowledgements Snap on is a trademark of Snap on Technologies Incorporated Sun is a trademark of Snap on Tools Company Dual 3412 is a registered trademark of Snap on Tools Co Copyright Information Dual 3412 User s Manual 1996 Snap on Incorporated The information specifications and illustrations in this manual are based on the latest information available at the time of printing Sun reserves the right to make changes at any time without notice Using this Manual This manual contains instructions for use and setup of the unit A table of contents and table of illustrations are provided to make this manual easy to use Some of the information shown in text or illustrations is obtained using optional equipment A Snap on Sun Sales Representative can determine option availability Conventions This section contains a list of conventions used in text Service and Manifold Hand Valves Refer
33. r Lights when power cord is connected to A C power Compressor On Indicator Lights when compressor is running High Pressure Indicator Lights when recovery tank pressure is above 300 psi Tank pressure above 300 typically means non condensable gas should be vented from recovery tank For additional information refer to Chapter 2 Purging Non condensable Gas Tank Full Indicator Lights when recovery tank weight reaches 40 pounds Overload Indicator Lights when compressor approaches a stall condition End procedure in process to prevent compressor damage when overload indicator lights Temperature Display Shows recovery tank temperature Use this along with pressure temperature chart on front panel when purging non condensable gas For additional information refer to Chapter 2 Purging Non condensable Gas Pressure Gauge Shows recovery tank pressure Use this along with pressure temperature chart on front panel when purging non condensable gas For additional information refer to Chapter 2 Purging Non condensable Gas Purge Button Use when purging non condensable gas from recovery tank For additional information refer to Chapter 2 Purging Non condensable Gas LCD Display Shows charged recovered amounts or gross weight of recovery tank Also Indicates software version Tank Full and Tank Empty conditions Moisture Indicator Shows moisture level in recycled refrigerant When moisture indicator changes color maste
34. r filter maintenance is required For additional information refer to Chapter 3 Master Filter 1 6 Introduction C Hour Meter On Sides Registers recovery compressor run time to guide master filter maintenance For additional information refer to Chapter 3 Master Filter D Master Filter Consists of a 10 micron particulate filter and desiccant to remove moisture For additional information refer to Chapter 3 Changing the Master Filter E Scale Electronically measures the amount of refrigerant dispensed recycled and remaining in the recovery tank Oil Separator Internal Removes oil and other contaminants from the refrigerant being recycled F Service Ports On Sides The yellow service hose from the gauge set attaches to the service port G Oil Drain Valve Used to drain recovered oil from unit after every recover recycle operation H Oil Cup Used to measure recovered oil RECYCLE CHARGE Figure 1 2 Typical Port Designation 1 7 Introduction R 12 Accessories Figure 1 3 R 12 Accessories A Gauge Set High and low pressure gauge manifold set monitors air conditioning system pressures Right hand valve opens and closes the high side service hose passage to Dual 3412 Left hand valve opens and closes the low side service hose p
35. red charge amount is reached close yellow service hose hand valve or coupler Refrigerant flow stops J If desired charge amount cannot be reached Close yellow and red service hose hand valves Run A C system Open yellow service hand valve Monitor tank weight and close hand valve when desired charge amount is reached Close blue liquid recovery tank hand valve Reattach yellow service hose with anti blowback valve to service port Monitor high and low side system pressures Refer to manufacturer specifications for proper operation and diagnosis Charge complete J When charging a vehicle after evacuation allow for the capacity of the hoses Each hose holds approximately two ounces so the charge amount should be increased by two ounces for each hose used f there is not enough refrigerant in the tank to charge refer to Adding Refrigerant to Dual 3412 in this chapter Installation and Operation Displaying Refrigerant Amount Tank Full Empty Use this procedure to determine the amount of refrigerant in recovery tank and amount able to be charged 1 Press Mode button until Gross weight displays on LCD 2 This is the total weight of the recovery tank plus recycled refrigerant The tank itself weighs approximately 16 lbs approximately 3 lbs of refrigerant is needed to meet the quil tube in the tank This makes the Tank Empty point 19 Ibs Any refrigerant over this amount is us
36. rge Amount 0 25 pounds Recovery Amount 0 25 pounds Recovery Rate 1 pound minute maximum Recycled Refrigerant Tank 30 Ib with purge port for each tank Introduction Storage Temperature 4 158 F Relative Humidity Up to 80 non condensing Capacities Recovery Up to 25 Ibs total 1 11 Introduction ooo Installation and Operation Use information in this chapter to Prepare Dual 3412 for initial use Recover vehicle refrigerant Create a vacuum before recharging and Recharge with recycled refrigerant Connecting Service Hoses to Dual 3412 Use the following procedure to connect service hoses to Dual 3412 Refer to Figure 2 1 Do not use Dual 3412 or leak detector equipment if R 12 substitutes are suspected R 12 refrigerant substitutes may be flammable Read understand and follow Safety Information in the front of this manual Refer to Page 1 4 4 Confirm refrigerant type in vehicle and use appropriate connections on unit 4 Always lubricate rubber gaskets and seals at hose connections with fresh refrigerant oil before connecting J Tighten hose connections finger tight Use electronic leak detector to insure connections are leak free Connect an anti blowback valve two found in unit accessories to end of each yellow service hose with hand valve Attach end of yellow hoses without hand valve to center port of manifold gauge assemblies Attach end of
37. umber 10 12 13 14 15 16 17 18 1 15080 between tank valve and blue hose Open blue liquid tank valve turn fully counterclockwise Identify red hose leading from bottom of unit Connect hose end with anti blowback valve to red vapor tank port Close red vapor tank valve turn fully clockwise Identify yellow hose leading from bottom of unit Connect hose end with anti blowback valve to tank purge port Rotate tank so yellow hose goes straight up into cabinet Close hand valve on red service hose Open the following Yellow service hose hand valve Blue service hose hand valve or coupler CW High side manifold hand valve and Low side low manifold hand valve Turn both compressor switches OFF Turn both vacuum recycle valves OFF Connect power cord to wall outlet having correct voltage for unit For additional information refer to Chapter 2 Specifications UNIT ON indicators illuminate Turn compressor switch ON COMPRESSOR ON indicator illuminates and compressor activates Turn vacuum recycle valve to VACUUM Low side manifold gauge shows vacuum increasing Monitor low side manifold gauge until a minimum of 25 inches of mercury is reached Turn vacuum recycle valve OFF 2 4 Installation and Operation 20 21 22 23 24 Turn compressor switch OFF COMPRESSOR ON indicator goes out and compressor stops running Close the fol
38. upling and manifold valves 3 9 Maintenance Troubleshooting Symptom Machine does not turn on Possible Cause Remedy Power cord not plugged in Plug in cord No power in AC outlet Check power source Refrigerant not being removed from vehicle Hand valves not open Open hand valves Change tank or Charge refrigerant Recovery tank full Excessive purging of non condensables Fitting s not properly connected to master filter Tighten fitting s finger tight Leaky service hose or adaptor connection drawing in air Tighten fittings or replace seals in finger tight fittings Does not charge Blue hand valve on recovery Open blue hand valve tank not open Fitting not properly Tighten fitting finger tight connected to recovery tank No refrigerant in tank Fill tank with refrigerant Machine does not draw a vacuum Loose hose connection Tighten loose hose connections Cil drain valve open Close oil drain valve Hissing noise from oil separator during recycle and or vacuum mode Cil drain valve open Close oil drain valve Refrigerant losses from tank on scale over time Make sure hand valves are either open completely CCW or closed completely CW and leak test Leaky hand valve s on tank Oil seal with refrigerant oil and reconnect OR replace fitting oil seal and reconnect Leaky fitting s Long recycle
39. use refrigerant to become poisonous phosgene gas Use Dual 3412 to remove refrigerant from air conditioning systems Exposure can irritate eyes nose and throat Ill Safety Information General Engine systems can malfunction expelling fuel oil vapors hot steam hot toxic exhaust gases acid refrigerant and other debris Wear safety goggles and protective gloves user and bystander Engine systems that malfunction can cause injury Engine compartment contains electrical connections and hot or moving parts Keep yourself test leads clothing and other objects clear of electrical connections and hot or moving engine parts Do not place test equipment or tools on fenders or other places in the engine compartment Contact with electrical connections and hot or moving parts can cause injury Service hoses can not withstand high temperatures or severe mechanical stress Keep the service hoses away from moving or hot engine parts Service hoses can split or burst causing injury Risk of explosion if improper tank is used Do not use any tank with this equipment other than part number EAA0157CO00A for R 12 or EAA0158CO0A for R 134a These tanks are D O T certified for refilling D O T certified tanks are marked D O T 4BA 350 or D O T 4BA 400 Explosion can cause injury Removing tubing assemblies from the pump may discharge refrigerant Wear safety goggles and protective gloves user and bystan
40. x a xau e dun d uai an 2 13 Displaying Refrigerant AMOUNT ecco pectore E Uet E x RP ERADR SPUR Pep eeS 2 14 Tank TfullEmply 252 2 t tee dude do eat ade deere ae sa era El tud ta dede ce ad 2 14 Removing Recovery AMI dap EEUU 2 14 Evacuating Service HOSES isset dernier xch haec en tl x d i e Ia X E x Rx e addu Ry Edu 2 14 Adding Refrigerant To Dual 3412 errenneren R 2 15 eels Sa ee rea ee ee eee er eer re en ee re 3 1 een 3 1 Nastor ale LL ERI 3 2 Melee 3 2 Master Filter Maintenance Schedule R12 ssssssssssseeeeeene emen 3 3 Master Filter Maintenance Schedule R134a ssssssssssee eee 3 5 Changing the Master Filter nennen entrent 3 6 o mee H 3 7 Mamando he Pup oreroraa an edes gtreta AAO En cePaD tea UDi MEE DER UEE 3 7 Prolonged Storage of Dual 3412 ssssssssssssssssssessssesnnenn aa ana aaa nnn nnns 3 9 vIcSIelel Tino PEE 3 10 Replacement Pars T 3 11 Optional ACCOSSOMES d L 3 11 Table of Contents L Table of Illustrations Introduction Figure 1 17 Typical Front VIEW 2 3 ede ee Fn Reni Pe i ee eee eee eb n Rue ede ede dees 1 5 Figure 1 2 Typical Port Designation sss nn nennen nnns 1 7 Figure 123 RTZ ACCeSSOTIGS etie iieet seis cocotte bre el eg dade be emu tenues 1 8 Figure 1 4 R213 4a ACCeSSOTIOS eret i i e ii d ra eed reda ada 1 9 Installati
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