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1. liquid recovery tank valve and Blue service hose coupler CW Connect the power cord to the proper wall outlet with the correct voltage for the unit For additional information refer to Power Up in this chapter and Chapter 1 Specifications Turn power switch ON The following screens will display Software Version screen and Main Menu screen 2 3 Installation and Operation 4 In the unlikely event the LCD screen is unreadable or a 10 11 12 13 14 15 16 different language is displayed upon power up adjust LCD contrast or change language selection Refer to Adjusting LCD Contrast or Accessing Language in this chapter Select VACUUM and press ENTER the following message displays VACUUM 30 00 Alv TO ADJUST TIME Press v buttons to adjust time to desired value Press NEXT and the following message displays OPEN PANEL VALVE Turn the panel valve to LOW and press START the following messages display PLEASE WAIT CHECKING FOR PRESSURE IN VEHICLE VACUUM RUNNING XX XX Monitor the low side panel gauge until a minimum of 25 inHg of vacuum is reached Close the following Blue liquid recovery tank valve and Blue service hose coupler CCW Press EXIT and the following message displays CLOSE PANEL VALVE THEN PRESS NEXT Turn the panel valve to OFF and press NEXT the following message displays for 5 seconds before the Main Menu scree
2. Blue hand valve on recovery tank not open Fitting not properly connected to recovery tank Leak in vehicle system Service hose couplers not open Panel valve off Open blue hand valve Tighten fitting finger tight Repair vehicle system leak Open couplers Turn panel valve to LOW BOTH or HIGH Machine does not draw a vacuum Loose hose connection Low or no oil in vacuum pump Leak in vehicle system Tighten loose hose connections Add oil to vacuum pump Repair vehicle system leak Maintenance Symptom Refrigerant loss from tank on scale over time Possible Cause Leaky hand valve s on tank Leaky fitting s Remedy Make sure hand valves are either open completely CCW or closed completely CW and leak test Oil seal with refrigerant oil and reconnect or replace fitting oil seal and reconnect Long recover times System being recovered is cold and has components that hold a substantial amount of liquid refrigerant Heat A C system by running engine with A C OFF and keep hood closed as much as practical to hold in heat Tank Temperature Error Operating outside normal temperature range Temperature probe damaged Return to normal operating temperature Call service Pressure Switch Err Internal excessive pressure Red hand valve on recovery tank is closed Red hose fitting on the recovery tan
3. Installation and Operation The refrigerant flows from the virgin tank through your KoolKare Xtreme unit and into the prepared recovery tank 4 A minimum of 6 Ibs of refrigerant needs to be in the recovery tank before a charge operation can be accomplished Refer to Tank Full Empty in this chapter 29 When the desired amount of refrigerant has been transferred into the recovery tank close the virgin tank hand valve and the blue service hose coupler AWARNING AWARNING Risk of expelling refrigerant under pressure pe Always close the tank valves before removing the hoses or fittings Wear safety goggles and protective gloves user and bystander Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses If any refrigerant gets into the eyes flush with water and seek a doctor s aid immediately even though irritation may cease Prevent refrigerant from contacting the skin Expelled refrigerant can cause injury 30 Allow the recover recycle operation to run until complete 31 When recovery operation is complete the unit will beep once the LCD screen will flash and the following message displays CLOSE PANEL VALVE THEN PRESS NEXT 32 Turn the panel valve to OFF and press NEXT the Amounts screen and then the Main Menu screen will display 33 Remove the blue service hose and adapter from the virgin tank and store the adapter with unit accessories 2 6 Installation and
4. NOT unplug the electrical connections from the compressor The capacitor will hold an electrical charge and an electrical shock can occur 4 Discard the O rings from the hose tube ends Figure 3 3 Compressor Connections 9 Remove the nuts holding the compressor in place 10 Lift compressor up and to the side to position compressor connections over a drain pan 3 5 Maintenance Figure 3 4 Lift Compressor 11 Drain the oil from the compressor Approximately 9 oz of oil should be recovered 12 Reinstall compressor to its normal position If approximately 9 oz of oil is not recovered repeat steps 10 11 4 Ensure compressor is not placed on binds or crimps any electrical wires or refrigerant hoses 13 Use the plastic bottle supplied with the oil change kit to pour 9 3 oz 275 cc of 3GS compressor oil into the input port of the compressor top port 14 Reinstall compressor hold down nuts 15 Install new O rings on the ends of the tubing and hose assemblies 16 Place a small amount of compressor oil on the O rings and reinstall the tubing and hose assemblies to their proper locations Torque to 65 in lbs 17 Replace front panel support brackets and plastic top panel 3 6 Maintenance Maintaining the Vacuum Pump Only if using the EEAC319A with vacuum pump Checking and Adding Vacuum Pump Oil 4 To obtain an accurate vacuum pump oil level reading the unit needs to be p
5. Oil Kit EEACSTOA V eoiieecisesche eei nen onere ran pec i Protective Cover For service or to order replacement parts or optional accessories contact your EquiServ Representative or call 1 800 225 5786 Maintenance aaa Sa Snap on Tools Company Limited One 1 Year Warranty Snap on Tools Company the Seller warrants only to the original purchaser that under normal use care and service the Equipment except as otherwise provided herein shall be free from defects in material and workmanship for one year from the date of original invoice Items such as leads probes external hoses adapters and all other attachments supplies and consumables except as otherwise provided here in are warranted for 90 calendar days from the date of original invoice Filter elements are not warranted SELLER S OBLIGATIONS UNDER THIS WARRANTY ARE LIMITED SOLELY TO THE REPAIR OR AT SELLER S OPTION REPLACEMENT OF EQUIPMENT OR PARTS WHICH TO SELLER S SATISFACTION ARE DETERMINED TO BE DEFECTIVE AND WHICH ARE NECESSARY IN SELLER S JUDGEMENT TO RETURN THIS EQUIPMENT TO GOOD OPERATING CONDITION NO OTHER WARRANTIES EXPRESS OR IMPLIED OR STATUTORY INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL APPLY AND ALL SUCH WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED This Warranty does not cover and separate charges for parts labor and related expenses shall apply to any damage to malfuncti
6. and lubricant manufacturers Exposure can irritate eyes nose and throat Risk of expelling oil under pressure Wear safety goggles and protective gloves user and bystander Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses If any oil gets into the eyes flush with water and seek a doctor s aid immediately even though irritation may cease Expelled oil can cause injury 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 Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses Service should be performed by a certified A C service technician Engine systems that malfunction can cause injury The 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 Barriers are recommended to help identify danger zones in test area Prevent personnel from walking through immediate test area Contact with electrical connections and hot or moving parts can cause injury IV Safety Information AWARNING RY AWARNING Service hoses can not withstand high temperatures or severe mech
7. 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 AWARNING 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 Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses If any refrigerant gets into the eyes flush with water and seek a doctor s aid immediately even though irritation may cease Do not remove master filter dryer while under pressure Follow instructions for removing master filter dryer For additional information refer to Chapter 3 Changing the Master Filter Dryer Prevent refrigerant from contacting the skin Read understand and follow Safety Information in the front of this manual Use your KoolKare Xtreme unit 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
8. liquid and red vapor recovery tank valves 4 Install the supplied tank adapter part number 1 15080 between the tank valve and the blue service hose The virgin tank should be upright valve up 4 Do not recover liquid refrigerant from a supply tank 3 Connect the blue service hose from the KoolKare Xtreme unit to the refrigerant supply tank Open the following Supply tank valve and Blue service hose coupler Connect the power cord to the proper wall outlet with the correct voltage for the unit For additional information refer to Power Up in this chapter and Chapter 1 Specifications Turn power switch ON Select RECOVER and press ENTER the following message displays EMPTY OIL DRAIN BOTTLE NOW Press NEXT and the following message displays OPEN PANEL VALVE Turn the panel valve to LOW and press START the following messages display PLEASE WAIT PURGING AIR 2 25 Installation and Operation RECOVERING AMOUNT RECOVERED xxLb XXOZ The refrigerant flows from the virgin tank through your KoolKare Xtreme unit and into the prepared recovery tank 4 Monitor the weight on the LCD display until the desired 10 11 12 13 amount of virgin refrigerant has been transferred Refer to Tank Full Empty in this chapter When the desired amount of refrigerant has been transferred into the recovery tank close the virgin tank hand valve Allow the recycler
9. pressure Perform the maintenance procedure for removing the master filter dryer 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 by recovering if necessary and pulling a vacuum For additional information refer to Chapter 2 Recovering Service Hoses 2 Turn OFF power to the KoolKare Xtreme unit and remove power cord from wall outlet 3 Unscrew the two hose fittings from the master filter dryer 3 2 Maintenance Figure 3 1 Master Filter Dryer 4 Remove the master filter dryer from its bracket 4 Dispose of the filter according to local state and federal regulations that apply in your area 5 Lightly oil hose seals and install a new master filter dryer matching the direction of FLOW on the filter with the flow decal on the cabinet 6 Attach the hose fittings hand tight 7 Reset master filter dryer percentage monitor Resetting Master Filter Dryer Monitor Use the procedure in this section to reset the automatic reminder monitor for the master filter dryer 4 This procedure should only be done when the master filter dryer is replaced 1 Power up the KoolKare Xtreme unit 2 Select SET UP from the Main Menu 3 Select FILTER from the Set Up Menu 4 Press RESET button 5 Press CONFIRM to reset the master filter dryer reminder monitor 3 3 Maintenance Com
10. reasonable time following purchaser s request All requests for Warranty service must be made during the stated Warranty period This Warranty is nontransferable Snap on Tools Company Kenosha Wisconsin 53141 1410
11. 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 Refer to Chapter 2 Recovering Refrigerant From Vehicle There is no need to perform a separate recycle function Recover evacuate and recharge functions are performed semi automatically This manual applies to the following KoolKare Xtreme models Model Number Refrigerant Type Voltage EEAC319A R 134a 120 VAC w vacuum pump EEAC320A R 134a 120 VAC w o vacuum pump Your KoolKare Xtreme unit includes A backlit Liquid Crystal Display LCD and four buttons to control operation Integral gauge set and manual control valves with service hoses fittings and adapters A 50 pound capacity recovery tank and electronic scale Master filter dryer with automatic replacement reminder An oil drain bottle and An oil injection bottle 4 The 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 re
12. vehicle compressor charge on high side only 4 Follow vehicle manufactures service procedures 18 Turn the panel valve to desired position and press NEXT to continue the auto sequence 2 21 Installation and Operation 19 The unit will charge the A C system as described in the individual test Charging A C System 20 When the auto sequence has completed the following message displays AUTO SEQUENCE IS COMPLETE CLOSE PANEL VALVE 21 Turn the panel valve to OFF and press NEXT the Amounts screen and then the Main Menu screen will display Displaying Refrigerant Amount Use this procedure to determine the amount of refrigerant in the recovery tank and the amount able to be charged 1 Press the AMOUNTS button to obtain RECOVERED and CHARGED amounts 2 Press the MORE button to obtain TANK amount tank temperature tank PSIG and FILTER DRYER percentage TANK amount is the total weight of the chargeable refrigerant in the recovery tank Approximately 3 lbs of refrigerant is needed to meet the quill tube in the tank This makes the Tank Too Low point 3 Ibs Any refrigerant over this amount is usable for charging FILTER DRYER percentage is the percentage left before the master filter dryer needs to be replaced This percentage number counts down from 100 Tank Full Empty Messages display when the recovery tank is full or empty 4 The unit may only be used to charge an A C system when the recove
13. 19A 185 Ibs 79 38 kg EEAC320A 175 Ibs 83 91 kg Dimensions Depth 29 Height 46 Width 23 Operating Temperature Range 50 120 F 10 49 C ambient Relative Humidity Up to 80 non condensing Maximum Operating Pressure 450 psi Pressure Range 30 inHg 300 psi Storage Temperature Range 4 140 F 20 60 C ambient Relative Humidity Up to 80 non condensing Refrigerant Charge Amount 0 42 Ibs 19 05 kg Recovery Amount 0 45 Ibs 20 41 kg Charge Oil Bottle Capacity 7 oz 2 kg Drain Oil Bottle Capacity 7 oz 2 kg Installation and Operation Use the information in this chapter to Prepare your KoolKare Xtreme unit for initial use Recover vehicle refrigerant Create a vacuum before recharging and Recharge with recycled refrigerant Connecting Service Hoses to the KoolKare Xtreme Unit Use the following procedure to connect service hoses to your KoolKare Xtreme unit AWARNING Do not use your KoolKare Xtreme unit or any 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 the appropriate connections on the unit 4 Always lubricate rubber gaskets and seals at hose connections with fresh refrigerant oil before connecting 4 Tighten hose connections fin
14. ESSURE IS TOO LOW Press EXIT and the following message displays CLOSE PANEL VALVE PRESS NEXT Follow steps 10 11 6 When recovery is complete the following message displays DRAINING OIL RECORD AMOUNT WHEN DONE Installation and Operation 7 Waste oil is automatically expelled into the oil bottle 8 The amount indicated on the bottle is the amount to add back into the vehicle A C system when recharging 4 Discard refrigerant oil in accordance with local state and federal regulations that apply in your area 9 When recovery operation is complete the unit will beep once the LCD screen will flash and the following message displays CLOSE PANEL VALVE THEN PRESS NEXT 10 Turn the panel valve to OFF and press NEXT the Amounts screen and then the Main Menu screen will display 11 When Main Menu screen appears close the red and blue service hose couplers Purging Non condensable Gas 4 Purging non condensable gases is an automatic feature executed by the KoolKare Xtreme unit Evacuating A C System Use this procedure to remove non condensible gases and moisture from the vehicle A C system 4 If using the EEAC319A with vacuum pump always check the oil level of the vacuum pump when the pump is first turned ON The oil level should be half way up the sight glass If no oil level is shown fill the vacuum pump with oil 1 Open the blue liquid and red vapor recovery tan
15. EXT The refrigerant flow stops 4 When charging a slow charge condition may occur due to pressure equalization between your KoolKare Xtreme unit and the vehicle A C system Finish charging by Turn the panel valve to OFF Starting the engine Turning the A C system ON Turn the panel valve to LOW and Allow unit to complete the charge 4 Never operate the vehicle A C system with the panel valve on HIGH or BOTH 7 Monitor the high and low side system pressures Refer to the manufacturer s specifications for proper operation and diagnosis 8 Turn the panel valve to OFF and press NEXT to return to the main menu Charge is complete Installation and Operation Auto Sequence The KoolKare Xtreme unit can be programmed to perform an automatic series of operations These operations include Recovering the refrigerant from a vehicle Evacuating the A C system Holding a vacuum for a predetermined time to find a leak e Adding refrigerant oil to the system and Charging the A C system with refrigerant Follow this procedure and the on display prompts to set up the unit for an auto sequence 4 Be sure the vehicle is at normal operating temperature before recovering refrigerant 1 Open the blue liquid and red vapor recovery tank valves 4 Empty the oil drain bottle left bottle before each recovery 2 Connect the service hoses to the vehicle and open service hos
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17. Operation Power Up Refer to this section to understand the power up sequence of the KoolKare Xtreme unit 1 Connect the power cord to the proper wall outlet with the correct voltage for the unit For additional information refer to Chapter 1 Specifications 2 Turn power switch ON 3 The KoolKare Xtreme unit will power up The following screens will appear in order Software Version screen Snap on KoolKare Xtreme Software Rev C 2002 Snap on Main Menu screen with default arrow position gt RECOVER CHARGE VACUUM SET UP AUTO SEQUENCE ENTER AMOUNTS 4 In the unlikely event the LCD screen is unreadable or a different language is displayed upon power up adjust LCD contrast or change language selection Refer to Adjusting LCD Contrast or Accessing Language in this chapter 2 7 Installation and Operation Accessing Set Up Adjusting LCD Contrast Use the procedure in this section to adjust the contrast on the LCD screen with or without being able to read the screen 1 Power up the KoolKare Xtreme unit 2 Press button once to select SET UP from the Main Menu and then press ENTER which is the left button under the LCD display CONTRAST gt Lbs kg gt LANGUAGE gt gt FILTER oS ee ENTER EXIT 3 Select CONTRAST from the Set Up Menu press ENTER CONTRAST will be the default selection when the Set Up Menu screen displays PRESS OR
18. Safety Information Safety Notice For your safety read this manual thoroughly before operating your KoolKare Xtreme unit Your KoolKare Xtreme unit 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 variations 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 onQ cannot possibly anticipate or provide advice or safety messages to cover every situation It is the automotive technicians 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 the vehicle or equipment being tested It is assumed that the operator has a thorough understanding of vehicle air conditioning systems before using this KoolKare Xtreme unit This understanding of principles and operating theories is necessary for competent safe and accurate use of this instrument Before using your KoolKare Xtreme unit always refer to and follow the safety messages and app
19. Unit Follow this procedure when storing your KoolKare Xtreme unit for prolonged periods 3 months or more of time 4 Storage temperature should not exceed the limits of 4 to 140 F 1 Change the compressor and vacuum pump oil Refer to Maintaining the Compressor and Changing Vacuum Pump Oil procedures in this chapter 2 Close both hand valves on the recovery tank 3 Remove the yellow hose from the recovery tank 4 Close both service hose couplers 5 Turn the panel valve to OFF Maintenance Troubleshooting Symptom Machine does not turn on e Possible Cause Power cord not plugged in Power switch OFF No power in A C outlet Remedy Plug in the power cord Turn power switch ON Check power source Refrigerant not being removed from vehicle Hand valves on tank not open Panel valve or service hose couplers not open Recovery tank full Tank Full Error Open hand valves Open panel valve or couplers Change tank or Charge refrigerant Excessive purging of non condensable gases Fitting s not properly connected to master filter dryer Leaky service hose or adapter connection drawing in air Maybe contaminated with a different refrigerant that has a higher pressure rating Tighten fitting s finger tight Tighten fittings or replace seals in finger tight fittings ID refrigerant if contaminated replace tank Does not charge
20. and Operation 12 Press NEXT and the following message displays OPEN PANEL VALVE 4 Have the panel valve turned to BOTH for the fastest recovery and best vacuum 4 Follow vehicle manufactures service procedures Press EXIT to abort auto sequence and return to Main Menu screen 13 Turn the panel valve to desired position and press START 14 If yes is selected for RECOVER the unit will recover the A C refrigerant from the system as described in the individual test Recover Recycle Refrigerant from Vehicle 15 If yes is selected to pull a vacuum the unit will evacuate the vehicle A C system as described in the individual test Evacuating A C System Vacuum time can be adjusted while an evacuation is in progress When evacuation process is complete the unit will perform a vacuum hold sequence for the specified time before advancing to the next step 4 If vacuum is lost over the specified amount of time there is a leak in the vehicle A C system and the auto sequence will not be completed 16 If yes is selected for an oil and refrigerant charge the unit will pause and beep once before initiating the refrigerant charge and the following message displays CHARGE OIL NOW PRESS NEXT WHEN FINISHED 17 Open the manual oil injection bottle valve to add refrigerant oil to the A C system Close the valve when the correct amount of oil has been added to the system 4 To reduce the possibility of damage to the
21. anical stress Keep the service hoses away from hot or moving 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 EAA0275L05A 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 may discharge refrigerant Wear safety goggles and protective gloves user and bystander Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses Expelled refrigerant may cause injury 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 it when testing is completed Do not leave a running engine unattended A moving vehicle can cause injury Risk of explosion Some vehicle fuel systems such as Mercedes light trucks and some Fiat models have the same service fittings as the A C systems Do not connect to similar fuel service fittings Connect only to A C service fittings If you mistakenly connect to fuel system Do not use any switches as this may ca
22. as can displace air in work area Use your KoolKare Xtreme unit in locations with mechanical ventilation providing at least four air changes per hour Impairment of breathing can cause injury Risk of electric shock and fire To avoid electric shock the power cord must be connected to a properly grounded A C outlet Do not remove or bypass the grounding pin Use the proper A C outlet for the unit to operate correctly See the ID plate on the back of the 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 Do not use on wet surfaces or expose to rain Use only fuses with the rating specified near the fuse holder Electric shock and fire can cause injury Il Safety Information Refrigerant AWARNING AWARNING AWARNING Risk of expelling refrigerant under pressure Wear safety goggles and protective gloves user and bystander Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses If any refrigerant gets into the eyes flush with water and seek a doctor s aid immediately even though irritation may cease Do not remove masier filter dryer while under pressure Perform maintenance procedure for removing master filter dryer in Chapter 3 Changing the Master Filter Dryer Prevent refrigerant from contacting the skin Expelled refrigerant can cause i
23. ay cease Avoid breathing A C refrigerant and lubricant vapor or mist Exposure may irritate eyes nose and throat To remove HFC 134a from the A C system use service equipment certified to meet the requirements of SAE J2210 HFC 134a Recycling Equipment Additional health and safety information may be obtained from refrigerant and lubricant manufacturers Exposure can irritate eyes nose and throat 1 5 Introduction Functional Description Front View Figure 1 1 Front View 4 DO NOT lift the KoolKare Xtreme unit by top plastic cover A Integral Gauge Set High and low pressure panel mounted gauge set for monitoring vehicle A C system pressures B Control Panel Houses backlit display screen and control buttons C Liquid Crystal Display LCD Screen Displays alpha numeric information Shows charged recovered amounts or chargeable weight of the recovery tank Also indicates software version Tank Full and Tank Too Low conditions 1 6 Introduction D Control Buttons Four buttons are used to enter information and control the KoolKare Xtreme system operation UP and DOWN v arrow buttons are used to select menu options on the screen Two buttons with variable functions depending on the screen display E Panel Valve Used to select OFF HIGH LOW or BOTH service hoses Panel valve turned to HIGH opens the high side service hose passage to your KoolKare Xtre
24. button Press CONFIRM to reset the master filter dryer reminder monitor Press EXIT twice to return to Main Menu 2 9 Installation and Operation Accessing Units of Weight Use the procedure in this section to change the refrigerant unit of weight measurement d 2 Power up the KoolKare Xtreme unit Select SET UP from the Main Menu press ENTER gt CONTRAST Lbs kg gt LANGUAGE FILTER ENTER EXIT Press v as needed to select Lbs kg from the Set Up Menu press ENTER gt 00Lb 00oz 0000z gt 00 00Ib gt gt 00 00kg gt Press v button to scroll through Ib oz Ib kg or oz Press SAVE EXIT to select a unit of measurement Press EXIT to return to Main Menu Installation and Operation Operation This section contains Procedures for connecting the service hoses to the vehicle and Procedures to Recover vehicle refrigerant Create a vacuum in the A C system before recharging and Recharge the A C system with recycled refrigerant After performing all of the installation procedures follow these recommended vehicle service procedures before using your KoolKare Xtreme unit for A C work Keep the service hoses away from moving or hot engine parts The service hoses can not withstand high temperatures or severe mechanical stress Close the tank valves when not using your KoolKare Xtreme unit Leaving tank valves open ma
25. cle A C system is too low below 20 PSI the LCD screen will flash and the following message displays CANNOT RECOVER VEHICLE PRESSURE IS TOO LOW Press EXIT and the following message displays CLOSE PANEL VALVE PRESS NEXT 6 When recovery is complete the following message displays DRAINING OIL RECORD AMOUNT WHEN DONE 7 Waste oil is automatically expelled into the oil bottle 4 Discard refrigerant oil in accordance with local state and federal regulations that apply in your area 8 When recovery operation is complete the unit will beep once the LCD screen will flash and the following message displays CLOSE PANEL VALVE THEN PRESS NEXT 9 Turn the panel valve to OFF and press NEXT the Amounts screen and then the Main Menu screen will display Service hose recovery is complete Evacuating Contaminated Service Hoses 4 If contaminated refrigerant or refrigerant other than R 134a is present in service hoses use separate recover only machine to collect refrigerant 2 24 Installation and Operation Adding Refrigerant to the Koo Kare Xtreme Unit Follow this procedure to add virgin or recycled refrigerant to your KoolKare Xtreme unit 4 A minimum of 6 Ibs of refrigerant needs to be in the recovery tank before a charge operation can be accomplished Refer to Tank Full Empty in this chapter Refer to Preparing and Installing Recovery Tank in this chapter Open the blue
26. d Operation No Tank Present A no tank message will occur if one of these conditions arises e There is no tank on the scale or The scale circuitry malfunctions If this should occur Install a recovery tank or Call service to repair the scale circuitry Replace Filter A replace filter message will occur when master filter dryer percentage has expired When this occurs replace the master filter dryer and reset the automatic reminder monitor refer to Accessing Master Filter Dryer Reset in this chapter Heater Error A heater error message will occur if internal heater temperature is too high Call service to repair the heater 2 28 Maintenance Equipment Tips Use this chapter to maintain your KoolKare Xtreme units Master filter dryer Compressor e Vacuum pump and When storing the unit for prolonged periods Troubleshooting information and a list of parts and accessories are also included OA stable scale weight reading with the refrigerant not moving around in the recovery tank is needed at the beginning and end of a recover recycle or charge program Do not lean on or move the unit at these times O Never attempt to change the recovery tank while your KoolKare Xtreme unit is in use 3 Always recover the service hoses before disconnecting them from your KoolKare Xtreme unit For additional information refer to Chapter 2 Recovering Service Hoses 3 Never drop the reco
27. e couplers For additional information refer to Connecting Service Hoses to Vehicle in this chapter 3 Select AUTO SEQUENCE and press ENTER the following message displays WILL YOU RECOVER FROM VEHICLE 4 Select YES or NO to recover refrigerant from the vehicle the following message displays WILL YOU BE PULLING A VACUUM 5 Select YES or NO If yes the following message displays PRESS v TO SET VACUUM PULL TIME 30 00 Installation and Operation 6 Press v buttons to set vacuum pull time and press NEXT the following message displays PRESS v TO SET VACUUM HOLD TIME 10 00 7 Press the v buttons to set vacuum hold time and press NEXT or press NONE for no hold time the following message displays WILL YOU BE CHARGING THIS SEQUENCE 8 Select YES or NO If yes the following message displays PRESS v TO SET CHARGE AMOUNT xxLb xxoz The unit of refrigerant measurement can be changed using the LBS KG soft key in the bottom right of the LCD display 9 Press the v buttons to set charge amount and press NEXT the following message displays PAUSE FOR OPTIONAL OIL CHARGE 4 This message will only appear if the refrigerant charge is 7 ounces or greater 10 Select YES or NO and the following message displays AUTO SEQUENCE SETUP IS COMPLETE 11 Press NEXT to start the auto sequence and the following message displays EMPTY OIL DRAIN BOTTLE NOW 2 20 Installation
28. eme unit to the low side service port on the vehicle 4 If the vehicle has more than one low side service port use the service port closest to the evaporator 3 Open the service hose couplers Refer to the vehicle manufacturer s service manual for proper diagnostic procedures and specifications Recover Recycle Refrigerant from Vehicle 4 Be sure that the vehicle is at normal operating temperature before recovering refrigerant 1 Open the blue liquid and red vapor recovery tank valves 4 Empty the oil drain bottle left bottle before each recovery 2 Connect the service hoses to the vehicle and open service hose couplers For additional information refer to Connecting Service Hoses to Vehicle in this chapter 3 Select RECOVER and press ENTER the following message displays EMPTY OIL DRAIN BOTTLE NOW 4 Press NEXT and the following message displays OPEN PANEL VALVE Installation and Operation 5 Turn the panel valve to BOTH and press START the following messages display PLEASE WAIT PURGING AIR RECOVERING AMOUNT RECOVERED xxLb XXOZ Refrigerant flows from the vehicle through your KoolKare Xtreme unit and into the recovery tank As refrigerant is recovered the panel gauges show increasing vacuum 4 If the initial pressure in the vehicle A C system is too low below 20 PSI the LCD screen will flash and the following message displays CANNOT RECOVER VEHICLE PR
29. erforming an evacuation with the vacuum pump running 1 Look through oil level sight glass to verify vacuum pump oil level Figure 3 5 Oil Level Sight Glass 2 Oil level should appear to be in the middle of the sight glass 3 If oil level is low squirt oil into vacuum pump fill port ESL 1 5 CFM 1425L M Figure 3 6 Vacuum Pump Fill Port 3 7 Maintenance Changing Vacuum Pump Oil Only if using the EEAC319A with vacuum pump The vacuum pump contains approximately 4 oz of oil The oil must be changed at least every 6 months or if vacuum pump performance decreases The oil may have to be changed earlier if the oil is no longer clear when viewed through the sight glass 1 Turn OFF power to the KoolKare Xtreme unit and remove power cord from wall outlet 2 Release Velcro strap holding vacuum pump 3 Gently slide vacuum pump to the left positioning vacuum pump drain off the end of the bracket 4 Put a container under the drain plug of the vacuum pump 5 Remove the filler and drain plugs and drain oil Figure 3 7 Pump Fill and Drain Ports 4 Discard refrigerant oil in accordance with local state and federal regulations that apply in your area 6 Install the drain plug 7 Pour the vacuum pump oil from kit p n EAKO227LO014A into the vacuum pump until the oil is visible halfway up the sight glass refer to fig 3 5 The amount of oil is then approximately 4 oz 8 Install t
30. frigerant 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 t depletes the protective ozone layer in the atmosphere t has relatively high global warming potential and ts 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 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 e Refrigerant be recycled and reused or properly disposed of
31. ger tight including master filter dryer connections Use electronic leak detector to insure connections are leak free 1 Connect the high red and low blue couplers to their respective hoses Rotate coupler knobs fully CCW closed 2 Attach other end of red hose to upper red labeled high side port on the back panel of the KoolKare Xtreme unit 3 Attach other end of blue hose to lower blue labeled low side port on the back panel of the KoolKare Xtreme unit Installation and Operation Preparing and Installing Recovery Tank The recovery tank is shipped with a dry air charge The charge must be vented and the tank evacuated before use Use the following procedure to evacuate the dry air from the recovery tank and install it in your Koo Kare Xtreme unit Do not use any tank with this equipment other than part number EAA0275L05A 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 the recovery tank before first use An unprepared tank can cause compressor burnout 4 The recovery tank 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 a new recovery tank in your KoolKare Xtreme un
32. he filler plug 9 Slide vacuum pump back into original position and replace Velcro strap 3 8 Maintenance 10 Was Connect the power cord to the proper wall outlet with the correct voltage for the unit For additional information refer to Chapter 1 Specifications Switch on the vacuum pump and let the pump run with closed intake for a few minutes Top off the oil level if necessary Particle Filter Assembly The particle filter assembly is connected to the blue liquid side valve of the recovery tank A clogged particle filter may limit or block refrigerant flow Figure 3 8 Particle Filter Assembly Maintaining the Particle Filter Perform the following procedure to clean the particle filter 1 Turn OFF power to the KoolKare Xtreme unit and remove power cord from wall outlet Close the blue liquid recovery tank valve Disconnect blue hose from particle filter assembly Remove filter assembly from tank valve Carefully remove O ring and screen element from brass housing Wash screen element with mild soap and water and blow dry with compressed air Reassemble filter taking care not to damage screen or O ring Lubricate O rings with refrigerant oil 3 9 Maintenance 8 Install filter assembly onto liquid tank valve 9 Connect blue hose from the bottom of the unit to the particle filter assembly 10 Open tank valve and check for leaks Storing the KoolKare Xtreme
33. ied repeat Recover Recycle procedure repair the leak and attempt the Evacuation procedure again Evacuation is complete Charging A C System 4 When charging a vehicle after evacuation allow for the capacity of the hoses Each hose holds approximately two ounces of refrigerant so the charge amount should be increased by two ounces for each hose used lf there is not enough refrigerant in the recovery tank to charge refer to Adding Refrigerant to the KoolKare Xtreme Unit in this chapter 1 Open the blue liquid and red vapor recovery tank valves 2 Connect the service hoses to the vehicle and open service hose couplers For additional information refer to Connecting Service Hoses to Vehicle in this chapter 3 Select CHARGE and press ENTER the following message displays PRESS v TO SET CHARGE AMOUNT xxLb XXOZ The unit of refrigerant measurement can be changed using the LBS KG soft key in the bottom right of the LCD display 4 Set desired charge amount and press NEXT the following message displays OPEN PANEL VALVE 5 Turn the panel valve to HIGH and press START the following messages display WAITING FOR STABLE SCALE CHARGING Refrigerant flows from the recovery tank into the vehicle Installation and Operation 6 When the charging operation is complete the unit will beep once the LCD screen will flash and the following message displays CLOSE PANEL VALVE THEN PRESS N
34. is a registered trademark of Snap on Technologies Inc Canada KoolKare Xtreme is a trademark of Snap on Tools Company USA and Canada Copyright Information KoolKare Xtreme User s Manual 2002 Snap on Incorporated All rights reserved The information specifications and illustrations in this manual are based on the latest information available at the time of printing Snap on reserves the right to make changes at any time without notice Using this Manual This manual contains instructions for use and set up of your KoolKare Xtreme 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 Sales Representative can determine option availability Conventions This section contains a list of conventions used in text Service Hose Couplers and Panel Valve References in text to opening and closing the service hose couplers assume Counterclockwise closes the valves and Clockwise opens the valves References in text to opening and closing the panel valve assume e Valve pointed up opens the high side service hose passage Valve pointed to the left opens both the high and low side service hose passages Valve pointed down opens the low side service hose passage and e Valve pointed to the right closes the service hose passages Check Note A check n
35. it New recovery tanks are charged with dry air which must be vented before using AWARNING Wear safety goggles user and bystander Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses Cover the blue hand valve port with a shop towel to help prevent debris from becoming projectiles e Read understand and follow Safety Information in the front of this manual 1 Vent dry air by slowly opening blue hand valve on the recovery tank 2 Gently set the recovery tank on the scale with the hand valves up facing the back of the unit 3 Place the Velcro strap securely around the recovery tank 2 2 Installation and Operation Temperature Probe Figure 2 1 Recovery Tank and Temperature Probe 4 Use only the 50 pound capacity recovery tank supplied with your KoolKare Xtreme unit or one indicated by the warning label on the back of the unit Inaccurate refrigerant amount may display if the correct tank is not used Using any other type or capacity tank could create the danger of explosion and potential for personal injury Install the particle filter assembly part number 1 192814 to liquid blue port of recovery tank port nearest to the blue hand valve Connect tank adapter part number 1 15080 to particle filler assembly on recovery tank Connect blue service hose from low side port of the KoolKare Xtreme unit to installed tank adapter Open the following Blue
36. k valves 2 Connect the service hoses to the vehicle and open service hose couplers For additional information refer to Connecting Service Hoses to Vehicle in this chapter 4 If the gauges indicate pressure above 20 PSI recover refrigerant from the service hoses before proceeding Refer to Recovering Service Hoses in this chapter Installation and Operation 3 Select VACUUM and press ENTER the following message displays VACUUM 30 00 A v TO ADJUST TIME Press v buttons to adjust time to desired value 4 Press NEXT and the following message displays OPEN PANEL VALVE 5 Turn the panel valve to BOTH and press START the following messages display PLEASE WAIT CHECKING FOR PRESSURE IN VEHICLE VACUUM RUNNING The panel gauges show vacuum increasing 4 Follow the manufacturer recommendations for evacuation time usually at least 30 minutes 6 When evacuation time is done the unit will beep once the LCD screen will flash and the following message displays CLOSE PANEL VALVE THEN PRESS NEXT 7 Turn the panel valve to OFF and press NEXT the following message displays PLEASE WAIT 8 Monitor the low side pressure for 5 minutes Any loss of vacuum indicates a leak in the vehicle System 4 If the source of the leak cannot be determined partially charge the system and perform a leak test using an electronic leak detector Installation and Operation 9 When the leak is identif
37. k is not installed or tight Open red hand valve on recovery tank Install or tighten red hose fitting on recovery tank High Pressure Error Excessive tank Excessive air in tank Turn panel valve OFF exit out of recovery screen pressure allow unit to purge and fix leak Tank Full e Recovery tank full or Charge into external tank overloaded Scale circuitry malfunctions Change tank Call service No Tank Present No tank on the scale Scale circuitry malfunctions Install a recovery tank Call service Tank Too Low Not enough refrigerant in tank to charge Scale circuitry malfunctions Add refrigerant to recovery tank Call service Replace Filter Master filter dryer monitor has reached 0 Replace master filter dryer and reset monitor Heater Error Internal heater temperature too high Call service Maintenance Replacement Parts Part Number Description 1 27280 1 5 needs Service Fitting Low Side 1 27 180 eed titan eee Service Fitting High Side EAAO0275L05A eoe Recovery Tank 50 pound 15192814 iae cnr gt Particle Filter Assembly EAKO0030CO1AB cic reni neas Master Drier Kit Optional Accessories EAK0027CO00AS Vehicle Adapter Repair Kit O rings 1245080 arsena Low Side Adapter Fitting EAK0029COO0AB se Compressor Oil Kit EAKO0227LO01A bte Vacuum Pump
38. licable 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 the hazard in a situation DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury to the operator or to bystanders WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury to the operator or to bystanders CAUTION indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury to the operator or to bystanders IMPORTANT indicates a situation which if not avoided may result in damage to the test equipment or vehicle Safety messages in this section contain three different type styles Normal type states the hazard Bold type states how to avoid the hazard e 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 a lack of oxygen Vehicle exhaust gases contain carbon monoxide Refrigerant g
39. losed or the red hose fitting on the recovery tank is not installed or tight While in recovery if this should occur the compressor will shut down Open the tank valve or install or tighten the red hose fitting on the recovery tank to alleviate the pressure and restart recovery sequence If the pressure switch error is still present call service High Pressure Error A high tank pressure error can occur if pressure in the recovery tank reaches 350 psi This high pressure will be seen if there is excessive air in the recovery tank due to vehicle A C system having a leak If this should occur turn panel valve to OFF and press EXIT Allow the KoolKare Xtreme unit to purge and fix vehicle A C system leak Tank Too Low Tank Full The chargeable amount is less than the available charge amount in the recovery tank Add refrigerant to the recovery tank A weight error will occur if one of these conditions arises The tank is empty or below 3lb in the tank or The scale circuitry malfunctions If this should occur e Add refrigerant to recovery tank or Call service to repair the scale circuitry A full tank message will occur if one of these conditions arises A full recovery tank weight is seen or The scale circuitry malfunctions If this should occur Charge a portion of the recovery tank into a certified tank Replace the recovery tank or Call service to repair the scale circuitry 2 27 Installation an
40. me unit Panel valve turned to LOW opens the low side service hose passage to your KoolKare Xtreme unit Panel valve turned to BOTH opens both service hose passages to your KoolKare Xtreme unit F Oil Separator internal Removes oil and other contaminants from the refrigerant being recycled G Oil Drain Bottle Used to measure the amount of recovered oil H Manual Oil Injection Bottle Used to inject oil back into the vehicle A C system 1 7 Introduction Back View Figure 1 2 Back View with Vacuum Pump Figure 1 3 Back View without Vacuum Pump A Main Power Switch Turns power ON and OFF Must be on I for unit operation B Master Filter Dryer Consists of a 10 micron particulate filter and desiccant to remove moisture On units with a vacuum pump the master filter dryer is located behind the vacuum pump For additional information refer to Chapter 3 Changing the Master Filter Dryer C Scale Electronically measures the amount of refrigerant dispensed recycled and remaining in the recovery tank D Recovery Tank Holds refrigerant from a vehicle A C service and supplies refrigerant for charging E Service Hose and Coupler High Side For connecting to high pressure side of vehicle A C system Service Hose and Coupler Low Side For connecting to low pressure side of vehicle A C system 1 8 Introduction F External Vacuum Pump Port Connects an external vac
41. n displays PLEASE WAIT 2 4 Installation and Operation 17 18 19 20 21 22 23 24 Remove the blue service hose from the tank Remove the tank adapter 1 15080 Identify the yellow hose leading from the bottom of the unit Connect the hose end to the tank purge port Identify the red hose leading from the bottom of the unit Connect the hose end with the anti blowback valve to the red vapor tank port Open the red vapor recovery tank valve Identify the blue hose leading from the bottom of the unit Connect the hose end with the anti blowback valve to the blue liquid tank port Open the blue liquid recovery tank valve Connect tank adapter part number 1 15080 to port of virgin refrigerant tank Connect the blue service hose from low side port of the KoolKare Xtreme unit to installed tank adapter 4 Position the virgin tank with the valve up Do not use the virgin tank with the valve underneath the tank 4 Do not recover liquid refrigerant from a supply tank 25 26 27 28 Open the following Virgin tank hand valve and Blue service hose coupler CW Select RECOVER and press ENTER the following message displays EMPTY OIL DRAIN BOTTLE NOW Press NEXT and the following message displays OPEN PANEL VALVE Turn the panel valve to LOW and press START the following message displays RECOVERING AMOUNT RECOVERED xxLb XXOZ 2 5
42. nd vehicle are ready to recover and recycle refrigerant Allow Adequate Evacuation Time Evacuate the vehicle A C system for a minimum of 30 minutes This helps ensure vehicle A C system is free of non condensable gases mostly air and moisture 4 Sometimes a small amount 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 cycle or a leak test and falsely report a leak condition that does not exist Follow Vehicle Manufacturer s A C Service Procedures When charging a slow charge condition may occur due to pressure equalization between your KoolKare Xtreme unit and the vehicle A C system Finish charging by Turn the panel valve to OFF Starting the engine Turning the A C system ON Turn the panel valve to LOW and Allow the unit to complete the charge 4 Never operate the vehicle A C system with the panel valve on HIGH or BOTH 4 It is the technician s responsibility to be familiar with vehicle manufacturer recommended service procedures Installation and Operation Connecting Service Hoses to Vehicle Follow this procedure to connect the service hoses to the vehicle 1 Connect the red high side service hose from the KoolKare Xtreme unit to the high side service port on the vehicle 2 Connect the blue low side service hose from the KoolKare Xtr
43. njury 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 60 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 your KoolKare Xtreme unit or any 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 cause refrigerant to become poisonous phosgene gas Use your KoolKare Xtreme unit to remove refrigerant from air conditioning systems Exposure can irritate eyes nose and throat Il Safety Information Oil Lubricant General ZO Risk of irritation to mucous membranes Avoid breathing air conditioning refrigerant and lubricant vapor or mist Exposure may irritate eyes nose and throat To remove HFC 134a from the A C system use service equipment certified to meet the requirements of SAE J2210 HFC 134a Recycling Equipment Additional health and safety information may be obtained from the refrigerant
44. oning inoperability or improper operation of the Equipment caused by resulting from or attributable to A abuse misuse or tampering B alteration modification or adjustment of the Equipment by other than Sellers authorized representatives C installation repair or maintenance other than specified operator maintenance of the Equipment or related equipment attachments peripherals or optional features by other than Sellers authorized representatives D improper or negligent use application operation care cleaning storage or handling E fire water wind lightning or other natural causes F adverse environmental conditions including without limitation excessive heat moisture corrosive elements dust or other air contaminants radio frequency interference electric power failure power line voltages beyond those specified for the Equipment unusual physical electrical or electromagnetic stress and or any other condition outside of Seller s environmental specifications G use of the Equipment in combination or connection with other equipment attachments supplies or consumables not manufactured or supplied by Seller or H failure to comply with any applicable federal state or local regulation requirement or specification governing emission analyzers and related supplies or consumables Repairs or replacements qualifying under this Warranty will be performed on regular business days during Seller s normal working hours within a
45. ote provides additional information about the subject in the preceding paragraph Example 4 For additional information refer to Chapter 2 Connecting Service Hoses to the KoolKare Xtreme Unit and Chapter 2 Connecting Service Hoses to Vehicle Equipment Tips Equipment tips provide information that applies to specific equipment Each tip is introduced by this icon O for easy identification Example O Never attempt to change a recovery tank during unit operation For additional information refer to Chapter 2 Removing Recovery Tank Using this Manual Equipment Damage 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 the compressor Safety Messages AWARNING pe 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 hazardous situation which if not avoided will result in death or serious injury to the operator or to bystanders Indicates a potentially hazardous situation which if not avoided could result in death or serious injury to the operator or to bystanders Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury to the operator or to bys
46. pressor For units w o vacuum pumps EEAC320A the oil in the compressor 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 of the parts necessary to change the compressor oil are included in this kit Maintaining the Compressor 1 Evacuate service hoses by recovering if necessary and pulling a vacuum For additional information refer to Chapter 2 Recovering Service Hoses 4 Recovery and evacuation operations must be performed to release pressure in the compressor 2 Insure the panel valve is off 3 Turn OFF power to the KoolKare Xtreme unit and remove power cord from wall outlet 4 Remove the four 4 bolts holding the plastic top cover refer to fig 3 2 for bolt locations 2 Bolts Figure 3 2 Top Cover Bolt Locations 5 Remove the plastic top cover 6 Slide front panel support brackets off of the dowel pins 7 Gently lay front panel forward 3 4 Maintenance AWARNING AWARNING Wear safety goggles and protective gloves user and bystander Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses Read understand and follow Safety Information in the front of this manual 8 Disconnect the tubing and hose assemblies from the compressor taking note of their locations 4 Fittings at the compressor may be under pressure AWARNING DO
47. ries sssssssssssssseesee mene mene enhn nnn nh nene rrr nnns nnn nennen 3 13 Table of Illustrations Introduction Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 FIOMUNIOW E D ccctasnccseiasele E AEEA 1 6 Back View with Vacuum Pump sss e nnn nnn nnn nnne 1 8 Back View without Vacuum Pump sssssssssssssee enne n nn nnn nnns 1 8 R 134a Accessories eet tene Ce xa toco doceo ce eer ee 1 9 Installation and Operation Figure 2 1 Maintenance Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Recovery Tank and Temperature Probe eee 2 3 Master sura L E 3 3 Top Cover Bolt Locations ssssssssesseeeeneeeeeeeneneen nennen nnns nnne 3 4 Compressor Connections eeeesssseeseeeeeeeeeenenee eene nene nennen nennen 3 5 Lift COMPLESSOM REM 3 6 Oil Level Sight Glass siiin anmiana anaie a aaia e aa enne nnn 3 7 Vacuum Pump Fill Port uini A ee seed epee eee 3 7 Pump Fill and Drain Ports eene eere eee eek eerie 3 8 Particle Filter Assembly seseesssssssssssseeeeeeennnn nnne nennen 3 9 iii Trademark and Copyright Information Trademark Acknowledgements Snap on is a registered trademark of Snap on Technologies Inc USA and Canada EquiServ is a registered trademark of Snap on Tools Company USA EquiServ
48. ry tank is full 4 The unit may be used to recover recycle or evacuate an A C system when the recovery tank is empty 4 Tank Too Low is displayed when the weight in the recovery tank is less than approximately 3 Ibs 4 Tank Full is displayed when the amount of refrigerant in the recovery tank is above 43 Ibs 2 22 Installation and Operation Removing Recovery Tank 4 Ensure both valves on the recovery tank are closed 1 2 3 Disconnect the hoses from the recovery tank Remove the Velcro strap on the recovery tank Gently remove the recovery tank from the scale Recovering Service Hoses Recover the service hoses before removing them from the KoolKare Xtreme unit Service hoses are not connected to a vehicle during this procedure 1 Connect the power cord to the proper wall outlet with the correct voltage for the unit For additional information refer to Chapter 1 Specifications Turn power switch ON Select RECOVER and press ENTER the following message displays EMPTY OIL DRAIN BOTTLE NOW Press NEXT and the following message displays OPEN PANEL VALVE Turn the panel valve to BOTH and press START the following messages display PLEASE WAIT PURGING AIR RECOVERING AMOUNT RECOVERED xxLb XXOZ 2 23 Installation and Operation Refrigerant flows through your KoolKare Xtreme unit and into the recovery tank 4 If the initial pressure in the vehi
49. s 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 amp Representative Improper repair and or adjustment may cause vehicle or equipment damage or unsafe operation SAVE THESE INSTRUCTIONS Table of Contents Cra EET M HP l Introductio p MP 1 1 laiton 1 2 Refrigerant Handling rtr erede er ea x era Ee ade Ee v cus 1 3 Refrigerant Safety nido pc e oua feta te Ear etta HE EUM TESA P ERN re Did legio 1 3 Refrigerant Substitute Warning sssssssssssesseesneeee nennen nennen nnn nenne 1 4 at iit cuml EE 1 5 Refrigerant Oil Safety idee awl iene yeni ie DR der Re da bation 1 5 Functional Description ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaaaaaa 1 6 Front SEE 1 6 Back VIGW cerae ete State de pet ADR Re tds d AR ERE ute de a Pate dad bande D aee de 1 8 H 134a ACCOSSOFI OS 11er aides e e rua eee ow pacer EX e Eae o dee DOE daas 1 9 Shri c Re 1 10 rnc LEER 1 10 Operating i32 x tud eec tu sedute ae a ee da ier Puta d eene HD eS es 1 10 en EET 1 10 Capacities Aea EP 1 10
50. t system contains a product of this type Question the customer about previous service Be aware of any unfamiliar odor from the system Do not use any leak detector equipment Do not use recycling equipment and Contact your state fire marshall or local EPA office 1 4 Introduction Refrigerant Oils In mobile air conditioning units the lubricant needed for the compressor is blended with the refrigerant Mineral petroleum oils were used with R 12 systems Mineral oils are not soluble in R 134a and the industry had to substitute synthetic lubricating fluids for the mineral oils Polyalkylene glycol oils PAGs were the first synthetics to meet the auto A C compressor manufacturers performance criteria and most automakers and compressor manufacturers devised their retrofit specifications with PAGs in mind Since then polyol ester oils ESTERS or POEs have been tested and also have been found to meet the performance criteria Although POEs have not been approved by the automakers or A C compressor manufacturers POEs are frequently used in A C retrofits in the automotive aftermarket Refrigerant Oil Safety Risk of irritation of mucous membranes Wear safety goggles and protective gloves user and bystander Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses If any refrigerant gets into the eyes flush with water and seek a doctor s aid immediately even though irritation m
51. tanders Some safety messages also 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 Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses Engine systems that malfunction can cause injury vi Using this Manual Terms Use the following definitions as a foundation to help understand your KoolKare Xtreme unit s processes and or components Virgin Tank A refrigerant tank disposable or refillable that contains new refrigerant When empty a disposable virgin tank must be evacuated and cannot be refilled Dispose of this 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 removed from a virgin tank or recovered from a vehicle On your KoolKare Xtreme unit refrigerant is filtered and dried before reaching the recovery tank Once in the recovery tank it is ready for reuse Recover The process of removing refrigerant from a system to prevent release of refrigerant into the atmosphere On your KoolKare Xtreme unit this process also recycles the refrigerant for reuse Recycle The process of removing refrigerant from a s
52. to contact open flame or be drawn into a running engine This can cause refrigerant to become poisonous phosgene gas Use your KoolKare Xtreme unit to remove refrigerant from air conditioning systems Read understand and follow Safety Information in the front of this manual Tighten all 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 Do not use your KoolKare Xtreme unit or any 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 176 Arctic Chill R 176 and GHG Refrigerant 12 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 refrigerant system State agencies and the Environmental Protection Agency EPA are moving to ban flammable substitutes If it is suspected that a refrigeran
53. to run until recovery is complete then close the blue service hose coupler When recovery is complete the following message will display DRAINING OIL RECORD AMOUNT WHEN DONE Waste oil is automatically expelled into the oil bottle 4 Discard refrigerant oil in accordance with local state 14 15 16 and federal regulations that apply in your area When operation is complete the unit will beep once the LCD screen will flash and the following message displays CLOSE PANEL VALVE THEN PRESS NEXT Turn the panel valve to OFF and press NEXT the Amounts screen and then the Main Menu screen will display Remove the blue service hose and adapter from the virgin tank and store the adapter with unit accessories 2 26 Installation and Operation Errors and Messages Error messages will flash on the bottom line of LCD screen and the LCD backlight will flash until conditions are corrected Temperature Error Temperature errors can occur when the KoolKare Xtreme unit is operating outside its normal temperature range or a temperature probe is damaged If this should occur the compressor will shut down Return the KoolKare Xtreme unit to normal operating temperature If the temperature error is still present call service Pressure Switch Err A pressure switch error can occur when internal excessive pressure is seen This high pressure will be seen if the red hand valve on the recovery tank is c
54. use sparks Do not move any metal items as this may cause sparks Unplug unit s power cord from the wall outlet Immediately ventilate the work area and call your local service representative Fuel in A C recovery unit can explode and cause injury Safety Information Risk of injury This equipment should be operated by qualified personnel only Use this equipment only as described in this manual Use only the manufacturer s recommended attachments Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged until it has been examined by a qualified service representative Care should be taken to arrange the power cord so that it will not be tripped over or pulled Always unplug equipment from electrical outlet when not in use Never use the cord to pull the plug from the outlet Grasp the plug and pull to disconnect Let the equipment cool completely before putting it away Loop the power cord loosely in proper location when storing Operation of your KoolKare Xtreme unit by anyone other than qualified personnel may result in injury Risk of refrigerant leakage Always close the quick coupler valves before disconnecting a hose coupling Loosened hose couplings can leak refrigerant into 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 result
55. uum pump to the unit G Particle Filter Assembly Filter attached to the liquid blue port of recovery tank Removes particles from the refrigerant H Vacuum Pump Sight Glass and Oil Fill Only located on EEAC319A models Left picture Used to verify vacuum pump oil level and oil to vacuum pump when necessary R 134a Accessories Figure 1 4 R 134a Accessories A Service Hoses Red and blue hoses with shut off adapters for your KoolKare Xtreme unit to connect to the vehicle For additional information refer to Chapter 2 Connecting Service Hoses to the KoolKare Xtreme Unit and Chapter 2 Connecting Service Hoses to Vehicle B Auto Shut off Adapters Couplers 1 Connects to high and low side service ports of vehicle 2 Quick connect disconnect valve actuation without refrigerant venting Couplers contain manual shut off hand valves to control flow of refrigerant while connected to service ports and prevent blow back while connecting disconnecting hoses C Low Side Adapter Fitting Adapter part number 1 15080 to connect low side service hose to a refrigerant tank for adding refrigerant to the KoolKare Xtreme unit or for new recovery tank preparation D Particle Filter Assembly Removes particles from the refrigerant part number 1 192814 1 9 Introduction Specifications General Operating Storage Capacities Power 120 VAC 60 Hz 6 amps maximum Shipping Weight EEAC3
56. v TO ADJUST LCD gt 25 lt DEFAULT EXIT 4 Press DEFAULT to automatically reset LCD contrast to default settings or press button to lighten contrast or v button to darken it 5 Press EXIT twice to return to Main Menu Accessing Language Use the procedure in this section to change the language selection of the KoolKare Xtreme unit 1 Power up the KoolKare Xtreme unit 2 Press button once to select SET UP from the Main Menu and then press ENTER which is the left button under the LCD display CONTRAST Lbs kg LANGUAGE FILTER gt ENTER EXIT 2 8 Installation and Operation 5 6 Press v button as needed to select LANGUAGE from the Set Up Menu press ENTER PRESS OR v TO CHANGE LANGUAGE ENGLISH Press v button to scroll through language selections Press SAVE EXIT to select a language Press EXIT to return to Main Menu Accessing Master Filter Dryer Reset Use the procedure in this section to reset the automatic reminder monitor for the master filter dryer 4 This procedure should only be done when the master filter dryer is replaced Power up the KoolKare Xtreme unit Select SET UP from the Main Menu press ENTER gt CONTRAST gt Lbs kg gt LANGUAGE gt gt FILTER a ENTER EXIT Press v buttons as needed to select FILTER from the Set Up Menu press ENTER FILTER 1508 OZ 99 RESET EXIT Press RESET
57. very tank onto the scale This may damage the scale assembly O Always oil the seals before connecting to any tank filter or fitting A leaky connection or no flow condition may result if the connection is assembled dry O Always close all recovery tank valves clockwise when your KoolKare Xtreme unit is not in use 3 1 Maintenance Master Filter Dryer Change the master filter dryer when the filter percentage monitor has diminished to 0 since the last master filter dryer change Replacement of the master filter dryer will be indicated by the REPLACE FILTER message on the LCD screen The filter monitor has a reset of 95 Ibs During the course of recycling this number decreases until it reaches zero When zero is reached the master filter dryer needs to be replaced and the monitor reset Refer to Resetting Master Filter Dryer Monitor in this chapter or Chapter 2 Accessing Master Filter Dryer Reset Recovered refrigerant quality may be compromised if the filter is not replaced when required Changing the Master Filter Dryer Use the procedure in this section to change the master filter dryer Wear safety goggles and protective gloves user and bystander Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses If any refrigerant gets into eyes flush with water and seek a doctor s aid immediately even though irritation may cease Do not remove the master filter dryer while under
58. y TANK oo eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee etree eee ee eee nnnnnnnnnnnnsn nnns nnne nnn nnne 2 23 Recovering Service HOSES 0 cece cee eeeeeeceeee eee e eee et ee aaea ease nennen enhn n nnmnenns enn nn nennt nnn ner nnns nnne 2 23 Evacuating Contaminated Service HOSES sse emere nnn 2 24 Adding Refrigerant to the KoolKare Xtreme Unit 2 25 Errors and Messages ccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseseeeeeeeasaaaaaaaaaaaaaaaaaaaaaaaaa 2 27 Table of Contents ECHTE 3 1 Eguipment TIPS eet E I 3 1 Erwan 3 2 Changing the Master Filter Dryer mme menm nennen nennen 3 2 Resetting Master Filter Dryer Monitor sssssssssee meme menn nnn 3 3 COMPrESSON een c c 3 4 Maintaining the Compressor inicie iie cte pensar se Rae E RR En ge a ERRARE RU E 3 4 Maintaining the Vacuum Pump ssssseen II I I e n n nnne 3 7 Checking and Adding Vacuum Pump Oil sssssssseee mene 3 7 Changing Vacuum Pump Oil menn n enne rrr nn rn rnnnnnnns 3 8 Particle Filter ASSembly cai REEE AEREE EEREN NES EEEE KAATAEN 3 9 Maintaining the Particle Filter seeseeeseseessseseeenneeneneene nennen nennen nenne 3 9 Storing the KoolKare Xtreme Unit ssssssssssssssssseeeeeeeeeeeenneneeemrrnenn nnne nnns 3 10 AOUDIGSMOOUNMG ce 3 11 Replacement z iiccm 3 13 Optional Accesso
59. y result in refrigerant loss from tank Do not use your KoolKare Xtreme unit outside of the following limits Warmer than 120 F 49 C Colder than 50 F 10 C and or Relative humidity greater than 80 Stabilize your KoolKare Xtreme unit to a moderate temperature and inspect for abnormalities Contact your Snap on representative before operating if unsure of condition Operating your KoolKare Xtreme unit 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 Preliminary Checks Successful use of your KoolKare Xtreme unit depends on several external factors The following information explains these Precondition Vehicle The refrigerant in the vehicle A C system is recovered faster and more completely when the components are warm 1 Connect the service hoses to the vehicle refer to Connecting Service Hoses to Vehicle in this chapter To efficiently recover refrigerant the vehicle should be at normal operating temperature Run the engine until normal operating temperature is reached with The A C system OFF and e The hood lowered as much as possible without damaging or crimping the service hoses 2 Turn off the engine when normal operating temperature is reached The unit a
60. ystem filtering drying and storing it in the recovery tank 4 Your KoolKare Xtreme unit 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 There is no separate recycle process to perform Evacuate Vacuum The process of drawing a vacuum on a refrigerant system to remove air and moisture On your KoolKare Xtreme unit 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 The situation where the reading from the refrigerant weight measuring device is steady Moving your KoolKare Xtreme unit causes the liquid refrigerant to slosh around in the recovery tank resulting in an unsteady scale reading Avoid moving your KoolKare Xtreme unit before taking scale readings viii Introduction Use your KoolKare Xtreme unit 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 by drawing the system into a deep vacuum and Recharge Refill the air conditioning system with a specified amount of refrigerant Your KoolKare Xtreme unit is a

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