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Bosch ACS 553, Service Manual

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ACS 553, ACS 563 Service Manual

1 689 975 295

2021-04-13

Robert Bosch GmbH

3

Table of Contents

 

Safety Warnings ...................................................................................................

4

 

 

Protective devices .............................................................................................................

7

 

 

PED directive 2014/68/EU .................................................................................................

7

 

 

Machine handling ..............................................................................................................

7

 

 

Target group ....................................................................................................................... 8

 

Introduction ..........................................................................................................

9

 

 

Introduction ...................................................................................................................... 10

 

 

Unit Specifications .......................................................................................................... 22

 

 

Maintenance Schedule .................................................................................................... 24

 

Diagnostics and Testing .................................................................................... 25

 

 

Functional Check ............................................................................................................. 26

 

 

Diagnostics and Testing ................................................................................................. 30

 

 

Troubleshooting ..............................................................................................................

39

 

 

Error Messages ................................................................................................................ 50

 

Electrical System Operation and Repair .......................................................... 55

 

 

Electrical System Operation ........................................................................................... 56

 

 

Electrical System Repair ................................................................................................. 63

 

Plumbing and Mechanical System Operation and Repair .............................. 68

 

 

Plumbing and Mechanical System Operation ............................................................... 69

 

 

Plumbing and Mechanical System Repair .................................................................... 70

 

 

Component Application Charts ......................................................................................

79

 

 

Flow Diagrams ................................................................................................................. 81

 

Main Component Descriptions .........................................................................

94

 

Notes  ...................................................................................................................96

Summary of Contents for ACS 553

Page 1: ...en Repair instruction A C Service Unit ACS 553 ACS 553 P ACS 563 ACS 563 P ...

Page 2: ...ACS 553 ACS 563 Service Manual 1 689 975 295 2021 04 13 Robert Bosch GmbH 2 Robert Bosch GmbH Robert Bosch GmbH Franz Oechsle Straße 4 1119D 73201 Plochingen SERVICE bosch prueftechnik bosch com ...

Page 3: ...ance Schedule 24 Diagnostics and Testing 25 Functional Check 26 Diagnostics and Testing 30 Troubleshooting 39 Error Messages 50 Electrical System Operation and Repair 55 Electrical System Operation 56 Electrical System Repair 63 Plumbing and Mechanical System Operation and Repair 68 Plumbing and Mechanical System Operation 69 Plumbing and Mechanical System Repair 70 Component Application Charts 79...

Page 4: ...es an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION Used without the safety alert symbol indicates a potentially hazardous...

Page 5: ...efrigerant reduces the oxygen available for breathing resulting in drowsiness and dizziness Exposure to high concentrations of refrigerant causes asphyxiation injury to the eyes nose throat and lungs and can affect the central nervous system Use the machine in locations with mechanical ventilation that provides at least one air change per hour If accidental system discharge occurs ventilate the wo...

Page 6: ...ate It is also recommended to buy it from specialized companies that guarantee its good quality DO NOT USE THIS MACHINE OUTDOORS DURING RAIN OR HIGH HUMIDITY Protect the machine from conditions that may cause electrical failure or other hazards relating to ambient interaction DO NOT USE THIS MACHINE IN DIRECT SUNLIGHT Position the machine far from heat sources such as direct sunlight which can cau...

Page 7: ...ction PED directive 2014 68 EU The machine includes parts subject to PED EU directive 2014 68 EU Pressure Equipment Directive PED directive regulates all the pressurized part defining for them categories based on volume pressure ratio and based on fluid refrigerant type Those parts then have not to be anyhow modified nor removed Under the responsibility of the owner the machine and parts falling i...

Page 8: ...rized by Robert Bosch GmbH in servicing the ACS 553 ACS 563 For specific work the service technician needs the following additional qualifications country specific Electrotechnical knowledge for working on electrotechnical systems and equipment as per EN 50110 1 and EN 50110 2 see accident prevention regulation for electrical systems and equipment e g DGUV V3 in Germany and qualified in ESD protec...

Page 9: ...l Maintenance 15 Electrical Protection 15 Tank Fill 15 Filter Maintenance 16 Vacuum Pump Maintenance 17 Edit Print Header 18 Replace Printer Paper only for variants with printer 18 Calibration Check 18 Pressure Decay Leak Test for R1234yf only 19 Printer kit installation 19 Calibration check kit installation optional 20 Refrigerant conversion kit 20 Unit Specifications 22 Maintenance Schedule 24 ...

Page 10: ...systems require special oils Refer to the A C system manufacturer s service manual for oil specifications 1 2 3 5 4 6 7 8 9 10 13 14 15 16 17 19 12 11 18 1 Gauge low pressure LP 2 Display and control panel 3 Gauge high pressure HP 4 1 x USB 2 0 slot 5 Main power supply switch 6 Fuse holder 7 Power supply socket 8 Fresh oil bottle PAG or POE 9 Oil drain bottle 10 Printer optional standard on P vari...

Page 11: ...he vehicle A C system VACUUM activates the sequence that pulls a deep vacuum on the vehicle A C system to remove air and moisture CHARGE activates the sequence that charges the vehicle A C system with a programmed amount of refrigerant HELP displays information related to the current display MENU accesses additional functions and parameters NEXT to move to the next screen or step BACK to return to...

Page 12: ...stem After flushing the refrigerant is recovered by the machine and filtered by the recycling circuit Tank Fill Use this function to transfer refrigerant from a source tank to the ISV The tank fill value may be adjusted up or down to suit the user s needs Refer to Tank Fill in the Maintenance section Glossary A C System The vehicle air conditioning system being serviced Evacuation Moistureandother...

Page 13: ...Activation Failure to register and activate the machine within 30 days of initial startup will cause the machine to lock out and not function Select this Settings Menu item and follow the prompts before the trial period expires Refrigerant Identifier only if enabled To enable or disable the purity test of the external refrigerant identifier connected to the USB port of the machine The display show...

Page 14: ... kg alert 56 kg Model R1234yf Replacement filter at 150 kg alert 138 kg This menu item displays the filter capacity remaining until the machine locks down and no longer functions Refer to Filter Maintenance in the Maintenance section Pump Maintenance Displays the amount of time remaining until the next vacuum pump oil change is needed For maximum vacuum pump performance change vacuum pump oil ever...

Page 15: ...ys FILL AMOUNT xx xxyy RECOVER CAPACITY xx xxyy CHARGE CAPACITY xx xxyy 5 Enter the fill amount at least 4 kg to ensure enough liquid refrigerant is available for charging and select OK icon Unit is set with 1 0 kg dead space first 1 0 kg are not shown on display anymore If the source tank is empty or has insufficient refrigerant for transfer tank fill will stop 6 Connect the low pressure service ...

Page 16: ...s for the new filter code to be entered ENTER NEW FILTER SERIAL NUMBER NOTE If SERIAL NUMBER WRONG is displayed the serial number has been incorrectly entered or the filter has already been used in this machine 2 Use the keypad to enter the serial number that appears on the new filter and select OK icon to continue The machine clears the existing filter and displays TURN POWER OFF AND REPLACE FILT...

Page 17: ...ure 1 6 9 Remove the oil drain fitting cap 3 and drain the oil into a suitable container for disposal Reinstall the oil drain cap 3 and close tightly 10 Slowly add vacuum pump oil to the pump through the oil fill port until the oil reaches the center of the sight glass 1 11 Reinstall the oil fill port cover 2 and close tightly 12 Select OK icon to continue 13 The display show a message that indica...

Page 18: ...dge of the paper over the roller 1 1 2 Figure 1 7 Replace Print Paper Calibration Check This function is used to ensure the machine s internal scale is always calibrated To perform this check make use of Bosch calibration kit optional including sample weight and magnet First time magnet must be installed 1 Verify the magnet on the bottom of the machine is clean Refer to Figure 1 8 2 Call up the Ma...

Page 19: ...covers refrigerant until 0 44 bar and returns to the Maintenance Menu ready for normal operation If an unacceptable pressure decay is detected the machine will prompt to check for leaks Take the machine to an authorized service center for repair NOTE Leak Check may also be selected at any time from the Maintenance Menu If you decline to run the Leak Check when prompted the machine will continue to...

Page 20: ... hoses away from you and anyone nearby For the conversion kit installation follow instructions hereby 1 Call up the Main Menu 2 Select NEXT icon 3 Select MENU icon 4 Select Maintenance Service menu and enter password then select OK icon 5 Select AC unit emptying and select OK icon to start the function NOTE To empty the A C unit make use of a second recovery machine with same refrigerant and suita...

Page 21: ...hten at 15 Nm torque 24 Place the Schrader valve in it 5 and tighten at 0 3 Nm 0 1 torque 25 Attach new high red and low side blue service hoses with quick couplers Tighten at 7 9 Nm torque 26 Connect the unit to a power source and place the power switch on 27 Follow the instructions on display to replace filter refer to Filter Maintenance in the Maintenance section and vacuum pump oil refer to th...

Page 22: ...nge 20 C 60 C 20 C 60 C Unit Operating Temperature Range 10 C 50 C 10 C 50 C Humidity non condensing 32 2 C 90 F 86 RH 32 2 C 90 F 86 RH Maximum Altitude 2000 m 6561 66 ft 2000 m 6561 66 ft IP Protection Rating IP20 IP20 Pollution dregree 2 2 Noise 70 dB A 70 dB A Dimensions 99 x 69 x 67 cm 99 x 69 x 67 cm Weight empty tank accessories 74 kg 74 kg Display 4 3in 262K RGB 480 x 272 color LCD with LE...

Page 23: ...5 cm3 Recovery performance maximum liquid phase Power Supply 230 Vac 1 50 60 Hz 230 Vac 1 50 60 Hz Vacuum Pump Free Air Displacement 70 l min 2 5 CFM 70 l min 2 5 CFM Ultimate Vacuum min 375 microns 375 microns Oil Capacity 310 ml 310 ml Type 1 stage oil bath 1 stage oil bath Power Supply 230 Vac 1 50 60 Hz 230 Vac 1 50 60 Hz Scales ISV scale accuracy 15 g 15 g ...

Page 24: ...to Vacuum Pump Maintenance in the Maintenance section of this manual Check casters and wheels for ease of operation Monthly Check internal scale calibration Monthly Refer to Calibration Check in the Maintenancesectionofthismanual Everyyear all scales must be calibrated by an authorized service center Check machine for leaks Automatic every 10 days Refer to Pressure Decay Leak Test in the Maintenan...

Page 25: ...fault Vacuum Time 38 Default Vacuum Leak Test Time 38 Default Precharge Leak Test Time 38 Service hose length 38 Enter plate only 38 Refrigerant tracking password 38 Customer configuration 38 Database configuration 38 Tank check valve test 38 AC unit emptying 38 Convert unit refrigerant 38 Troubleshooting 39 Grounding Noise and Power Issues 39 Will Not Power Up No Display 40 Will Not Fill Tank 40 ...

Page 26: ...minutes 12 Reboot the unit when prompted 13 When the unit reboot confirm the installation procedure by press Yes button when the bootloader black and white screen is shown 14 The unit will go through a file updating period it can take several minutes to finalize the entire update procedure then will display the Main Menu Install Current Software with WiFi Once WiFi connection has been established ...

Page 27: ...r is enabled checks the refrigerant in the source tank to verify it is R1234yf and not contaminated The machine displays the following screens INITIALIZING REFRIGERANT IDENTIFIER ANALYZING REFRIGERANT SAMPLE REFRIGERANT PURITY PASSED 9 The unit performs a self cleaning cycle to clean the internal hoses from refrigerant traces if any 10 The function stops when the refrigerant is fully recovered 11 ...

Page 28: ... side 3 Select OK icon to continue Machine is asking to input Oil inject Yes or No If select No unit don t inject any oil Oil amount xxx ml is possible set as ml oz or lb Oil type 2 option PAG or POE Type the measured ambient temperature and set the viscosity of oil being used 4 Confirm with OK icon and begin the charge process Moving or bumping the unit at this point may result in an inaccurate c...

Page 29: ...icle The charge is complete 9 Select OK icon then the unit will begin a hose clearing process to remove refrigerant from the hoses followed by a short recovery 10 At the end unit shows the charged data and print out option 11 If the charge was cancelled Charge complete will change to Charge cancelled and the values on the display will disappear 12 Select OK icon to exit 13 The unit will begin a ho...

Page 30: ...w it to run through the boot sequence 2 Select NEXT icon 3 Select MENU icon 4 Select MAINTENANCE 5 From the maintenance menu scroll up and find SERVICE MENU 6 Enter password then select OK icon The following displays Service Menu Calibrate Load cell Output test Input Test Calibrate air flow ISV Purge condition A C unit internal clearing Service vacuum End user install Maintenance counters Keypad t...

Page 31: ...Use the calibration weight as displayed for this step The first weight should be 0 as displayed on the screen Select OK icon to save the displayed weight value NOTE DO NOT DISTURB unit during weight calibration After 5 seconds 6 Place a 10 kg editable weight on the scale and enter the weight using the keypad When finished select OK icon to save the entered weight value 7 If the calibration is acce...

Page 32: ... is useful as a troubleshooting method to determine if a device is operating properly or not 1 From the Service Menu scroll toOutput Test 2 Select OK icon The following displays Placeholder X indicates the state of the output device A 1 or 0 indicates whether the device is ON or OFF A list of the tests is provided in the table below OUTPUT TEST Low Side Inlet Solenoid S4 High Side Inlet Solenoid S...

Page 33: ... Press X XYYY Low Side Pressure AC Press X XYYY Accumulator Pressure ISV Temp X X0 Y ISV Temperature HP Sw X High Pressure Switch Air Flow XXXXrpm Fan Air Flow for R1234yf only 3 Scroll through the sensors or devices to observe their values When finished select BACK icon to return to the Service Menu Calibrate air flow for R1234yf only The air flow inside the unit must be present at the correct vo...

Page 34: ...ring is used to evacuate service hoses oil separator and dryer filter compressor discharge not cleared Components ON 1 LS inlet Solenoid S4 2 HS Inlet Solenoid S5 3 Recover Solenoid S11 4 Compressor 5 The vacuum pump should turn on and the time begins to count down Process will stop early if sufficient vacuum level is achieved To pause at any point during the process select PAUSE icon At the Pause...

Page 35: ...ct OK icon The following displays End User Install The End User Install allows the service technician to access review and or change the parameters set during the initial setup of the machine The functions include Language selection License agreement review Units Metric Imperial selection Date and Time adjustment Edit Print Header Service Vacuum Oil inject viscosity selection Internal tank fill Th...

Page 36: ... dryer filter has been changed Vacuum cycles displays the number of vacuum cycles performed from the station Vacuum working time displays the total operating hours of the vacuum pump Vac pump oil change displays the number of times the vacuum pump oil has been changed Vac pump oil time displays the vacuum pump operating hours since the last oil change Charge cycles displays the number of charge cy...

Page 37: ...otModemakesitpossibletobootinto a mode other than Normal default The choices to boot are Normal Filter Change Required Leak Test Required and End User Install 1 From the Service Menu scroll to Set Boot Mode and select OK icon 2 Enterpassword28768347thenselectOKicon If the password is valid the following displays 3 Scroll to the boot mode desired and select OK icon The unit will boot to the selecte...

Page 38: ...echarge Leak Test Time The Default Precharge Leak Test Time is editable Default 5 min CAUTION this time is editable to make easier diagnostic and repair change the timing as default could reduce the unit performance Service hose length It is used to set the service hose length 2 5 m or 5 m Enter plate only The Enter plate only is used to enable disable the vehicle data input page where only licens...

Page 39: ... varies with the type and intensity of the noise Power Issues The power applied to the unit must be from a stable low impedance source Long term stability must be within 10 of the nominal voltage For a nominal 230 V line the limits are 207 V to 253 V The unit will operate above and below the voltage limits However problems in operation may appear if the voltage drops sags below or rises above surg...

Page 40: ...s properly connected and threaded completely onto the source tank fitting Check quick seal on low side service hose and make sure virgin tank valve is open 2 Is there a message on the display stating the source tank is empty If so verify the source tank has liquid refrigerant and the source tank valve is open 3 Verify the source tank and the tank is positioned to supply liquid refrigerant to the l...

Page 41: ...ucer reading and the calibrated test gauge reading should match replace the accumulator transducer and retest 9 Check Tank Liquid solenoid S7 for debris 10 Verify the oil drain solenoid isn t leaking the vacuum Place a finger over the end of the oil drain tube and check for suction If a suction is detected replace the oil drain solenoid Retest 11 Disconnect the manifold end of the compressor oil r...

Page 42: ...ications on the transducer ID plate 7 Check the oil return S13 solenoid for bleed through and proper operation Repair as needed 8 Check Tank Liquid solenoid S7 for debris 9 If problem still exists check the vacuum S9 solenoid as applicable NOTE If the compressor fails to operate refer to Compressor Troubleshooting Will Not Drain Oil 1 Verify the accumulator transducer is functioning properly 2 Is ...

Page 43: ...le info in maintenance menu with the reading on the low side panel gauge The readings should match assuming the low side panel gauge is accurate Will Not Evacuate Vacuum NOTE The vacuum pump should be running during this test If the pump does not run refer to Vacuum Pump Troubleshooting in the Vacuum Pump section of this manual 1 Verify the service hoses are properly attached to the unit valves op...

Page 44: ...ease which may be interpreted by the unit as a leak This will vary somewhat with ambient temperature conditions 1 Verify the service hoses are properly attached to the unit valves open without any restrictions 2 If vacuum can not be maintained using Service Leak Check in the service menu pressurize the unit and use a leak detector to check all hoses fittings and components for leaks Repair as need...

Page 45: ...rd 7 Verify operation of the oil inject check valve Replace as needed Will Not Charge NOTE There is no component that pumps refrigerant into a system during the charge process The refrigerant flows due to a pressure differential If the system is not in a vacuum unit will not charge 1 Verify the service hoses are properly attached to the unit without any restrictions and coupler valves are open 2 V...

Page 46: ...lean or replace if necessary 6 If slow charge persists there may be a pin hole leak in the ISV dip tube Substitute a known good ISV tank Will Not Print only for variants with printer 1 Does the printer have power 2 Does the printer have paper Verify the paper is installed correctly in the printer The paper should be rolling off the back of the roll 3 If the machine is operating in direct sunlight ...

Page 47: ...hose and by accessing the tank The tank pressure transducer can be checked by charging a hose and comparing to the low side transducer or the gauges They should be reasonably close initially but the gauge or low side reading should drop quickly if the tank is warm Control Board Troubleshooting 1 Possible reasons to replace control board Repeated read errors Repeated Communication errors Keys don t...

Page 48: ... components Repair as needed If voltage is not present replace the power board 8 Perform functional check Compressor Testing Procedure 1 Disconnect unit from the power source 2 Remove all three lines attached to the compressor 3 Unscrew the screws and remove the compressor 4 Cap off the compressor oil return port 5 Connect a manifold set to the compressor high side to the compressor discharge and ...

Page 49: ...ower to the vacuum pump is off 7 Check for 230 V from the power board on connector P6 pins 3 and 4 If voltage is present check wiring between the power board and the vacuum pump Repair as needed 8 Perform functional check 9 Reinstall the front plastic cover Figure 2 2 Vacuum Pump Assembly Vacuum Pump Troubleshooting 1 Check gauges for vacuum 2 If pressure is over 0 7 bar 10 psi recover hoses 3 If ...

Page 50: ...n Drain Oil Oil drain halted Pressure error Pressure insufficient to push oil out of separator Select RETRY or ESC icon Drain Oil Oil drain halted Flow error Oil drain timed out Select RETRY or ESC icon Enter Password Invalid password Password entered is incorrect Verify function password is correct Select RETRY or ESC icon Fast Charge Charge stalled Check connections and valves XX XXXYY of XX XXX...

Page 51: ...C Fault System missing date time information Select ESC icon to run RTC routine System Flush Insufficient refrigerant 6 00 kg required for system flush Select ESC icon then perform tank fill System Flush Pressure too high for flush System must be recovered Select ESC icon then perform recovery Tank Fill Source tank is empty Filled XX XXYY Source tank emptied during the tank fill process Connect ne...

Page 52: ...r filter is broken White paper filter is clogged White paper filter is disconnected 4 Identifier air intake or air exhaust clogged 5 Identifier solenoid leaking during calibration Refrigerant Identification Identifier Unstable Reading Error 2 Possible reasons 1 Sampling path problem Brass filter clogged and or sample hose clogged Sample hose is broken cracked or punctured Sample hose is disconnect...

Page 53: ...er filter defective White paper filter is broken White paper filter is clogged White paper filter is disconnected 4 Identifier air intake or air exhaust clogged 5 Identifier solenoid leaking during calibration Refrigerant Identification Identifier Refrigerant Flow Error Possible reasons 1 Sampling path problem Brass filter clogged and or sample hose clogged Sample hose is broken cracked or punctur...

Page 54: ...Refrigerant Identification Identifier Factory Calibration Expired Possible reason 1 Refrigerant identifier analysis parameters calibration expired Refrigerant Identification Identifier Communication Error Possible reasons 1 Identifier power supply chain issue Identifier internal power supply issue Identifier power supply cable issue Power supply output for Identifier issue 2 Identifiercommunicatio...

Page 55: ...ard Connector Assignments 56 Control Board Operation 57 Control Board Connector Assignments 57 Control Board Functions 57 Sensors and Transducers 58 Control Board Software Updating Methods 58 Electrical System Repair 63 Replacement Power Board 63 Replacement Control Board 64 Replacement High Pressure Cut Out Switch 65 Replacement Fan Air Flow 66 Replacement Scale Assembly 67 Scale Calibration Load...

Page 56: ...2 P2 Control Board P19 P3 AC Input P4 Power Supply J1 P6 Vacuum Pump Compressor P7 High Pressure Switch Figure 3 1 Power Board P8 Solenoids S4 1 S4 2 S5 1 S5 2 S6 S7 S8 S9 S11 S13 S14 and Fan The Power Board PB receives AC voltage at PBP3 from the power switch to PBP3 pins Pin 1 Unit ground Pin 2 AC low Pin 3 AC high The input voltage is immediately applied to the Power Supply PS through PBP4 and ...

Page 57: ...ce supplies voltage to the optional printer P6 P13 J8 P17 J1 P19 P18 P15 P8 P16 P1 Control Board Functions 1 Reads Keypad If a key does not respond it s most likely that 1 it isn t supposed to respond at that time 2 the keypad is faulty replace keypad 3 Operates Display The display contrast changes with temperature and light conditions Always try to adjust the contrast before replacing the control...

Page 58: ...adjusting fluid weight based on density 4 Refrigerant Identifier ID identifies R1234yf refrigerant and tests refrigerant for purity external through the USB port Transducers include 1 Low side Pressure LSP measures the pressure in the low side of the vehicle A C system 2 Accumulator Pressure AP measures the pressure in the oil separator to ensure proper oil separation from the refrigerant NOTE The...

Page 59: ... 2021 04 13 Robert Bosch GmbH 59 Electrical GND ss01906 P1 J1 P4 P3 P2 P6 PSL PSN PSG P13 J8 P17 J1 P19 6 1 V ADJ J1 J2 P41 P50 P38 P37 P46 P31 P49 Figure 3 4 Electrical Connections Sheet 1 of 4 POWER SUPPLY CONTROL BOARD POWER BOARD Power Switch ...

Page 60: ...Electrical Connections Sheet 2 of 4 ss01904 P6 P10 P20 P6 P8 P15 P13 P1 J8 P17 P18 J1 P19 P28 P11 P53 NOTE The Air Flow Sensor AF is integrated in the fan LOW SIDE PRESSURE TRANSDUCER LSP ISV TANK TEMPERATURE SENSOR TT ACCUMULATOR PRESSURE TRANSDUCER AP CONTROL BOARD SCALE ASSEMBLY AIR FLOW SENSOR AF ...

Page 61: ...26 P19 P22 P24 P21 P23 P18 P17 P16 P12 P13 P14 P15 Figure 3 4 Electrical Connections Sheet 3 of 4 POWER BOARD MANIFOLD ISV S4 1 Low side inlet 1 S4 2 Low side inlet 2 S5 1 High side inlet 1 S5 2 High side inlet 2 S7 Tank liquid S8 Oil drain S9 Vacuum S11 Recover S13 Oil return S14 Oil inject High pressure switch S6 Air purge ...

Page 62: ...ch GmbH 62 Electrical Figure 3 4 Electrical Connections Sheet 4 of 4 ss01907 P3 P1 P2 P4 P1 GND P6 P1 P8 P15 P13 J8 P17 P18 J1 P19 P8 P1 P7 J1 P4 P3 P6 P2 P40 P53 P25 P42 GND P11 PRINTER ASSEMBLY if present VACUUM PUMP FAN AIR FLOW COMPRESSOR CONTROL BOARD POWER BOARD ...

Page 63: ...eps to replace the power board Refer to Figure 3 5 Figure 3 5 Power Board Connector Identification Remove Existing Power Board 1 Disconnect unit from the power source 2 Remove the four screws under the control panel 3 Tilt the control panel upwards the front of the unit 4 Disconnect all wires from power board 5 Remove screws securing power board in place and remove power board Install Replacement ...

Page 64: ...t Control Board NOTE All control boards are shipped from the factory without any software on board Service centers must follow these installation procedures to set the board and get unit ready to use 1 Attach the display and keypad ribbon cables to the control board 2 Connect wires as shown in Figure 3 6 3 Keep the original SD card and format as FAT 32 4 Download right service software and unzip i...

Page 65: ...ires to the new switch 11 Tilt the control panel down and secure with four screws 12 Reinstall the front plastic cover 13 Connect the unit to the power source 14 Operate the unit and check for leaks 12 Select Languages and confirm 13 SelectAC ACS model unit require the input 2 times and confirm 14 Set time date and confirm 15 Set serial number unit require the input 2 times Take the one in the uni...

Page 66: ...er 3 Remove the four screws under the control panel 4 Tilt the control panel upwards the front of the unit 5 Remove the compressor Refer to Replacement Compressor in the Plumbing and Mechanical section 6 Remove 4 nuts inside the frame to free the fan 7 Note the orientation of the fan blades 8 Disconnect the FAN connector from the fan 9 Remove the fan 10 With the fan blades properly oriented as not...

Page 67: ...ale with two bolts 14 Reinstall the front plastic cover Replacement Scale Assembly WARNING Disconnecttheunitfromthe powersourcebeforebeginningservice work Incorrectuseorconnectionscan cause electrical shock WARNING Wear safety goggles when working with refrigerants Refrigerants can cause eye injury WARNING Use extreme caution when disconnecting hoses Pressurized refrigerant may be present in hoses...

Page 68: ...d Low Side Blue Service Hoses 69 Plumbing and Mechanical System Repair 70 Replacement Compressor 70 Replacement Vacuum Pump 72 Replacement ISV Assembly 74 Replacement Manifold 75 Repairing or Replacing a Solenoid 77 Replacing Check Valve 78 Component Application Charts 79 Flow Diagrams 81 Tank Fill 81 Low Side Clearing 82 Recovery 83 Oil Drain 84 Vacuum 85 Vacuum Leak Test 86 Air Purge 87 Oil Inje...

Page 69: ...nt source tank Sensor and solenoid on the ISV include Air Purge S6 ISV Temperature TT sensor Vapor and liquid valves Manifold The manifold assembly consists of solenoids Low Side Inlet 1 S4 1 Low Side Inlet 2 S4 2 High Side Inlet 1 S5 1 High Side Inlet 2 S5 2 Tank liquid S7 Oil Drain S8 Vacuum S9 Recover S11 Oil Return S13 Oil inject S14 Also included are transducers Low Side Pressure LSP transduc...

Page 70: ...slide the compressor out from the rear retainer 8 Disconnect the compressor pigtail from the COMP connector on the main harness 9 Remove the compressor from the unit CAUTION To prevent personal injury use caution when removing the compressor The capacitor may still be energized Installing Replacement Compressor Refer to Figure 4 1 during this installation 1 Install the rubber mounts into the base ...

Page 71: ... 295 2021 04 13 Robert Bosch GmbH 71 Plumbing and Mechanical Figure 4 1 Compressor Interconnection Diagram NOTES 1 Apply Loctite 222 to equivalent to threads 2 Torque hose fittings to 8 5 0 5 Nm ss01942 MANIFOLD ASSEMBLY COMPRESSOR OIL DRAIN ...

Page 72: ...p to the frame of the unit 7 Disconnect the vacuum PUMP connector from the main harness 8 Remove the cap from the vacuum pump oil fill port 9 Remove the vacuum pump from the unit Installing Replacement Vacuum Pump 1 Remove the cap from the vacuum pump oil fill port 2 Place the vacuum pump in the unit 3 Slide the horizontal tab of the pump base through the rectangular hole in the base so the tab is...

Page 73: ...Manual 1 689 975 295 2021 04 13 Robert Bosch GmbH 73 Plumbing and Mechanical ss01943 Figure 4 3 Plumbing Interconnection Diagram ISV Assembly Vacuum pump High side gauge Low side gauge Vapor Liquid Manifold Top View Oil Inject ...

Page 74: ...V Assembly WARNING Disconnecttheunitfrom the power source before beginning service work Incorrect use or connections can cause electrical shock WARNING Wear safety goggles when working with refrigerants Refrigerants can cause eye injury WARNING Use extreme caution when disconnecting hoses Pressurized refrigerant may be present in hoses Point hoses away from you and anyone nearby Instructions These...

Page 75: ...ck valves replace the O rings and use thread sealant where necessary Removing Manifold 1 Clear service hoses and remove them 2 Disconnect unit from the power source 3 Remove the front plastic cover 4 Remove the four screws under the control panel 5 Tilt the control panel upwards the front of the unit 6 Disconnect all hoses from the manifold 7 Disconnect all wires from the block components 8 Remove...

Page 76: ... Transducer AP Oil Return Solenoid S13 High Pressure Switch HPS Vacuum Solenoid S9 Oil Inject Solenoid S14 HS Inlet 2 Solenoid S5 2 HS Inlet 1 Solenoid S5 1 LS Inlet 1 Solenoid S4 1 LS Inlet 2 Solenoid S4 2 Tank Liquid Solenoid S7 Recover Solenoid S11 Manifold Assembly Top View Low Side Pressure Transducer LSP Oil Drain Solenoid S8 Manifold Assembly Side View ISV Assembly Side View Tank Temperatur...

Page 77: ... coil NOTE Once the nut and coil on top has been remove a special tool 14 mm stud remover has to be used to dismount the plunger 8 Remove the solenoid assembly 9 Check the manifold block for any debris before installing a repaired or replacement solenoid Installing Solenoid 1 Lubricate the O rings and threads on the new solenoid assembly 2 Install the repaired or replacement solenoid assembly and ...

Page 78: ...ards the front of the unit 6 Remove the faulty check valve Installing Replacement Check Valve 1 Lubricate the O rings on the new check valve 2 Install the new check valve and hand tighten 3 Torque the check valve to 8 5 Nm 4 Tilt the control panel down and secure with four screws 5 Reinstall the front plastic cover 6 Connect the unit to the power source perform a function test and check for leaks ...

Page 79: ...POE Pre Charge Charge Tank Conditioning Hose Flush Periodic Leak Test LS Inlet 1 2 solenoid S4 ON ON ON ON ON I I I HS Inlet 1 2 solenoid S5 ON ON ON ON ON ON I I I Air Purge solenoid S6 I Tank liquid solenoid S7 I I ON ON ON ON I Oil Drain solenoid S8 ON Vacuum solenoid S9 ON Recover solenoid S11 I ON I I I I I ON Oil Return solenoid S13 I I I I I I I ON Oil inject solenoid S14 ON Vacuum Pump ON ...

Page 80: ... Figure No Tank Fill 4 6 Low Side Clearing 4 7 Recover 4 8 Oil Drain 4 9 Vacuum 4 10 Vacuum Leak Test 4 11 Air Purge 4 12 Oil Inject PAG POE 4 13 Pre charge for R1234yf only if enabled 4 14 Charge 4 15 Tank Conditioning 4 16 Hose Flush 4 17 Periodic leak test for R1234yf only 4 18 Fluid Flow Diagram Locations ...

Page 81: ...oid Valve High Side Service Hose Vacuum Pump Compressor Internal Tank High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Check Valve VU4 ...

Page 82: ...igh Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Check Valve VU4 Solenoid valve Solenoid valve Accum Press Transducer P2 Air Purge Solenoid Valve S6 Air Diff...

Page 83: ...Hose Vacuum Pump Compressor Internal Tank High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Check Valve VU4 Solenoid valve Solenoid valv...

Page 84: ... Compressor Internal Tank High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Check Valve VU4 Solenoid valve Solenoid valve Accum Press Tr...

Page 85: ...r Internal Tank High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Check Valve VU4 Solenoid valve Solenoid valve Accum Press Transducer P...

Page 86: ...Compressor Internal Tank High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Check Valve VU4 Solenoid valve Solenoid valve Accum Press Tra...

Page 87: ... 2 Vacuum Solenoid Valve Recover Solenoid Valve High Side Service Hose Vacuum Pump Compressor Internal Tank High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Se...

Page 88: ...alve Recover Solenoid Valve High Side Service Hose Vacuum Pump Compressor Internal Tank High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Injec...

Page 89: ...nk High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Check Valve VU4 Solenoid valve Solenoid valve Accum Press Transducer P2 Air Purge S...

Page 90: ...ump Compressor Internal Tank High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Check Valve VU4 Solenoid valve Solenoid valve Accum Press...

Page 91: ...witch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Check Valve VU4 Solenoid valve Solenoid valve Accum Press Transducer P2 Air Purge Solenoid Valve S6 A...

Page 92: ... Recover Solenoid Valve High Side Service Hose Vacuum Pump Compressor Internal Tank High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Ch...

Page 93: ...Internal Tank High Pressure Switch High Side Gauge Oil Drain Bottle Low Side Service Hose Oil Drain Solenoid valve Manifold Low Side Press Transducer Pressure Relief S11 S9 S8 COMP PUMP P1 M2 Low Side Gauge M1 T2 T1 Oil Inject Bottle Solenoid valve S14 VU1 V2 System Oil Separator F2 Tank Check Valve P3 Service Port Oil Inject Check Valve VU4 Solenoid valve Solenoid valve Accum Press Transducer P2 ...

Page 94: ...eeps the compressor from exceeding its normal operating temperature The fan runs whenever the power switch is turned on FILTER DRYER SPIN ON Used to remove moisture and particles from refrigerant Must be changed every time 150 kg R1234yf 68 kg R134a of refrigerant is recovered GAUGE HIGH SIDE Monitor high side pressure of the vehicle being serviced GAUGE LOW SIDE Monitors low side pressure of the ...

Page 95: ...ergized at the end of the Recover process to drain oil SOLENOID S9 VACUUM When energized allows a vacuum or deep recovery to be pulled on the A C system being serviced SOLENOID S11 RECOVER When energized provides the primary pathway of removing refrigerant from the system being serviced This solenoid is also powered during the Flush process SOLENOID S13 OIL RETURN When energized it returns compres...

Page 96: ...ACS 553 ACS 563 Service Manual 1 689 975 295 2021 04 13 Robert Bosch GmbH 96 Notes Notes ...

Page 97: ......

Page 98: ...Robert Bosch GmbH Automotive Service Solutions Franz Oechsle Straße 4 73207 Plochingen DEUTSCHLAND www bosch com bosch prueftechnik bosch com 1 689 975 295 2021 04 13 ...

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