Bosch ACS 753 Page 54 Repair Instructions Download

Page: 54 / 110

ACS 753, ACS 763, ACS 863 Service Manual

SP00D00609

2018-03-26

Robert Bosch GmbH

Diagnostics and Testing

PROCEDURE

ERROR/WARNING

DESCRIPTION OF ERROR/

WARNING

Calibrate Load Cells Calibration failed! Slope is out

of range.

Difference between upper and lower

limits is too great. Select

RETRY

ESC

icon

Calibrate Load Cells

Calibration failed! Verification

weight X. XXXYY.

Weight too high or low.

Select

RETRY

ESC

icon.

Calibration Check

Calibration failed.

Select

RETRY

icon to return to the

beginning of the calibration check,

ESC

icon to return to the service

menu.

Charge

Insufficient vacuum for

charge.

System vacuum to low to draw in

enough refrigerant. Select

AUTO-

MATIC

RETRY

ESC

icon.

Charge

Insufficient refrigerant

available for charge.

Refrigerant in ISV too low. Select

ESC

icon. May require tank fill.

Charge Leak Test

Leak test failed!

Check for leaks and retest.

Select

ESC

icon.

Drain Oil

Oil drain halted. Pressure

error.

Pressure insufficient to push oil out

of separator. Select

RETRY

ESC

icon.

Drain Oil

Oil drain halted. Flow error.

Oil drain timed out. Select

RETRY

ESC

icon.

Enter Password

Invalid password!

Password entered is incorrect. Verify

function password is correct. Select

RETRY

ESC

icon.

Fast Charge

Charge stalled! Check

connections and valves.

XX.XXXYY of XX.XXXYY

charged.

Check panel valve position and

couplers. Select

RETRY

ESC

icon.

Filter Change

Invalid serial number!

Filter serial number must be different

from any other filter serial number

previously installed. Select

RETRY

ESC

icon.

Filter Change

Serial number has already

been used.

Filter serial number must be different

from any other filter serial number

previously installed. Select

RETRY

ESC

icon.

Helium Leak Test

Transducer error.

For production only. Exit test.

Leak Check

Pressure test failed. Check

for leaks.

Locate and repair any leaks. Select

RETRY

ESC

icon.

Leak Check

Vacuum test failed. Check for

leaks.

Locate and repair any leaks. Select

RETRY

ESC

icon.

ERROR MESSAGES

Summary of Contents for ACS 753

Page 1: ...ACS 753 ACS 763 ACS 863 en Repair instruction A C Service Unit ...

Page 2: ...ACS 753 ACS 763 ACS 863 Service Manual SP00D00609 2018 03 26 Robert Bosch GmbH 2 Robert Bosch GmbH Robert Bosch GmbH Franz Oechsle Straße 4 1119D 73201 Plochingen SERVICE bosch prueftechnik bosch com ...

Page 3: ... Check 24 Diagnostics and Testing 28 Depressurizing the Unit 40 Troubleshooting 41 Error Messages 54 Electrical System Operation and Repair 57 Electrical System Operation 58 Electrical System Repair 65 Plumbing and Mechanical System Operation and Repair 72 Plumbing and Mechanical System Operation 73 Plumbing and Mechanical System Repair 75 Component Application Charts 85 Flow Diagrams 87 Main Comp...

Page 4: ...cates 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 hazard...

Page 5: ...ST Refrigerant 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 th...

Page 6: ... refrigerants other than those indicated on the technical data plate 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 ma...

Page 7: ... door must always be closed and the above panel in place Refrigerant Tank Test Official records and recurring tests necessary for pressurized instruments are governed by laws and or national regulations depending on the country where the refrigerant tank is used The system manager is responsible for respect of laws regulations and technical rules During nor mal service refrigerant tanks do not nee...

Page 8: ...ary 11 Setup Menu 11 General Maintenance 14 Electrical Protection 14 Tank Fill 14 Filter Maintenance 15 Internal Refrigerent Identifier Maintenance ACS 863 only V 16 Vacuum Pump Maintenance 16 Edit Print Header 17 Replace Printer Paper 17 Calibration Check 18 Scales Reset 18 Pressure Decay Leak Test R1234yf only 19 Lockout 19 Unit Specifications 20 Maintenance Schedule 22 ...

Page 9: ...equire special oils Refer to the A C system manufacturer s service manual for oil specifications 1 2 3 6 7 5 4 8 13 14 15 16 17 18 19 20 21 22 23 12 11 10 9 abc def jkl mno tuv wxyz ghi pqrs 1 Gauge low pressure LP 2 Visual alert 3 Gauge high pressure HP 4 2 x USB 2 0 slot 5 Identifier Filter ACS 863 only 6 Master switch 7 Circuit breaker 8 Power supply socket 9 UV dye bottle 10 Fresh oil bottle 2...

Page 10: ...sequence to recover refrigerant from the 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...

Page 11: ...od of removing oil and impu rity by forcing liquid refrigerant through an A C system or components of an A C system 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 Mainten...

Page 12: ...ime a print function is used Unit 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 Oil Load Cells To enable or disable the operation of fresh oil PAG fresh oil POE used oil and UV dye scales Refrigerant Identifier ACS 763...

Page 13: ...been filtered Model R134a Replacement filter at 68 kg alert 56 kg Model R1234yf Replacement filter at 150 kg alert 138 kg This menu item displays the filter capacity re maining 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 ...

Page 14: ...it is set with 2 2 kg dead space first 2 2 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 hose blue to the liquid connector on a full source tank 7 Position the source tank in such a way that liquid refrigerant is supplied to the connection Open the source tank valve 8 Select OK ico...

Page 15: ...l 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 FILTER 1 Figure 1 4 Filter Location 3 Switch off the machine 4 Open the service rear door 5 Remove the old filter 1 by turnin...

Page 16: ...ose the service rear door 15 Switch on the machine 16 Select OK icon to continue 17 The display show a message that indicate to the user to check that the oil level is at the center of the sight glass pump NOTE In case it is necessary to add more oil repeat steps 8 9 10 12 13 14 and 15 for add oil Internal Refrigerent Identifier Maintenance ACS 863 only A refrigerant identifier samples refrigerant...

Page 17: ...e header on each printout 1 Call up the Main Menu 2 Select NEXT icon 3 Select MENU icon 4 Select Edit Print Header in the Settings Menu The cursor is in the first field 5 Update the text by using the arrows and the multi tap interface on the numeric keypad BACKSPACE icon acts as a backspace key Right or left arrow moves the cursor to the right or to the left Zero 0 key also acts as a spacebar Up a...

Page 18: ...assed the scale is calibration Select OK icon to return to the Maintenance Menu If the display shows Calibration failed the scale is out of calibration Select RETRY icon to retry If calibration continues to fail contact an authorized service center for assistance 1 Figure 1 9 Magnet Location Scales Reset This procedure should be carried out regularly as the deviation from the zero point of the oil...

Page 19: ...achine displays PRESSURE CHECK IN PROGRESS 6 Pressure is held for five minutes and moni tored for decay Minutes and seconds count down on the display If an acceptable pressure decay is de tected the machine recovers refrigerant and returns to the Functions Menu ready for normal operation If an unacceptable pressure decay is de tected the machine will prompt to check for leaks Take the machine to a...

Page 20: ...C 20 C 60 C 20 C 60 C Unit Operating Tempera ture Range 10 C 50 C 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 3 C 90 F 86 RH Maximum Altitude 2000 m 6561 66 ft 2000 m 6561 66 ft 2000 m 6561 66 ft IP Protection Rating IP20 IP20 IP20 Pollution dregree 2 2 2 Noise 70 dB A 70 dB A 70 dB A Dimensions 105 x 75 x 77 cm with HMI on shipping position 105 x 75 x 77 cm wit...

Page 21: ... MALE M26 2x1 8 ADAPTER 1234YF LS J639 MALE 12 7 mm ACME16 1234YF LS J639 MALE TO W21 8 1 14LH ADAPTER ADAPTER 1234YF LS J639 MALE M26 2x1 8 ADAPTER 1234YF LS J639 MALE 12 7 mm ACME16 QUICK COUPLER FOR COMMERCIAL TANK 1 4 SAE TANK ADAPTER R134a 21 8 14 G 1 4 Compressor Power 1 4 HP 1 4 HP 1 4 HP Displacement 8 85 cm3 8 85 cm3 8 85 cm3 Recovery performance maximum liquid phase Power Supply 230 Vac ...

Page 22: ...e Maintenancesectionofthismanual Everyyear all scales must be calibrated by an authorized service center Reset of PAG and POE Injection Oil drain oil and UV dye scales Wheneveritisnecessary RefertoScalesReset in the Maintenance section of this manual Check machine for leaks Automaticevery10days forR1234yf orevery yearly for R134a Refer to Pressure Decay Leak Test in the Maintenance section of this...

Page 23: ...rant Identifier ACS 863 only C 39 Charge Leak Test 39 10 Days Leak Test R1234yf only 39 Default Vacuum Time 39 Default Vacuum Leak Test Time 39 Default Precharge Leak Test Time 39 Service hose length 39 Depressurizing the Unit 40 Unit is Functional 40 Unit is Not Functional 40 Troubleshooting 41 Grounding Noise and Power Issues 41 Will Not Power Up No Display 42 Will Not Fill Tank 43 Stuck In Clea...

Page 24: ...screen that ask to reboot the unit at the end of the update process and so recyle the unit power 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 pe riod it can take several minutes to finalize the entire update procedure then will dis play the Main Menu Install Current Sof...

Page 25: ...inated The machine displays the following screens INITIALIZING REFRIGERANT IDENTIFIER ANALYZING REFRIGERANT SAMPLE REFRIGERANT PURITY PASSED 9 The unit will run low side clearing then enter into a 1st stage Recovery 10 When the system has recovered to 0 4 bar the vacuum pump starts and runs until recover is complete 11 2th stage recovery Unit perform special deep recovery function where pump and c...

Page 26: ...isplays Machine is asking to input Charge amount min is 10 g Select charge hoses 3 option High Low and Both 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 neither the recovered one Oil amount xxx ml is possible set as ml oz or lb Oil type 2 option PAG or POE Dye inject amount xxx ml is possible set as ml oz or lb 4 Confirm w...

Page 27: ...vehicle 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 show 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 ...

Page 28: ...ct MENU icon 4 Select MAINTENANCE 5 From the maintenance menu scroll up and find SERVICE MENU 6 Enter yearly password then select OK icon The following displays Calibrate load cell All units include load cell scales ISV Load Cell Drain Load Cell PAG Load Cell POE Load Cell and Dye Load Cell ISV Load Cell Calibration 1 After selecting Calibrate Load Cell from the Service Menu by pressing OK icon th...

Page 29: ... to save the displayed weight value NOTE DO NOT DISTURB unit during weight calibration After 5 seconds 5 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 6 If the calibration is accepted the offset and slope will be calculated If either calculation fails a fail screen for the offset or slope will be displ...

Page 30: ...ce menu Follow all remaining calibration instructions displayed First point calibration without nothing Second point calibration with 500 g edit able Check with 250 g not editable and con firm with OK icon NOTE DO NOT DISTURB unit during weight calibration 7 If the calculation is accepted the following is displayed 8 Typically adding 1 00 kg 2 lb is sufficient to perform this test 9 If OK icon is ...

Page 31: ...ion Selecting ESC icon returns to the Calibrate Load Cell service menu Follow all remaining calibration instructions displayed First point calibration without nothing Second point calibration with 500 g edit able Check with 250 g not editable and con firm with OK icon NOTE DO NOT DISTURB unit during weight calibration 2 Select OK icon to enter the POE Load Cell calibration menu The following displ...

Page 32: ...bration Output Test The Output Test checks the electrical outputs from the power board and wiring harnesses to the various solenoids fan vacuum pump and compressor This test is useful as a troubleshooting method to determine if a device is operating properly or not 1 From the Service Menu scroll to Output Test 2 Select OK icon The following displays Placeholder X indicates the state of the output ...

Page 33: ...zed the motors of the fan vacuum pump and compressor should start the beacon if installed will flash once and the beeper will sound 4 When the test is complete select BACK icon to return to the Service Menu INPUT TEST Sensor or Device Value Format Property ISV Weight X XXXYY ISV Weight PAG Weight X XXXYY PAG Weight POE Weight X XXXYY POE Weight Dye Weight X XXXYY Dye Weight Drain Weight X XXXYY Dr...

Page 34: ... unit internal clearing The A C unit internal clearing is used to evacuate service hoses distillator and dryer filter after compressor discharge pressure is still in 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 5 minutes To pause at any point during the process select PAUSE icon At...

Page 35: ...e counters run in the background 1 From the Service Menu scroll to Maintenance Counters and select 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 ...

Page 36: ... from the station Pump Vacuum Pump Run Time displays the total operating hours of the vacuum pump Oil Cyc Vacuum Pump Oil Change Cycles displays the number of times the vacuum pump oil has been changed VP Oil Vacuum Pump Oil Time displays the vacuum pump operating hours from the last oil change Chg Cyc Charge Cycles displays the charge cycles number performed from the station Chgd Charged Refriger...

Page 37: ... Manufacturing Date and select OK icon The following displays 2 Enter the manufacturing date using the keypad and select OK icon 3 Select ESC icon to return to the Service Menu without saving the new manufacturing date Keypad Test The Keypad Test is used to determine if the keys on the control panel are functioning when pressed The keys affected by this test are listed in the table below F1 1 6 Up...

Page 38: ...d the following displays 3 Scroll to the boot mode desired and select OK icon The unit will boot to the selected mode at the next power up cycle 4 To leave set boot mode without change select BACK icon to return to the Service Menu Reset Board Unless absolutely necessary resetting the board is not recommended Resetting the board will erase any calibration customization and restore the factory defa...

Page 39: ...e default 5 min CAUTION this time is editable to make easier diagnostic and repair change the timing as default could reduce the unit performance Default Vacuum Leak Test Time The Default Vacuum 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 Default Precharge Leak Test Time T...

Page 40: ...recovery unit to the lateral contamination port ACS 863 only or by quick coupler adapter connection 2 Open service menu and goes into Output test Refer to Output test in the Diagnostics and Testing section 3 Enable Tank liquid solenoid S22 Low Side Charge Solenoid S7 and or High Side Charge Solenoid S6 Unit is Not Functional 1 Disconnect the high and low side service hosesfromvehicleorservicetank ...

Page 41: ...ct 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 su...

Page 42: ...3 If no continuity check the power switch for proper operation Repair or replace as required 4 Connect the unit to a proper AC power source and place the unit power switch on The display should illuminate If the unit is still inoperative perform the following voltage checks a Measure the voltage at the output of the power supply from PSJ2 pin 2 to pin 3 Voltage should be 12 VDC If 12V is not prese...

Page 43: ...e clearing Low side clearing activates the compressor only and runs until the accumulator transducer reads 0 45 bar 13 in HG plus 15 seconds The unit will then go into the first stage of recovery There is no high side clearing in these units If a unit gets stuck in the clearing process use the following procedure to troubleshoot this condition 1 Attach a calibrated gauge to the accumulator test po...

Page 44: ...ing as it will be pulling in air and adding it to the ISV Be sure to purge the air from the ISV once the machine is repaired 17 If the unit doesn t complete clearing test the compressor as reccomended procedure Refer to Compressor Troubleshooting in the Compressor section of this manual Will Not Recover NOTE The compressor should be running during this test If it does not run refer to Compressor t...

Page 45: ...i intheaccumulator Only this solenoid will be activated at a time and it will be pulsed intermittently 4 Test the pump per the test procedure in the Vacuum Pump section If it fails replace the pump Vacuum Pump Not Running 1 Check for proper power source circuit breaker and electrical connectors for damage or corrosion Replace or repair as required 2 Connect the unit power cable directly to the pow...

Page 46: ...control board Will Not Air Purge 1 Verify the air purge solenoid S1 is receiving power and opening properly If not receiving power check the continuity of the wiring between solenoid and power board Repair as needed If the wiring is correct and no power is being applied to the solenoid replace the power board NOTE Verify the tank temperature sensor and pressure transducer are functioning properly ...

Page 47: ...ded If the wiring is correct and no power is being applied to the solenoid replace the power board 6 Check the PAG S2 POE S14 and dye S15 solenoids for bleed through and proper operation This can be done by checking for suction at the oil dye inject tube in the oil dye inject bottle Remove the oil dye inject bottle during the vacuum process and check for suction at oil dye inject tube or watch for...

Page 48: ... reading Compare the low side transducer reading shown in the service menu with the reading on the low side panel gauge The readings should match assuming the low side panel gauge is accurate If the low side inlet transducer is reading pressure while the system is in a vacuum replace the transducer Verify the replacement transducer reads zero at atmosphere by plugging it into the wiring harness pr...

Page 49: ...if the next vehicle to be serviced contains a different type of A C system oil than the previous vehicle serviced 1 Verify the service hoses are properly attached to the unit storage ports without any restrictions and coupler valves are open 2 Check Tank Liquid solenoid evacuating the tank with a recovery service unit in advance and tank hoses are properly connected to the ISV 3 If there is no pre...

Page 50: ... If printer still does not print replace the control board Printer Does Not Have Power Verify the printer is receiving power at harness connector P45 Test for 5 VDC across the RED pin 1 or YELLOW pin 2 and BLACK pins 3 4 wires If voltage is present at P30 replace the printer assembly and retest If not check for printer power at CBP15 The control board receives power from the power board PBP2 throu...

Page 51: ...at the accumulator port low side 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 Repeate...

Page 52: ...t check wiring between the power board and the compressor start components Repair as needed If voltage is not present replace the relay board 6 Perform functional check Compressor Testing Procedure 1 Remove shrouding from the unit 2 Remove all three lines attached to the compressor 3 Cap off the compressor oil return port 4 Connect a manifold set to the compressor high side to the compressor disch...

Page 53: ...cuit breaker and electrical connectors for damage or corrosion Replace or repair as required 2 Connect the unit power cable directly to the power source Do not use an extension cord 3 Check for 230 V at the vacuum pump connector pins 2 and 3 If voltage is present replace vacuum pump assembly If voltage is not present continue to next step NOTE When checking voltage to the vacuum pump it is normal ...

Page 54: ...con 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 X...

Page 55: ...XXYY of XX XXXYY charged Check panel valve position and couplers Select RETRY or ESC icon Startup System Fault RTC Fault System missing date time information Select ESC icon to run RTC routine System Flush Insufficient refrigerant 6 00kg 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 re...

Page 56: ...or ESC icon Recovery Identifier error 2 high output Move unit away from any EMF or RFI sources if the re frigerant identifier is present Analysis refrigerant test failed known error 2 Select RETRY or ESC icon Recovery Identifier error 3 air calibra tion low Check ventilation if the refrigerant identifier is present Analysis refrigerant test failed known error 3 Select RETRY or ESC icon Recovery Id...

Page 57: ... Assignments 58 Control Board Operation 59 Control Board Connector Assignments 59 Control Board Functions 59 Sensors and Transducers 60 Control Board Software Updating Methods 60 Electrical System Repair 65 Replacement Power Board 65 Replacement Control Board 66 Replacement High Pressure Cut Out Switch 67 Replacement Fan Assembly 68 Replacement Scale Assembly Magnet 69 Scale Calibration Load Cells...

Page 58: ... P6 Vacuum Pump Compressor Figure 3 1 Power Board P7 High Pressure Switch P8 Solenoids S1 S2 S3 S14 S15 S17 is used on ACS 863 unit only S19 and S20 P9 Solenoids S4 S5 S6 S7 S8 S9 S11 S12 S13 and S22 The Power Board PB receives AC voltage at PBP3 from the power switch and circuit breaker to PBP3 pins Pin 1 Unit ground on center divider Pin 2 AC low Pin 3 AC high The input voltage is immediately ap...

Page 59: ...7 P11 P1 J5 J6 Three regulated power supplies of 8 VDC 5 VDC and 3 3 VDC provide the power for the logic and data circuitry Afourth regulated power source supplies voltage to the optional printer 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 cont...

Page 60: ... Cells senses the weight of the oil available for use by the unit servicing the vehicle A C system and provides information to the unit as to how much oil was injected into the vehicle A C system 7 Dye Load Cell same as PAG or POE Load Cells but for dye 8 Refrigerant Identifier identifies R1234yf refrigerant and tests refrigerant for purity internal on the ACS 863 external through the USB port on ...

Page 61: ...R L1 3 CB1 CB2 7 PS3 J7 J3 P13 J8 P17 J2 J1 P19 6 1 V ADJ J1 J2 P2 P2 P1 P1 P2 P1 P3 Figure 3 4 Electrical Connections Sheet 1 of 4 NOTE Internal refrigerant indentifier is included on ACS 863 unit only POWER SUPPLY CONTROL BOARD POWER BOARD BRN BLU BLU BLU BRN BRN GRN YEL GRN YEL BRN Internal Refrigerant Identifier Door Switch Power Socket Circuit Breaker Main Switch ...

Page 62: ...5 P19 P1 P5 P2 NOTE Air Flow Sensor is disabled on ACS 753 unit only Internal refrigerant indentifier is included on ACS 863 unit only LOW SIDE PRESSURE TRANSDUCER LSP ISV TANK TEMPERATURE SENSOR TT ISV TANK PRESSURE TRANSDUCER TT ACCUMULATOR PRESSURE TRANSDUCER AP AMBIENT TEMPERATURE SENSOR AMBT CONTROL BOARD DYE LOAD CELL OIL DRAIN LOAD CELL POE LOAD CELL PAG LOAD CELL REFRIGERANT IDENTIFIER ID ...

Page 63: ...D MAIN MANIFOLD INJECTION MANIFOLD ISV FLUSH N2H2 MANIFOLD S3 Oil drain S4 Low side inlet S5 High side inlet S6 High side charge S7 Low side charge S8 Recycle S9 Vacuum S11 Recover S12 Deep recover S13 Oil return S17 Identifier High pressure switch S15 Dye S14 Oil inject 2 POE S2 Oil inject 1 PAG S22 Tank liquid S20 N2H2 Vent S1 Air purge S19 N2H2 Inlet BRN VIO WHT WHT VIO YEL YEL BLU BLK BLU RED ...

Page 64: ...lectrical Figure 3 4 Electrical Connections Sheet 4 of 4 P1 P2 ss01907 P3 P1 P2 P4 P2 GND P6 P8 P12 P3 P2 P9 P10 J7 J3 P15 P13 J8 P17 J2 P7 P11 P18 J1 P19 P8 P5 P9 P1 P7 J1 P4 P3 P6 P2 P4 P3 P1 GND LED BOARD PRINTER ASSEMBLY VACUUM PUMP BRN BLU FAN COMPRESSOR CONTROL BOARD POWER BOARD ...

Page 65: ...tion Instructions These instructions outline the basic steps to replace the power board Refer to Figure 3 5 Remove Existing Power Board NOTE It may be necessary to remove the power supply to gain access to the bottom attaching screws of the power board 1 Disconnect unit from the power source 2 Remove shroud 3 Disconnect all wires from power board 4 Remove screws securing power board in place and r...

Page 66: ...on 4 Disconnect all wires from control board including keypad and display ribbon cables 5 Remove screws securing control board in place and remove control board Install Replacement Control Board NOTE All control boards are shipped from the factory in the Production Boot Mode Service centers must follow these installation procedures to set the boot mode to Normal 1 Attach the display and keypad rib...

Page 67: ...he faulty high pressure cut out switch 5 Carefully remove the faulty cut out switch 6 Clean the fitting by wiping away dirt grease and oil NOTE DO NOT apply thread sealant to any internal threads Apply thread sealant to only the external pipe threads of the fittings WARNING Thread sealant contains ADHHM 128 anaerobic adhesive and methacrylic ester If there is skin contact with the sealant thorough...

Page 68: ...he fan blades 7 Disconnect the FAN connectors and fan ground connector from the fan assembly 8 Remove the fan assembly 9 Fasten the fan ground connector to the ground screw on the replacement fan body 10 With the fan blades properly oriented as noted in step 6 install the replacement fan assembly by securing it to the lateral panel assembly with two sheet metal screws 11 Connect the FAN connectors...

Page 69: ... 3 9 Removing Scale Assembly 1 Disconnect the unit from the power source 2 Remove the shroud 3 Disconnect the liquid hose and vapor hose from the tank 4 Disconnect the wires from the air purge solenoid tank temperature sensor and pressure transducer 5 Remove the two bolts securing the tank to the scale 6 Remove the tank from the scale 7 Remove the two bolts holding the scale in place 8 Remove the ...

Page 70: ...he scale assembly 5 Remove the tank from the scale and verify there is no weight on the scale or anything interfering with the operation of the scale 6 Access the SERVICE MENU 7 Enter yearly password 8 Complete the necessary steps to select CALIBRATE LOAD CELLS NOTE Calibration can be performed in Imperial or Metric units The unit of measure displayed is determined at machine set up 9 Perform Cali...

Page 71: ...adapter block internal side of the panel and outside the panel see picture 6 Remove the load cell Installing the Load Cell 1 Connect the new load cell to the adapter block and secure in place with screws arrow going down see picture 2 Be sure adapter or load cells don t toching the external frame 3 Connect the load cell wire harness to the control board 4 Close the HMI back panel and put the frame...

Page 72: ...Plumbing and Mechanical System Repair 75 Replacement Compressor 75 Replacement Vacuum Pump 77 Replacement Manifold Block 79 Replacement Injection Manifold 81 Replacement Flush N2H2 Manifold 82 Repairing or Replacing a Solenoid 83 Replacing Check Valve 84 Component Application Charts 85 Flow Diagrams 87 Tank Fill 87 Internal Clearing 88 Refrigerant Identification 89 Recovery 90 Deep Recovery 91 Oil...

Page 73: ...nit for the recovery and vacuum processes For vacuum pump specifications see Unit Specifications chapter of this manual Main Manifold The main manifold assembly consists of solenoids Oil Drain S3 Low Side Inlet S4 High Side Inlet S5 High Side Charge S6 Low Side Charge S7 Recycle S8 Vacuum S9 Recover S11 Deep Recover S12 Oil Return S13 Identifier S17 Also included are transducers Low Side Pressure ...

Page 74: ... dye injection point through Dye Inject Solenoid S15 Flush N2H2 Manifold This assembly serves as the attachment ports for the high and low side service hoses as the N2H2 or N2 injection point through N2H2 Inlet Solenoid S19 Oil Drain Bottle This bottle provides a reservoir for used oil and must be drained when the user is instructed to do so by the control panel Operators should drain this bottle ...

Page 75: ...the compressor away from the rear retainer 5 Disconnect the hoses from the compressor 6 Disconnect the compressor pigtail from the COMP connector on the main harness 7 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 In...

Page 76: ...just position of ISV liquid and vapor hoses so that the hoses do not contact the center divider or vacuum pump shelf 2 Apply Loctite 242 to equivalent to threads 3 Torque hose fittings to 8 5 0 5Nm 4 Route replacement hoses and tubes in the same positions and places as the original securing with tie wraps where appropriate MANIFOLD ASSEMBLY COMPRESSOR OIL DRAIN ASSEMBLY ...

Page 77: ...l panel to its support and rotate the control panel toward the front of the unit 4 Remove the two plastic lines from the vacuum pump 5 Remove the two bolts fastening the vacuum pump to the pump shelf 6 Disconnect the vacuum PUMP connector from the main harness 7 Remove the vacuum pump from the unit Installing Replacement Vacuum Pump 1 Place the vacuum pump into the unit 2 Secure the vacuum pump to...

Page 78: ...sch GmbH 78 Plumbing and Mechanical ss01943 Figure 4 3 Plumbing Interconnection Diagram Main Manifold Side View ISV Assembly Vacuum pump High side gauge Low side gauge Liquid Vapor Main Manifold Top View Injection Manifold Reference Only Flush N2H2 Manifold Reference Only ...

Page 79: ...e faulty component in place after following steps 1 through 2 in Removing Manifold Block The remaining steps 3 5 outline the procedure for removing the entire manifold block See Figure 4 4 If the injector manifold is being repaired refer to the Replacement Manifold Solenoid or Replacement Manifold Check Valve as needed When installing hoses solenoids and check valves replace the O rings and use th...

Page 80: ...High Side Charge Solenoid S6 Low Side Charge Solenoid S7 Vacuum Solenoid S9 Identifier Solenoid S17 Recycle Solenoid S8 Deep Recover Solenoid S12 Manifold Assembly Top View Injection Manifold Assembly PAG Solenoid S2 Dye Solenoid S15 N2H2 Inlet Solenoid S19 POE Solenoid S14 4psi Relief Check Valve for Vacuum Pump Low Side Pressure Transducer LSP Oil Drain Solenoid S3 Manifold Assembly Side View IS...

Page 81: ...the Injection Manifold 1 Disconnect the unit from the power source 2 Remove the front plastic covers and the service hoses 3 Remove the two screws securing the injection manifold to the panel of the unit 4 Disconnect the high and low side inlet lines from the manifold block 5 Remove the injection manifold from the unit 6 Remove the wiring from the oil injection solenoid s 7 Remove the inside high ...

Page 82: ...e O rings and use thread sealant where necessary Removing the Flush N2H2 Manifold 1 Disconnect the unit from the power source 2 Remove the front plastic covers and the service hoses 3 Remove the two screws securing the flush N2H2 manifold to the panel of the unit 4 Disconnect the plastic hose inlet lines from the manifold block 5 Remove the coils cables from the manifold 6 Remove the complete bloc...

Page 83: ...4 Disconnect the two wires connected to the solenoid being repaired or replaced 5 Remove the fastener holding the coil on the solenoid and remove the coil 6 Remove the solenoid assembly from the manifold block 7 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 ...

Page 84: ...alve 1 Disconnect the unit from the power source 2 Remove the front plastic covers 3 Depressurize the unit 4 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 9 Nm 70 80 in lb 4 Mount the front plastic covers 5 Connect the unit to the power source perform a fun...

Page 85: ... complete a full charge the compressor and recycle solenoid cycle to build tank pressure COMPONENT APPLICATION CHARTS Manifold Component Application Chart ACS 753 ACS 763 and ACS 863 Function Component Tank Fill Internal Clearing Refrigerant Identification Recover Deep Recover Oil Drain Vacuum Vacuum Leak Test Air Purge Oil Inject 1 PAG Oil Inject 2 POE UV Dye Inject Pre Charge Charge Recycle Powe...

Page 86: ...ng 4 8 Refrigerant Identification 4 9 Recover 4 10 Deep Recover 4 11 Oil Drain 4 12 Vacuum 4 13 Vacuum Leak Test 4 14 Air Purge 4 15 Oil Inject 1 PAG 4 16 Oil Inject 2 POE 4 17 UV Dye Inject 4 18 Pre charge 4 19 Charge 4 20 Recycle Power charge 4 21 Hose Flush 4 22 Periodic leak test 4 23 N2H2 Injection 4 24 N2H2 Venting 4 25 Fluid Flow Diagram Locations ...

Page 87: ...lter Drier High Pressure Cutout Swtich Main Manifold Pump Exhaust Check Valve Oil Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Dr...

Page 88: ...e Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port ID Orifice Refrigerant Identifier RI Filter Oil Inject...

Page 89: ...rvice Hose Vacuum Pump Compressor Oil 1 Inject Bottle Oil Drain Bottle High Side Service Hose Injection Manifold Accumulator Transducer Deep Recover Solenoid HS Gauge Vacuum Pump Exhaust Filter Drier High Pressure Cutout Swtich Main Manifold Pump Exhaust Check Valve Oil Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check ...

Page 90: ... Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port ID Orifice...

Page 91: ... Main Manifold Pump Exhaust Check Valve Oil Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Sto...

Page 92: ...t Swtich Main Manifold Pump Exhaust Check Valve Oil Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low ...

Page 93: ...il Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port ID Orifi...

Page 94: ...ifold Pump Exhaust Check Valve Oil Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port...

Page 95: ...harge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port ID Orifice Refrigerant Identifi...

Page 96: ...k Valve Oil Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port...

Page 97: ...k Valve Oil Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port...

Page 98: ... Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port ID Orifice...

Page 99: ...arge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port ID Orifice Refrigerant Identifie...

Page 100: ... Manifold Pump Exhaust Check Valve Oil Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage ...

Page 101: ...Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port ID Orifice Refrigerant Identifier RI Filter Oil Inject 2...

Page 102: ... High Pressure Cutout Swtich Main Manifold Pump Exhaust Check Valve Oil Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Soleno...

Page 103: ... Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port ID Orifice...

Page 104: ...Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port ID Orifice Refrigerant Identif...

Page 105: ...k Valve Oil Return Solenoid LS Charge Solenoid LS Charge Check Valve HS Charge Solenoid HS Charge Check Valve Recycle Solenoid Recover Check Valve Recover Solenoid Heat Exchanger System Oil Separator Compressor Oil Separator LS Inlet Solenoid HS Inlet Solenoid Vacuum Solenoid Oil Inject 1 Solenoid Oil Inject 1 Check Valve Oil Drain Solenoid Service Port Low Side Storage Port High Side Storage Port...

Page 106: ...enever 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 vehicle being serviced HIGH PRESSURECUTOUTSWITCH Switch opens at 22 5 0 7 bar 326 1...

Page 107: ...reases tank pressure to assist the charging function SOLENOID S9 VACUUM Whenenergized 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 S12 DEEP RECOVER When energized uses vacuum pump to...

Page 108: ...ARATOR Measures the pressure within the system oil separator TRANSDUCER AIR PURGE Measures the pressure within the ISV TRANSDUCER LOW SIDE Measures the pressure of incoming refrigerant from the A C system Pressure readings are then relayed to the control board VACUUMPUMP Pumpdesignedtoremoved moisture and air from an A C system Also aids in the recovery process by performing a deep recovery of A C...

Page 109: ...ACS 753 ACS 763 ACS 863 Service Manual SP00D00609 2018 03 26 Robert Bosch GmbH 109 Notes Notes ...

Page 110: ...Robert Bosch GmbH Franz Oechsle Straße 4 73207 DEUTSCHLAND www bosch com bosch prueftechnik bosch com SP00D00609 2018 03 26 ...

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