Bosch ACS 500 Series Repair Instructions
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Bosch ACS 500 Series Repair Instructions

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Summary of Contents for Bosch ACS 500 Series

  • Page 1 ACS 500 Repair instructions AC Service Unit...
  • Page 2 ACS 500 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 3: Table Of Contents

    5.3. 1 2 Menu for calibration of force and pressure sensors ...11 12. 1 General terminal diagram ............27 12.2 Wiring harness terminal diagram ........... 28 12.2. 1 Connection to actuation circuit board ........28 12.2.2 Connection to valve block ............28 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 4: Important Information

    General and component overview . 1 Overview Installation and/or repairs may only be carried out by trained and instructed Robert Bosch GmbH customer service staff . 1 . 1 Electronic compartment or organizations authorized by Robert Bosch GmbH. Opening or modification of the units by unauthorized persons will invalidate all warranty entitlements.

  • Page 5: Cold Chamber

    4. Solenoid valve (OUT R) for filling phase 5. Solenoid valves (OUT A) for recovery/recycling phase Fig. 2: Component overview in cold chamber 6. Solenoid valves (OUT B) for vacuum phase 1. Refrigerant flask (reservoir) 7. Pressure sensor 2. Scale 8. Connection to vacuum pump 3. Vacuum pump 9. Connection to processing unit 4. Processing unit 10. Connection to refrigerant flask 11. Connection to oil separator 12. Non-return valve 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 6: Processing Unit

    5. Inlet hose for refrigerant flask 6. Inlet hose for used oil tank 7. Solenoid valve (OUT S) for oil drain 8. Condenser with fan 9. Compressor 10. Filter and driver cartridge 11. Expansion valve 12. Non-return valve 13. Pressure switch 459786_9 Fig. 6: Refrigerant flask component overview 1. Safety valve (overpressure) 2. Safety valve (for non-compressible gases) 3. LP fitting connection 4. HP fitting connection 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 7: Troubleshooting

    Open valve cocks on refrigerant flask. vehicle A/C system reached. • Check fill quantity in refrigerant flask and top up if necessary. External tank empty! External flask for filling is empty. • Obtain new flask with refrigerant. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 8: By Symptoms

    (see Chap. 9.4.2). Mechanical malfunction in the scale Check whether the movement of the scale and the refriger- movement. ant cylinder is blocked mechanically by other components. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...
  • Page 9 Aspirated ambient air. Inspect the vehicle air conditioning system and ACS for vacuum pump. leaks and repair. Small quantities of smoke in the first min- utes of the vacuum phase are permitted. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 10: Calibration And Customer Service Menu

    Channel for refrigerant scale CH 1 Channel for fresh oil scale CH 2 Channel for used oil scale CH 3 Channel for UV contrast medium scale CH 4 Channel for pressure sensor 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 11: Menu For Time And Date Setting

    Throughput quantity of refrigerant when filling the internal refrigerant flask with an external refrigerant flask.  Pump operating time Operating time of vacuum pump.  R134 filled Throughput quantity of refrigerant in filling phase. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 12: Calibrating Force And Pressure Sensors

    "Calibration OK" appears on the display. 16. Acknowledge message with <V>. 17. Exit " Calibration " menu item with <O>. 18. Exit " Service " menu with <O>. 19. Remove calibration weight. Calibration successfully completed. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 13: Calibrating The Pressure Sensor

    9. After updating, confirm the message with < OK >. 10. Exit the software. 11. Check the displayed version on the ACS display. 12. Turn off ASC 500. 13. Turn off Pc. 14. Remove Sub-D cabel. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 14: Test

    (see Section 9.6). 4. Test pressure switch for continuity: Continuity - Pressure switch OK. No continuity - Check connecting lead. Replace pressure switch (see section 9.8). 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 15: Repairs

    2. Replace cover (2) backwards and lift upwards. Closing the electronic compartment: 1. Replace cover (2) and slide forwards underneath the control panel (3). 2. Secure cover with four self-tapping screws (1). 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 16: Replacing The Actuation Circuit Board

    8. Install new actuation circuit board in connection box. 9. Secure actuation circuit board with bolts (4). 10. Connect connecting lead for control/display unit and if necessary for printer. (See Section 12.1) 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 17: Control/Display Unit

    Calibrate force sensors (see section 6.1).  Calibrate pressure sensor (see section 6.2). 9.. Checking control/display unit Procedure: 1. Carry out function test (see section 5). 2. After successful test, re-attach electronic compartment cover. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...
  • Page 18 20. Open stop cocks (see Fig. 13, 2) and shut-off valves Fig. 15: Scale (see Fig. 13, 4) on refrigerant flask. 9. Remove complete scale (7) from the ACS 500. 21. Attach electronic compartment and cold chamber covers. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 19: Replacing Valve Block

    Fig. 17: Solenoid valve connector 5. Remove all solenoid valve connectors (1). Fig. 19: Control/display unit 11. Disconnect pressure sensor connecting lead (10). 12. Remove valve block (8). 13. Install new valve block. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 20: Replacing The Pressure Sensor

    7. Screw the pressure sensor into the valve block (1). flask. 8. Install valve block (see section 9.5). 22. Attach covers. 9. Calibrate pressure sensor (see section 6.2). 23. Calibrate pressure sensor (see section 6.2). 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 21: Replacing The Vacuum Pump

    10. Pull connecting lead (7) and remove from lead 29. Open stop cocks and shut-off valves on the refrigerant connection (6). flask. 11. Open union nut on hose line (3). 30. Attach cold chamber cover. 12. Connect hose line (3). 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 22: Replace The Preparation Unit

    10. Remove ground cable at the foot of the processing unit retaining plate. 11. Remove connecting leads from solenoid valve for oil drain and on pressure switch. 12. Disconnect connecting lead for condenser fan. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 23: Replacing The Pressure Switch

    4. Apply a thin layer of pipe sealant to the connecting thread (4). 5. Screw pressure switch into the connection and tighten with the connecting thread counterholder. 6. Reinstall processing unit (see Section 9.8.2). 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 24: Replacing Force Sensors For Used Oil, Fresh Oil And Uv Contrast Medium Scales

    7. Remove hexagon bolts (5). 8. Remove force sensor with pipe union from the retaining plate (3). 9. Remove hexagon bolts (7) and remove retaining plate (2) for pipe union from the force sensor. 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 25: Hose System Diagram

    5 ACS 500 Hose system diagram Fig. 30: Hose system diagram 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 26: Pneumatic Circuit Diagram

    -1 - 15 bar OUT I 0 - 10 bar OUT A OUT B OUT R OUT L 14,4 bar 16 bar 12,8 bar OUT S 459790-8 Fig. 31: Pneumatic circuit diagram 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 27: Electrical Terminal Diagram

    1. Control/display unit 10. Master switch 2. Interface for firmware download 11. Actuation circuit board 3. Pressure switch 12. Scale for refrigerant 4. Compressor 13. Scale for oil injection 5. Vacuum pump 14. Scale for oil drain 6. Valve block 15. Scale for UV contrast medium injection 7. Solenoid valve for oil drain 16. Battery 8. Solenoid valve for connection of LP or HP terminal 9. Solenoid valve for UV contrast medium injection 1 689 975 197 (2006-09-22) Robert Bosch GmbH...

  • Page 28: Wiring Harness Terminal Diagram

    Fig. 33: Wiring harness connection to actuation circuit board 1.. Connection to valve block POM2C OUT 1A 459790-6 POM2 OUT 1 OUT 4 OUT 3 OUT 8 Fig. 34: Wiring harness connection to valve block 1 689 975 197 (2006-09-22) Robert Bosch GmbH...
  • Page 29 ACS 500 0 684 50 500 ACS 500 -S1 0 684 50 501 Robert Bosch GmbH Automotive Aftermarket Test Equipment Franz-Oechsle-Str. 4 D 73207 Plochingen www.bosch.com e-Mail: Bosch.Prueftechnik@de.bosch.com Printed in Germany - Imprimé en Allemagne 1 689 975 197 (2006-09-22)

This manual is also suitable for:

Acs 500-s1

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