Bosch ACS 753 Repair Instructions
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Bosch ACS 753 Repair Instructions

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Control Panel Functions
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ACS 753 - ACS 763 - ACS 863
en Repair instruction
A/C Service Unit

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  • 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 Robert Bosch GmbH Franz-Oechsle-Straße 4 1119D-73201 Plochingen SERVICE: bosch.prueftechnik@bosch.com © Robert Bosch GmbH SP00D00609 2018-03-26 Robert Bosch GmbH...

  • Page 3: Table Of Contents

    ACS 753, ACS 763, ACS 863 Service Manual able of onTenTs Safety Warnings ....................4 Introduction ......................8 Introduction ........................9 Unit Specifications ......................20 Maintenance Schedule ....................22 Diagnostics and Testing ..................23 Functional Check ......................24 Diagnostics and Testing ....................28 Depressurizing the Unit ....................

  • Page 4: Safety Warnings

    CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. These safety messages cover situations Bosch is aware of. Bosch cannot know, evaluate, or advise you as to all possible hazards. You must verify that conditions and procedures do not jeopardize your personal safety.
  • Page 5 ACS 753, ACS 763, ACS 863 Service Manual WARNING: To prevent personal injury, ALLOW ONLY QUALIFIED PERSONNEL TO OPERATE THE MACHINE. Before operating the machine, read and follow all instructions and warnings in this manual. The operator must be familiar with air conditioning and refrigeration systems, refrigerants, and the dangers of pressurized components.
  • Page 6 R1234yf (ACS 763, ACS 863) or R134a (ACS 753) refrigerant. Do not attempt to adapt the machine for another refrigerant. Do not mix refrigerant types through a system or in the same container; mixing of refrigerants will cause severe damage to the machine and the vehicle air conditioning system.
  • Page 7 ACS 753, ACS 763, ACS 863 Service Manual Protective devices The machine is equipped with the following protective devices: • Over pressure valves. • A maximum pressure switch stops the compressor when excessive pressure is sensed. WARNING: Tampering with these protective devices could result in serious injury.

  • Page 8: Introduction

    Introduction ACS 753, ACS 763, ACS 863 Service Manual n TroduCT I o n Introduction ......................9 Control Panel Functions ....................10 Icon Legend ........................10 Glossary .......................... 11 Setup Menu ........................11 General Maintenance ..................... 14 Electrical Protection ....................... 14 Tank Fill ...........................

  • Page 9: Introduction

    Introduction ACS 753, ACS 763, ACS 863 Service Manual Introduction These units are designed to be compatible with existing service equipment and standard service procedures. These machines utilize a single-pass system that meets specifications for recycled refrigerant. Follow recommended service procedures for the containment of refrigerant.

  • Page 10: Control Panel Functions

    Introduction ACS 753, ACS 763, ACS 863 Service Manual Control Panel Functions Main Menu 09:36 Standby V 076.026.050 3.544 kg ARROW UP moves selection of a Refrigerant 7.34 bar menu item to the previous item. 205 ml 205 ml 205 ml ARROW DOWN moves selection of a menu item to the following item.

  • Page 11: Glossary

    Introduction ACS 753, ACS 763, ACS 863 Service Manual Setup Menu HS LS to set which side to charge thru (high pressure, low pressure or The machine launches into the initial Setup both sides). mode (the first time the machine is powered up).
  • Page 12 Introduction ACS 753, ACS 763, ACS 863 Service Manual Periodic Leak Test Oil Load Cells Performs double test (in vacuum and pressure) To enable or disable the operation of fresh oil to detect any leakage on the machine. PAG, fresh oil POE, used oil and UV dye scales.
  • Page 13 Introduction ACS 753, ACS 763, ACS 863 Service Manual WiFi Configuration Pump Maintenance To configure the WiFi connection to the ma- Displays the amount of time remaining until chine. The display shows four selection options: the next vacuum pump oil change is needed.

  • Page 14: General Maintenance

    Introduction ACS 753, ACS 763, ACS 863 Service Manual General Maintenance 8. Select OK icon to start the tank fill process. Do not use abrasive cleaning agents, solvents 9. The machine (ACS 863 only) checks the (petrol, diesel, etc.) and coarse workshop cloths refrigerant in the source tank to verify it to clean the machine.

  • Page 15: Filter Maintenance

    Introduction ACS 753, ACS 763, ACS 863 Service Manual • Connect a second recovery machine to 3. Switch off the machine. the fitting (1) located on the side of the 4. Open the service rear door. machine. See Figure 1-3. Run a recovery 5.

  • Page 16: Internal Refrigerent Identifier Maintenance (Acs 863 Only)

    Introduction ACS 753, ACS 763, ACS 863 Service Manual Internal Refrigerent Identifier Vacuum Pump Maintenance Maintenance (ACS 863 only) NOTE: Vacuum pump oil must be changed with A refrigerant identifier samples refrigerant every filter change, every 100 hours pump runs going into the ISV to verify it is R1234yf and or more often as necessary.

  • Page 17: Edit Print Header

    Introduction ACS 753, ACS 763, ACS 863 Service Manual Edit Print Header 18. Select ESC icon to return to the Mainte- nance Menu. To make changes to the printer text (available in Setting menu) appearing in the header on each printout: 1.

  • Page 18: Calibration Check

    Introduction ACS 753, ACS 763, ACS 863 Service Manual Calibration Check Scales Reset This function is used to ensure the machine’s This procedure should be carried out regularly, internal scale is always calibrated. During this as the deviation from the zero point of the test, use only the calibration weight provided oil/dye scales is corrected in the process.

  • Page 19: Pressure Decay Leak Test (R1234Yf Only)

    Introduction ACS 753, ACS 763, ACS 863 Service Manual Pressure Decay Leak Test Lockout This function is available on Function menu. Never leave the machine live if an immediate To ensure a safe, environmentally friendly, use is not scheduled. To ensure that unauthor-...

  • Page 20: Unit Specifications

    Introduction ACS 753, ACS 763, ACS 863 Service Manual UNIT SPECIFICATIONS ACS 763 ACS 863 ACS 753 Refrigerant R1234yf R1234yf R134a ISV total capacity (water 22 l 22 l 22 l capacity) Internal Vessel Maximum 19.655 kg of R1234yf 19.655 kg of R1234yf 21.671 kg of R134a...
  • Page 21 Introduction ACS 753, ACS 763, ACS 863 Service Manual ACS 763 ACS 863 ACS 753 Flush Port Refrigerant Identifier Optional as external Embedded device Flush Kit Optional for R1234yf Optional for R1234yf Optional for R134a N2H2 Yes, embedded port Yes, embedded port...

  • Page 22: Maintenance Schedule

    Introduction ACS 753, ACS 763, ACS 863 Service Manual MAINTENANCE SCHEDULE MAINTENANCE TASK RECOMMENDED INTERVAL After (SEE TABLE) of refrigerant has been filtered. Refer to Filter Change in the Maintenance section of this manual. Model Replacement filter at: Change filter R134a...

  • Page 23: Diagnostics And Testing

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual I a g n o s T I C s and esTIng Functional Check ....................24 Updating System Software Instruction ................24 Recover Function ....................... 25 Charge Function ......................... 26 Diagnostics and Testing ..................28...

  • Page 24: Functional Check

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual FUNCTIONAL CHECK Prior to performing a functional or diagnostic 14. The unit will go through a file updating pe- check, make sure the software version is riod (it can take several minutes) to finalize current.

  • Page 25: Recover Function

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual 11. 2 stage recovery. Unit perform special N O T E : R e f e r t o S c a l e C a l i b r a t i o n a t...

  • Page 26: Charge Function

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Charge Function Machine is asking to input: • Oil inject (Yes or No). If select No unit Automatic leak tests will be performed during don’t inject any oil (neither the recovered the charge function.
  • Page 27 Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual 8. If the amount of refrigerant is sufficient 11. If the charge was cancelled, Charge to charge the system to completion, the complete will change to Charge cancelled display will show hoses compendation a...

  • Page 28: Diagnostics And Testing

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual DIAGNOSTICS AND TESTING NOTE: These are the Service Options at the time of printing this service manual. Some options may be added or deleted in future circuit board and software updates and revisions.
  • Page 29 Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual After 5 seconds: 2. Select OK icon to enter the ISV load cell 5. Place a 10 kg (editable) weight on the scale calibration. and enter the weight using the keypad.
  • Page 30 Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual 7. If the calculation is accepted, the following Drain Load Cell Calibration is displayed: 1. With the Calibrate Load Cell menu displayed, use the up/down arrow keys to toggle to the Drain Load Cell service menu.
  • Page 31 Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual PAG Load Cell Calibration POE Load Cell Calibration 1. With the Calibrate Load Cell menu displayed, 1. With the Calibrate Load Cell menu displayed, use the up/down arrow keys to toggle to the use the up/down arrow keys to toggle to the PAG Load Cell service menu.

  • Page 32: Output Test

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Dye Load Cell Calibration Output Test 1. With the Calibrate Load Cell menu displayed, The Output Test checks the electrical outputs use the up/down arrow keys to toggle to the from the power board and wiring harnesses Dye Load Cell service menu.

  • Page 33: Input Test

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual OUTPUT TEST INPUT TEST Tank liquid solenoid S22 Sensor or Value Property Device Format ISV Weight X.XXXYY ISV Weight Vacuum Pump PAG Weight X.XXXYY PAG Weight Compressor POE Weight X.XXXYY POE Weight...

  • Page 34: A/C Unit Internal Clearing

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual 5. The vacuum pump should turn on and the 5. If Ok unit come back to service menu. time begins to count down (5 minutes). 6. If failed unit ask to retry.

  • Page 35: End User Install

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual 8. If the Inlet pressure rises above 0.35 bar Maintenance Counters during the Service Vacuum, any outputs Maintenance Counters record the number that are ON will turn OFF and the vacuum of times a maintenance function has been time will stop counting down.
  • Page 36 Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual The second line of the display, above, represents 7. Scroll to the next desired Maintenance Counter. If none is desired, select BACK the item to be reset. icon to return to the Service Menu.

  • Page 37: Keypad Test

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Keypad Test Set Serial Number The Keypad Test is used to determine if the Setting the serial number is usual after main keys on the control panel are functioning when board replacement only.

  • Page 38: Set Boot Mode

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Set Boot Mode Reset Board Setting the Boot Mode makes it possible to Unless absolutely necessary, resetting the boot into a mode other than Normal (default). board is not recommended. Resetting the board...

  • Page 39: Refrigerant Identifier (Acs 863 Only)

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Refrigerant Identifier (ACS 863 only) Default Vacuum Leak Test Time The Refrigerant Identifier is used to enable/ The Default Vacuum Leak Test Time is editable disable internal refrigerant identifer. (default 5 min). CAUTION: this time is editable to make...

  • Page 40: Depressurizing The Unit

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual DEPRESSURIZING THE UNIT WARNING: Contact with refrigerant can cause eye injury. Always wear safety goggles when working with refrigerants. Disconnect lines and hoses with extreme caution! Pressurized refrigerant may be present in lines and hoses. Always point lines and hoses away from you and anyone nearby.

  • Page 41: Troubleshooting

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual TROUBLESHOOTING Grounding, Noise, and Power Issues Power Issues The power applied to the unit must be from To provide proper protection and maximize a stable, low-impedance source. Long-term system reliability, it is important to consider stability must be within ±10% of the nominal...

  • Page 42: Will Not Power-Up, No Display

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Will Not Power Up, No Display 4. Connect the unit to a proper AC power source and place the unit power switch on. 1. Verify the unit is connected to a known good The display should illuminate.

  • Page 43: Will Not Fill Tank

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Will Not Fill Tank Stuck In Clearing NOTE: The compressor should be running NOTE: The recover process begins with low- during this test. If it does not run, refer to side clearing.

  • Page 44: Will Not Recover

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual 10. Verify the oil drain solenoid isn’t leaking Will Not Recover the vacuum. Place a finger over the end of NOTE: The compressor should be running the oil drain tube and check for suction. If during this test.

  • Page 45: Will Not Deep Recover

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Will Not Deep Recover Vacuum Pump Not Running 1. Check for proper power source, circuit Vacuum Pump Running breaker, and electrical connectors for 1. Verify no issue on ISV recovery way (one damage or corrosion.

  • Page 46: Will Not Drain Oil

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Will Not Drain Oil Will Not Air Purge 1. Verify the accumulator transducer is 1. Verify the air purge solenoid (S1) is receiving functioning properly. power and opening properly.

  • Page 47: Will Not Evacuate (Vacuum)

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Will Not Evacuate (Vacuum) Vacuum Pump Not Running 1. Check gauges for vacuum. NOTE: The vacuum pump should be running 2. If pressure is over 690 mBar (10 psi), recover during this test.

  • Page 48: Fails Leak Test

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Fails Leak Test Will Not Inject Oil or Dye NOTE: To ensure an accurate leak test, it 1. Verify the oil and dye injector bottles is imperative that a thorough recovery and are securely attached and contains an evacuation of the system be performed.

  • Page 49: Will Not Charge

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Will Not Charge Slow Charge NOTE: There is no component that pumps When the charge has slowed, the unit will enter refrigerant into a system during the charge the power charge process to build tank pressure process.

  • Page 50: Will Not Print

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Will Not Print Replace the Printer Paper 1. Pull the cover open by inserting a finger into 1. Does the printer have power? the pocket in the cover and pull.

  • Page 51: Power Board Troubleshooting

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Power Board Troubleshooting Control Board Troubleshooting 1. Possible reasons to replace the power 1. Possible reasons to replace control board: board: • Repeated read errors. • No power to any components.

  • Page 52: Compressor Troubleshooting

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Compressor Troubleshooting ss00649 1. Check for proper power source, circuit breaker, and electrical connectors for damage or corrosion. 2. Connect the unit directly to a known good power source. Do not use an extension cord.

  • Page 53: Vacuum Pump Troubleshooting

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual Vacuum Pump Troubleshooting Vacuum Pump Does Not Run 1. Check for proper power source, circuit 1. Check gauges for vacuum. breaker, and electrical connectors for 2. If pressure is over 0.7 bar (10 psi), recover damage or corrosion.

  • Page 54: Error Messages

    Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual ERROR MESSAGES PROCEDURE ERROR/WARNING DESCRIPTION OF ERROR/ WARNING Calibrate Load Cells Calibration failed! Slope is out Difference between upper and lower of range. limits is too great. Select RETRY...
  • Page 55 Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual PROCEDURE ERROR/WARNING DESCRIPTION OF ERROR/ WARNING Oil Inject Oil inject error. Inject: XXXYY 1. Check if enough oil is present in oil bottle. 2. Check for oil inject tube kinks or cuts.
  • Page 56 Diagnostics and Testing ACS 753, ACS 763, ACS 863 Service Manual PROCEDURE ERROR/WARNING DESCRIPTION OF ERROR/ WARNING Recovery Purity test failed. Recover Refrigerant analysis test failed contaminated refrigerant from (generic error). Select RETRY or system and hoses (if the re-...

  • Page 57: Electrical System Operation And Repair

    Electrical ACS 753, ACS 763, ACS 863 Service Manual leCTrICal ysTem peraTIon and epaIr Electrical System Operation .................58 Power Board and Power Supply Operation ..............58 Power Board Connector Assignments ................58 Control Board Operation ....................59 Control Board Connector Assignments ................59 Control Board Functions ....................

  • Page 58: Electrical System Operation

    Electrical ACS 753, ACS 763, ACS 863 Service Manual ELECTRICAL SYSTEM OPERATION The electrical system provides the various P7: High-Pressure Switch voltage levels required for the machine to P8: Solenoids S1, S2, S3, S14, S15, S17 operate effectively. The power board, power...

  • Page 59: Control Board Operation

    Electrical ACS 753, ACS 763, ACS 863 Service Manual Control Board Operation Three regulated power supplies of 8 VDC, The Control Board, Figure 3-3, is mounted in 5 VDC, and 3.3 VDC provide the power for the the control panel and provides the control for logic and data circuitry.

  • Page 60: Sensors And Transducers

    Electrical ACS 753, ACS 763, ACS 863 Service Manual Sensors and Transducers Control Board Software Updating Methods The sensors and transducers provide the To access the operational capability of the input and feedback data needed to control the unit, or to provide an interface to an external operation of unit.
  • Page 61 Electrical ACS 753, ACS 763, ACS 863 Service Manual ss01906 Power Socket CONTROL GRN/YEL BOARD Main Switch S/L2 R/L1 POWER SUPPLY V/T2 U/T1 ADJ. Door Switch GRN/YEL Circuit Breaker POWER BOARD Internal Refrigerant Identifier Figure 3-4. Electrical Connections (Sheet 1 of 4) NOTE: Internal refrigerant indentifier is included on ACS 863 unit only.
  • Page 62 LOAD CELL ASSEMBLY TRANSDUCER (LSP) Figure 3-4. Electrical Connections (Sheet 2 of 4) NOTE: • Air Flow Sensor is disabled on ACS 753 unit only. • Internal refrigerant indentifier is included on ACS 863 unit only. SP00D00609 2018-03-26 Robert Bosch GmbH...
  • Page 63 Electrical ACS 753, ACS 763, ACS 863 Service Manual ss01905 FLUSH + N2H2 MANIFOLD S19 N2H2 Inlet S1 Air purge S20 N2H2 Vent S22 Tank liquid INJECTION MANIFOLD S2 Oil inject 1 (PAG) S14 Oil inject 2 (POE) S15 Dye...
  • Page 64 Electrical ACS 753, ACS 763, ACS 863 Service Manual ss01907 P7 P11 BOARD CONTROL BOARD PRINTER ASSEMBLY VACUUM PUMP POWER BOARD COMPRESSOR Figure 3-4. Electrical Connections (Sheet 4 of 4) SP00D00609 2018-03-26 Robert Bosch GmbH...

  • Page 65: Electrical System Repair

    Electrical ACS 753, ACS 763, ACS 863 Service Manual ELECTRICAL SYSTEM REPAIR Replacement Power Board Instructions These instructions outline the basic steps to WARNING: Disconnect the unit from replace the power board. Refer to Figure 3-5. the power source before beginning Remove Existing Power Board service work.

  • Page 66: Replacement Control Board

    Electrical ACS 753, ACS 763, ACS 863 Service Manual Replacement Control Board 4. Disconnect all wires from control board including keypad and display ribbon cables. WARNING: Disconnect the unit from 5. Remove screws securing control board in the power source before beginning place and remove control board.

  • Page 67: Replacement High-Pressure Cut-Out Switch

    Electrical ACS 753, ACS 763, ACS 863 Service Manual 9. Return to the Service Menu and scroll to Set 4. Disconnect the wires from the faulty high- serial number and select OK icon to select. pressure cut-out switch. 10. Enter the serial number from the serial 5.

  • Page 68: Replacement Fan Assembly

    Electrical ACS 753, ACS 763, ACS 863 Service Manual Replacement Fan Assembly 13. Install the back panel assembly. 14. Restore compressor plumbing and/or WARNING: Disconnect the unit from perform the steps to re-install the compressor. the power source before beginning 15.

  • Page 69: Replacement Scale Assembly/Magnet

    Electrical ACS 753, ACS 763, ACS 863 Service Manual Replacement Scale Assembly/Magnet Removing Scale Assembly 1. Disconnect the unit from the power source. WARNING: Disconnect the unit from 2. Remove the shroud. the power source before beginning 3. Disconnect the liquid hose and vapor hose service work.

  • Page 70: Scale Calibration (Load Cells)

    Electrical ACS 753, ACS 763, ACS 863 Service Manual Scale Calibration (Load Cells) 1. Switch the power on. The unit will verify application loaders, files, and sensors during the power up sequence and then will display the amount of refrigerant available ss01362 in the internal tank.

  • Page 71: Replacing Load Cells

    Electrical ACS 753, ACS 763, ACS 863 Service Manual Replacing Load Cells Installing the Load Cell 1. Connect the new load cell to the adapter WARNING: Disconnect the unit from block and secure in place with screws the power source before beginning (arrow going down see picture).

  • Page 72: Plumbing And Mechanical System Operation And Repair

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual lumbIng and eChanICal ysTem peraTIon and epaIr Plumbing and Mechanical System Operation ............73 Compressor ........................73 Vacuum Pump ........................73 Main Manifold ........................73 Internal Storage Vessel (ISV) ..................... 73 Cooling Fan .........................

  • Page 73: Plumbing And Mechanical System Operation

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual PLUMBING AND MECHANICAL SYSTEM OPERATION The plumbing and mechanical system • Recover (S11) is controlled by electrical impulses from • Deep Recover (S12) the electrical system. There are four main •...

  • Page 74: Cooling Fan

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual Ancillary components and assemblies included Oil Drain Bottle: This bottle provides a are: reservoir for used oil and must be drained when the user is instructed to do so by the control Cooling Fan: The cooling fan is necessary panel.

  • Page 75: Plumbing And Mechanical System Repair

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual PLUMBING AND MECHANICAL SYSTEM REPAIR Replacement Compressor Installing Replacement Compressor Refer to Figure 4-1 during this installation. WARNING: Disconnect the unit from 1. Install the rubber mounts (included in kit) the power source before beginning into the base of the compressor.
  • Page 76 Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual MANIFOLD ASSEMBLY ss01942 COMPRESSOR OIL DRAIN ASSEMBLY NOTES: 1. Adjust position of ISV liquid and vapor hoses so that the hoses do not contact the center divider or vacuum pump shelf.

  • Page 77: Replacement Vacuum Pump

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual Replacement Vacuum Pump 4. Remove the two plastic lines from the vacuum pump. WARNING: Disconnect the unit from 5. Remove the two bolts fastening the vacuum the power source before beginning pump to the pump shelf.
  • Page 78 Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual High-side gauge ss01943 Low-side gauge Main Manifold (Side View) ISV Assembly Liquid Vapor Main Manifold (Top View) Flush + N2H2 Manifold (Reference Only) Vacuum pump Injection Manifold (Reference Only) Figure 4-3.

  • Page 79: Replacement Manifold Block

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual Replacement Manifold Block Removing Manifold Block 1. Disconnect the unit from the power source. WARNING: Disconnect the unit from 2. Remove the front plastic covers. the power source before beginning 3.
  • Page 80 Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual NOTE: All wires must be clear of moving parts, pinch points, and sharp edges. High Side Inlet Low Side Inlet Solenoid (S5) High-Pressure Solenoid (S4) N2H2 Inlet N2H2 Vent...

  • Page 81: Replacement Injection Manifold

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual Replacement Injection Manifold Installing the Injection Manifold 1. Attach the inside high- and low-side lines to WARNING: Disconnect the unit from the injection manifold. the power source before beginning 2.

  • Page 82: Replacement Flush + N2H2 Manifold

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual Replacement Flush + N2H2 Manifold Installing the Flush + N2H2 Manifold 1. Attach the inside plastic hose to the flush + WARNING: Disconnect the unit from N2H2 manifold. the power source before beginning 2.

  • Page 83: Repairing Or Replacing A Solenoid

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual Repairing or Replacing a Solenoid Installing Solenoid 1. Lubricate the O-rings and threads on the WARNING: Disconnect the unit from new solenoid assembly. the power source before beginning 2. Install the repaired or replacement solenoid service work.

  • Page 84: Replacing Check Valve

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual Replacing Check Valve Installing Replacement Check Valve 1. Lubricate the O-rings on the new check WARNING: Disconnect the unit from valve. the power source before performing 2. Install the new check valve and hand- service work.

  • Page 85: Component Application Charts

    4. Vacuum Process: The unit may purge air or tank fill in the background of the vacuum process. 5. Recycle/Power Charge Process: If the unit does not complete a full charge, the compressor and recycle solenoid, cycle to build tank pressure. Manifold Component Application Chart, ACS 753, ACS 763 and ACS 863 Function Component...
  • Page 86 Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual Fluid Flow Diagram Locations Function Figure No. Tank Fill Internal Clearing Refrigerant Identification Recover 4-10 Deep Recover 4-11 Oil Drain 4-12 Vacuum 4-13 Vacuum Leak Test 4-14 Air Purge 4.15...

  • Page 87: Flow Diagrams

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual FLOW DIAGRAMS TANK FILL PROCESS During the Tank Fill process the compressor, fan, tank fill, and oil return solenoids are activated. The output state of the tank fill solenoid is controlled to maintain 2.4 bar (35 psi) in the accumulator, and is based on the ambient temperature which can vary depending on the temperature reading from the temperature sensor.

  • Page 88: Internal Clearing

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual INTERNAL CLEARING PROCESS During the Internal Clearing process, the compressor is activated. The process continues until -0.45 bar (13 in Hg) is reached, plus 15 seconds. Figure 4-8. Internal Clearing...

  • Page 89: Refrigerant Identification

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual REFRIGERANT IDENTIFICATION PROCESS (ACS 863 only) When the recover or tank fill function is selected, the machine will check pressures on the service hoses. Once pressure is verified the machine will initiate identification of the refrigerant. The low side identifier solenoid (S17) will open intermittently, allowing refrigerant to flow to the refrigerant identifier, through the 0.028-inch internal diameter...

  • Page 90: Recovery

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual RECOVERY PROCESS During the first stage of the recovery process, the fan, compressor, high side and low side inlet solenoids are activated. Recover and oil return solenoids are activated intermittently. Recovery stops when 135 mbar (4 in Hg) is reached, plus 15 seconds.

  • Page 91: Deep Recovery

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual DEEP RECOVERY PROCESS During the Deep Recovery process, the recover solenoid is deactivated, high side, and low side inlet solenoids remain activated. The vacuum pump, compressor, and deep recover solenoids are activated. The output state of the oil return and power charge solenoids are controlled to maintain 0 to 207 mbar (3 psi) in the accumulator.

  • Page 92: Oil Drain

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual OIL DRAIN PROCESS During the Oil Drain process, the recyclesolenoid is activated until there is greater than 1.1 bar (16 psi) in the accumulator. The recycle solenoid is then deactivated and the oil drain solenoid is activated until there is either a greater than 0.01 bar (0.15 psi) change per second in the accumulator or less than 0.62 bar (9 psi)

  • Page 93: Vacuum

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual VACUUM PROCESS The default vacuum time is 5:00 minutes. When the vacuum process begins, the vacuum pump is activated. After a 5 second delay, the vacuum, high side and low side inlet solenoids are also activated. When the timer reaches 0 (zero), the vacuum process will stop.

  • Page 94: Vacuum Leak Test

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual VACUUM LEAK TEST PROCESS High side inlet and low side inlet solenoids are activated to equalize high and low sides of system being serviced. Unit checks low-side transducer for rise in vacuum. If the unit sees a rise of 338 mbar (10 in Hg) within 5 minutes time, the vacuum leak test will fail (this is not a service menu test.)

  • Page 95: Air Purge

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual AIR PURGE PROCESS The air purge solenoid is activated to release excess pressure from the internal storage vessel (ISV). The air purge will occur when the machine is on and idle for 5 minutes, and prior to background fill.

  • Page 96: Oil Inject 1 (Pag)

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual OIL INJECT 1 (PAG) PROCESS The oil injection is an automatic process. During the charge setup, the operator must enter the amount of oil wanted and the machine injects the oil automatically. The system being serviced must have a vacuum to pull oil from the oil PAG inject bottle.

  • Page 97: Oil Inject 2 (Poe)

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual OIL INJECT 2 (POE) PROCESS The oil injection is an automatic process. During the charge setup, the operator must enter the amount of oil wanted and the machine injects the oil automatically. The system being serviced must have a vacuum to pull oil from the oil POE inject bottle.

  • Page 98: Uv Dye Inject

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual UV DYE INJECT PROCESS During the Charge process, the unit activates the dye inject solenoid to inject a preset amount of dye into the vehicle A/C system to check for leaks. The system being serviced must have a vacuum to pull dye from the dye inject bottle.

  • Page 99: Pre-Charge

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual PRE-CHARGE PROCESS (R1234yf only if enabled) During the pre-charge process (before to perform the charge), the unit charge a little amount of refrigerant in the A/C system and perform a pressure test to check any leaks.

  • Page 100: Charge

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual CHARGE PROCESS During the Charge process, the end user may select either high-side charge, low-side charge, or both. When the charge process gets close to the programmed weight, the unit slows down. The unit charges by compensation and will prompt the user in completing the charge.

  • Page 101: Recycle/Power Charge

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual RECYCLE/POWER CHARGE PROCESS If the unit does not complete a full charge, the compressor and recycle solenoid are activated, then stop to build tank pressure. Figure 4-21. Recycle/Power Charge...

  • Page 102: Hose Flush

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual HOSE FLUSH PROCESS Flushing of the hoses is required if the next vehicle to be serviced contains a different type of A/C system oil than the previous vehicle serviced. During the Hose Flush Process, the compressor is activated. The high side and low side charge, high side and low side inlet and recover solenoids are intermittently activated in a charge/recover process to flush hoses or residual oils.

  • Page 103: Periodic Leak Test

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual PERIODIC LEAK TEST (R1234yf only) During the periodic leak test process the circuit is pressurized. The unit activates the high side charge, low side charge, high side inlet, low side inlet, recycle, oil return, recover solenoids to check any pressure decay.

  • Page 104: N2H2 Injection

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual N2H2 INJECTION PROCESS During the N2H2/N2 injection process, the N2H2 Inlet Solenoid opens to allow the gas flooding the vehicle A/C system thru the ACS service hoses. Pressure is monitored by the Low Side Tranducer.

  • Page 105: N2H2 Venting

    Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual N2H2 VENTING PROCESS During the N2H2/N2 injection process (when injection is completed), the N2H2 Vent Solenoid opens to purge N2H2/ N2 trapped into the ACS inlet. Vacuum is then performed to remove any possible remained N2H2/N2 after venting.

  • Page 106: Main Component Descriptions

    Parts and Components ACS 753, ACS 763, ACS 863 Service Manual MAIN COMPONENT DESCRIPTIONS 12V POWER SUPPLY— Provides 12 Volts GAUGE, HIGH-SIDE— Monitor high-side to power the circuit boards, all solenoids, and pressure of the vehicle being serviced. sensors requiring 12V power.
  • Page 107 Parts and Components ACS 753, ACS 763, ACS 863 Service Manual POWER CORD— Supplies main power to the SOLENOID (S11), RECOVER— When unit. energized, provides the primary pathway of removing refrigerant from the system being PRESSURE RELIEF VALVE — Spring-loaded serviced.
  • Page 108 Parts and Components ACS 753, ACS 763, ACS 863 Service Manual TANK TEMPERATURE SENSOR— Monitors the temperature inside the ISV. TRANSDUCER, ACCUMULATOR (SYSTEM OIL SEPARATOR) — Measures the pressure within the system oil separator. TRANSDUCER, AIR PURGE— Measures the pressure within the ISV.

  • Page 109: Notes

    Notes ACS 753, ACS 763, ACS 863 Service Manual oTes Robert Bosch GmbH SP00D00609 2018-03-26...
  • 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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