Bosch ACS 753 Setup guide

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

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: [email protected]

ACS 753, ACS 763, ACS 863 Service Manual
SP00D00609 2018-03-26Robert Bosch GmbH 3
Table of ConTenTs
Safety Warnings ................................................................................................... 4
Introduction .......................................................................................................... 8
Introduction........................................................................................................................ 9
  UnitSpecications .......................................................................................................... 20
Maintenance Schedule.................................................................................................... 22
Diagnostics and Testing .................................................................................... 23
Functional 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 Component Descriptions ....................................................................... 106
Notes ................................................................................................................. 109

ACS 753, ACS 763, ACS 863 Service Manual
SP00D00609 2018-03-26 Robert Bosch GmbH
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Explanation of Safety Decals Used on the Machine
Carefully read all instructions.
Do not use in open air in case of rain or high humidity.
Wear gloves.
Wear protection goggles.
Alternating voltage.
Grounding protection.
Electrical shock hazard.
Safety Warnings
Explanation of Safety Signal Words Used in this Manual
Safety signal words designate the degree, or level, of hazard seriousness.
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
CAUTION: Used without the safety alert symbol indicates a potentially hazardous 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.

ACS 753, ACS 763, ACS 863 Service Manual
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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. If the operator cannot read this manual, all operating instructions
and safety precautions must be read and discussed in the operator’s native language.
USE THE MACHINE AS OUTLINED IN THIS MANUAL. Using the machine in a manner for
which it was not designed will compromise the machine and nullify the protections provided.
PRESSURIZED TANK CONTAINS LIQUID REFRIGERANT. Do not overll the internal
storage vessel (ISV), because overlling may cause explosion resulting in personal injury
or death. Do not recover refrigerants into a nonrellable container; use only type-approved
rellable containers that have a pressure relief valve.
HOSES MAY CONTAIN LIQUID REFRIGERANT UNDER PRESSURE. Contact with
refrigerant may cause personal injury, including blindness and frozen skin. Wear protective
equipment, including goggles and gloves. Disconnect hoses using extreme caution. Ensure
the phase has been completed before disconnecting the machine to prevent the release
of refrigeration to the atmosphere.
DO NOT BREATHE REFRIGERANT AND LUBRICANT VAPOR OR MIST. 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 the work area before resuming service.
DO NOT DISPERSE THE REFRIGERANT INTO THE ENVIRONMENT. Such a precaution
is necessary to prevent the possible presence of refrigerant in the working environment.
The refrigerant R1234yf (ACS 763, ACS 863 only) is heavier than air and tends to
concentrate in the pits of the workshop.
TO REDUCE THE RISK OF FIRE, do not use the machine in the vicinity of spilled or open
containers of gasoline or other ammable substances.
TO REDUCE THE RISK OF FIRE, do not use an extension cord. An extension cord may
overheat and cause re. If you must use an extension cord, use the shortest possible cord
with a minimum size of 14 AWG.
TO REDUCE THE RISK OF FIRE, do not use the machine in the vicinity of ames and
hot surfaces. Refrigerant decomposes at high temperatures, freeing toxic substances to
the environment which are noxious to the user.
TO REDUCE THE RISK OF FIRE, do not use the machine in environments containing
explosive gases or vapors.
TO REDUCE THE RISK OF FIRE, Do not use this machine in ATEX classied zones
or areas. Protect the machine from conditions that may cause electrical failure or other
hazards relating to ambient interaction.
WARNING: To prevent personal injury,

ACS 753, ACS 763, ACS 863 Service Manual
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DO NOT USE COMPRESSED AIR TO PRESSURE TEST OR LEAK TEST THE MACHINE
OR VEHICLE AIR CONDITIONING SYSTEM. Mixtures of air and refrigerant can be
combustible at elevated pressures. These mixtures are potentially dangerous and may
result in re or explosion causing personal injury and/or property damage.
HIGH VOLTAGE ELECTRICITY INSIDE THE MACHINE HAS A RISK OF ELECTRICAL
SHOCK. Exposure may cause personal injury. Disconnect the power before servicing the
machine.
NEVER LEAVE THE MACHINE LIVE IF AN IMMEDIATE USE IS NOT SCHEDULED.
Disconnect the electrical supply before a long period of inactivity or before internal
maintenance is performed. To ensure that unauthorized personnel cannot run the machine,
use the Lockout / Tag Out feature.
TO PREVENT CROSS-CONTAMINATION, USE THIS MACHINE WITH R1234yf
(ACS 763, ACS 863) OR R134a (ACS 753) REFRIGERANT ONLY. The machine is
equipped with special connectors to recover, recycle, and recharge only 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.
Do not use 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 machine far from heat
sources, such as direct sunlight which can cause excessive temperatures. The use of this
machine under normal environmental conditions (10°C to 50°C) keeps pressures under
reasonable limits. Make sure the machine does not exceed the operating temperature
indicated on the technical data plate.
DO NOT USE THIS MACHINE IN AREAS WHERE THERE IS A RISK OF EXPLOSION.
Place the station on a at surface and in sufcient lighting conditions; lock the front wheels
and do not subject them to vibration.
Further information regarding health and safety may be obtained from the refrigerant
manufacturer.
CAUTION : To prevent equipment damage,
NOTE (R1234yf only): To minimize the risk of ignition, the unit software guided leak check is pe-
riodically performed otherwise the unit will lock. For same purpose, also hardware features such
as ventilation fan monitoring system, suitably located vents on cart bottom (R1234yf is heavier
than air) and sealed power switching circuits are present.
CAUTION:Themachineisnotintendedtooperatewithoilsclassiedasammable
or hazardous according to EN 1272/2008 (CLP).

ACS 753, ACS 763, ACS 863 Service Manual
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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.
WARNING: Do not modify the pressure relief valve or change the control system
settings. Using the machine in a manner for which it was not designed will compromise
the machine and nullify the protections provided.
CAUTION: Check always the pressure gauges values to ensure that pressures are
maintainedwithinthelimitsspeciedinthe“Unitspecications”section.
Door switch
Door switch on service rear door disconnects electrical power to the unit when opened.
WARNING: Do not tamper the interlock switch. During normal operation, the rear
service door must always be closed and the above panel in place.
Refrigerant Tank Test
Ofcial 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 need maintenance. Refer to the Maintenance section of this
manual for more information.
Machine handling
The unit should normally be moved on at surfaces with a maximum slope of 15 ° and on the four
wheels, avoiding excessive shaking. When stopped then the brake on the front wheels must be
inserted. On slightly irregular surfaces, the unit can be moved by keeping it slightly inclined and
grounded on the two rear wheels by making sure to have a rm grip on the rear handle.
CAUTION: Although heavier components of the unit are installed on the bottom of
the unit in order to lower as much as possible the center of gravity, it’s however not
completely removed the risk of overturning.

ACS 753, ACS 763, ACS 863 Service Manual
SP00D00609 2018-03-26 Robert Bosch GmbH
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Introduction
In 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 ...........................................................................................................................14
Filter Maintenance ..........................................................................................................15
  InternalRefrigerentIdentierMaintenance(ACS863only) .......................................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Specications ............................................................................................20
Maintenance Schedule......................................................................................22

ACS 753, ACS 763, ACS 863 Service Manual
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Introduction
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 specications for recycled
refrigerant. Follow recommended service procedures for the containment of refrigerant.
Each unit includes a high-vacuum pump for fast, thorough evacuation. The compressor rst pulls
the A/C system to -0.4 bar; the compressor then works with the vacuum pump to pull a vacuum
to an absolute pressure of less than 1.0 bar.
NOTE: Refrigerant systems require special oils. Refer to the A/C system manufacturer’s service
manual for oil specications.
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. Identier Filter
(ACS 863 only)
6. Master switch
7. Circuit breaker
8. Power supply socket
9. UV dye bottle
10.Fresh oil bottle 2 (POE)
11. Fresh oil bottle 1 (PAG)
12.Used oil bottle
13.Printer
14.Display and control panel (HMI)
15.N2H2 or N2 inlet port max 14 bar (1.4 MPa)
16.Flush port (high pressure*)
17.Flush port (low pressure*)
18.Service hose port (high pressure*)
19.Service hose port (low pressure*)
20.Contaminant recovery outlet port
(ACS 863 only)
21.Front wheels with locking brake
22.Rear wheels
23.Hoses wraping support
(*) max 25 bar (2.5 MPa)
Figure 1-1. Description of machine

ACS 753, ACS 763, ACS 863 Service Manual
SP00D00609 2018-03-26 Robert Bosch GmbH
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Introduction
Control Panel Functions
ARROW UP moves selection of a
menu item to the previous item.
ARROW DOWN moves selection of
a menu item to the following item.
ARROW RIGHT scrolls to next
screen.
ARROW LEFT scrolls to previous
screen.
SELECTION KEYS (function keys)
to select the functions shown on
display (bottom icons).
The input keys can be used to
enter letters, numbers and special
characters in the input boxes.
0...9
A...Z
Figure 1-2. Control Panel Keyboard
Refrigerant
Main Menu 09:36
V 076.026.050
Standby
3.544 kg
7.34 bar
205 ml
POE
205 ml
PAG
205 ml
Dye
Icon Legend
DATABASE supplies information
regarding charge capacity by vehicle
model.
AUTOMATIC activates a menu that
helps the user set up an automatic
recover / vacuum / leak test / charge
sequence.
RECOVER activates the 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 next screen
or step.
BACK to return to the previous
screen or step.
ON/OFF to enable or disable the
selected function.
OK to confirm, proceed or save
settings.
ESC to cancel the operation and
return to the previous function or the
Main menu.
UP to move menu selection upward.
DOWN to move menu selection
downward.
PRINT to perform a print.
BACKSPACE to erase the character
to the left of the cursor.
PAUSE to pause a process.
PLAY to resume a paused process.
RETRY to repeat the last step.
DELETE to delete a selected entry
from the memory of the machine.
WIFI indicates that the WiFi
connection is enabled.
BLUETOOTH indicates that the
Bluetooth connection is enabled.