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Bosch ACS 751 Repair Instructions

A/c service unit
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Summary of Contents for Bosch ACS 751

  • Page 1 ACS 651/751 en Repair instructions A/C service unit...

  • Page 2: Table Of Contents

    2 | ACS 751/651 | Contents English Panels Opening the top panel Important information Opening the front panel Opening the rear panel Testing and resources Opening the right panel Opening the left panel Description Replacing the front wheels ACS 651/751 Replacing the rear wheels 3.1.1...

  • Page 3: Acs 751/651 | 3

    | ACS 751/651 | 3 ACS 751/651 | 3 Compressor and fan 12.1 Replacing the compressor 12.2 Checking the compressor function 12.3 Replacing the fan assembly Replacing the wiring harness 13.1 Replacing the wiring harness 1 13.2 Replacing the wiring harness 2 13.3 Replacing the wiring harness 3...

  • Page 4: Important Information

    4 | ACS 751/651 | Important information Important information Testing and resources Installation and/or repairs may only be carried out by General tools for electricians and A/C mechanics trained and instructed Robert Bosch GmbH Digital multimeter customer service staff or organizations authorized by Loctite 577 for hoses Robert Bosch GmbH.

  • Page 5: Description

    Description | ACS 751/651 | 5 ACS 751/651 | 5 Description 3.1.2 Rear view ACS 751/651 3.1.1 Front view Fig. 2: Rear view 1 HMI support 2 Power switch 3 Left service hatch Fig. 1: Front view 4 Left panel...

  • Page 6: Components

    6 | ACS 751/651 | Description Components 3.2.2 Human Machine Interface (HMI) 3.2.1 Mounting place Fig. 4: ACS 751/651 HMI module 1 HP gauge 2 Status and warning light 3 LP gauge 4 LCD 5 Input keys 6 Selection and function keys 7 Printer Fig.

  • Page 7: Refrigerant Cylinder

    Description | ACS 751/651 | 7 ACS 751/651 | 7 3.2.3 Refrigerant cylinder 3.2.6 Compressor Fig. 5: Refrigerant cylinder overview Fig. 8: Compressor overview 3.2.4 Pressure manifold 3.2.7 Fig. 6: Pressure manifold overview 3.2.5 Vacuum pump Fig. 9: Fan overview Fig.

  • Page 8: I/O Board

    8 | ACS 751/651 | Description 3.2.8 Human Machine Interface board (main board) 3.2.9 board ACS-NP-IO-C-0030 Fig. 10: HMI Board (main board) 1 Connection to LCD 2 Coin battery CR2032 3 Connection to USB host (for firmware update) 4 Connection to LED Fig.

  • Page 9: Troubleshooting

    UV DYE RECHARGE UV DYE Bottle Not Found tle is disconnected, connect the bottle. R Check for blockage on the oil charge solenoid path. R Check for blockage in the ACS 751/651. 5001 R134a RECHARGE R Check if quick couplers are open.
  • Page 10 10 | ACS 751/651 | Troubleshooting Error code Messages Actions R Check the connection to high pressure switch 5004 R134a RECHARGE R Check if the connection to the blue valve on the cylinder is open. High Pressure shutdown R Check for blockage in the blue hose R Weight limit reached.
  • Page 11 Troubleshooting | ACS 751/651 | 11 ACS 751/651 | 11 | 11 Error code Messages Actions R Measure the resistance across 7602 UV Dye Sensor Connection Failed - Red-Black - Green-White If any of the two measurement shows inifinite resistance, change the load sensor.
  • Page 12 R Check if paper roll is present in the printer. If not, insert paper roll. 9600 PRINTER Out of paper To order printer paper, use the order number F 002 DG1 450. R Check for blockage in ACS 751/651. A101 INTERNAL BOTTLE FILL R Check R134a scale. Service Timeout...
  • Page 13 R Check the electrical connection between all the load sensors and I/O board. R Check if the vehicle A/C system is on. A601 REFRIGERANT TOP UP R Check for blockage in the ACS 751/651. Service Timeout R Check the refrigerant cylinder scale. R Check for blockage in the hoses...
  • Page 14 Refrigerant cylinder full erant in internal refrigerant cylinder. R Load cell is defective. Replace the load cell. R Check for leakage / blockage in the HP/ LP hoses of the ACS 751/651. D002 A/C PERFORMANCE TEST R Check if the quick couplers are connected properly to the ser- Service Timeout vice connections on the vehicle A/C system.

  • Page 15: By Symptoms

    Aspirated ambient air Inspect the vehicle A/C system and also the from the vacuum pump. ACS 751/651 for leaks and repair. Small quan- tities of smoke in the first few minutes of op- eration of the vacuum phase are permitted.

  • Page 16: Entering The Debug Mode

    1. Connect the power cable to the mains supply. Calibration of scales 2. Switch on the power supply. 3. Press the C key and power on the ACS 751/651. 4. Enter the password 33284. 5.1.1 Fresh Oil / used oil / UV dye scales 1.

  • Page 17: Calibration Of The Refrigerant Tank Scale

    Scales | ACS 751/651 | 17 ACS 751/651 | 17 | 17 ? The following screen is displayed. The calibrating weight has couplings on either ends (Fig.12). Depending on the sensor that is calibrated, the calibrating weight can be connected to any of the sensors.

  • Page 18: Replacing Scales

    18 | ACS 751/651 | Scales Replacing scales 5.2.1 Replacing used oil/fresh oil/ UV dye scale Fig. 14: Attaching the calibrating weight to the refrigerant cylinder 14. Select "Place Standard Calibration Weight". 15. Enter the value of the calibrating weight.

  • Page 19: Replacing Scale Assembly For Refrigerant Cylinder

    5. Lift the top panel up. 1. Remove the refrigerant tank from the mounting posi- tion (Chap. 8.1). 2. Place the cylinder outside the ACS 751/651 unit. Ensure the hydraulic connections are not strained or damaged. 3. Disconnect the electrical connections from the scale to the I/O board.

  • Page 20: Opening The Front Panel

    20 | ACS 751/651 | Panels Opening the front panel Opening the right panel 1. Apply the brakes. 1. Apply the brakes. 2. Switch off the ACS 751/651. 2. Switch the ACS 751/651 off. 3. Remove the top panel 3. Unfasten the knob screws on the service hatch and 4.

  • Page 21: Replacing The Front Wheels

    1. Switch off the ACS 751/651. Opening the HMI 2. Disconnect the mains supply. 3. Provide a support to the ACS 751/651 so that it is convenient to replace the front wheels. Danger - Electric shock hazard! 4. Unfasten the screws of the wheel stopper and re- Touching live parts on the power board move the wheel.

  • Page 22: Replacing The Lcd

    22 | ACS 751/651 | HMI module Replacing the LCD Replacing the printer 1. Open the HMI (chap. 7.1). 2. Undo all the electrical connections to the HMI board. 3. Unfasten the HMI board 4. Remove the HMI board from its position.

  • Page 23: Replacing The Keypad

    7. Connect the hoses back to the gauges. 8. Close and Fix the HMI module back in position. 9. Start the ACS 751/651 in debug mode (Chap. 4.3). 10. Select Actuators and press E. 11. Select RE, HL and LP and press .

  • Page 24: Boards

    24 | ACS 751/651 | Boards Boards Replacing the I/O board Replacing the HMI board Danger - Electric shock hazard! Touching live parts of the power switch or Danger - Electric shock hazard! on the power board can result in serious Touching live parts of the power switch or injury or death.

  • Page 25: Refrigerant Cylinder

    Refrigerant cylinder | ACS 751/651 | 25 ACS 751/651 | 25 | 25 Refrigerant cylinder 20. Start the ACS 751/651 in the debug mode (Chap. 4.3) Replacing the refrigerant cylinder 21. Calibrate the scale of the refrigerant tank (Chap. 5.12).

  • Page 26: Replacing The Air Purge Manifold On The Cylinder

    6. Connect the LP hose from manifold to the external cylinder and open the LP valve on the external cylin- der. 7. Start the ACS 751/651 in debug mode. 8. Select CTRL, RE, HL, IN, CX and FA. 9. Monitor the PST (mbar) and R134a (g) values.

  • Page 27: Replacing The Temperature Sensor On The Cylinder

    LP (blue) valve on the external cylinder. 8. Start the ACS 751/651 in debug mode. 9. Select CTRL, RE, HL, IN, CX and FA. 10. Monitor the PST (mbar) and R134a (g) values.

  • Page 28: 10. Pressure Manifold

    28 | ACS 751/651 | Pressure Manifold 10. Pressure Manifold cylinder and the pressure manifold 10.1 Replacing the valve block of the pres- Warning - Danger of frostbite! sure manifold During repair work on the ACS 751/651 refrigerant in liquid or gaseous form can 1.

  • Page 29: Replacing The Poe Solenoid Valve

    8. Connect the power cable to the mains supply. 9. Switch on the ACS 751/651 in the debug mode. 10. Select "Actuators" and press E Ensure that the O-rings used for connecting the hoses are properly placed before connecting the hoses.

  • Page 30: Replacing The Poe Plug

    30 | ACS 751/651 | Vacuum pump 11. Vacuum pump 10.4 Replacing the POE plug 11.1 Replacing the vacuum pump This procedure is applicable only to the ACS 751/651 with POE option. Warning - Danger of burns! 1. Switch off the ACS 751/651.

  • Page 31: Checking The Vacuum Pump Function

    1. Connect the power cable to the mains supply. 12.1 Replacing the compressor 2. Switch on the ACS 751/651 in the debug mode. 3. Select "Actuators" and press E. 4. Select VISO and VC. 5. Observe the value of PSV for one minute.

  • Page 32: Checking The Compressor Function

    32 | ACS 751/651 | Compressor and fan 12.3 Replacing the fan assembly 15. Complete the electrical connections. 16. Close the rear and left panel. 17. Check the compressor (Chap. 11.2). 1. Switch off the ACS 751/651. 2. Disconnect the mains connection.

  • Page 33: Replacing The Wiring Harness

    Replacing the wiring harness | ACS 751/651 | 33 ACS 751/651 | 33 | 33 13. Replacing the wiring 16. Connect the cable B9 to the pressure switch on the harness manifold. 17. Place the cord relief by loosening the 2 screws.

  • Page 34: Replacing The Connecting Cable For The Temperature Sensor

    34 | ACS 751/651 | Replacing the wiring harness 13.4 Replacing the wiring harness 4 7. Place the new wiring harness in position. 8. Fix the cable to X8 and X9 connectors on I/O board. Power supply I/O board to HMI board 9.

  • Page 35: 14. Replacing Hoses

    9. Connect the other end of the PA11 hose to the mani- Touching live parts of the power switch or fold. on the power board can result in serious 10. Switch on the ACS 751/651 in the debug mode. injury or death. ¶ Do not touch any live parts.

  • Page 36: 15. Replacing Power Supply

    36 | ACS 751/651 | Replacing Hoses 15. Replacing power supply 14.3 Replacing the PA12 hose for the vacuum pump 15.1 Replacing the cable socket 1. Perform hose drain. 2. Switch off the ACS 751/651. 1. Switch off the ACS 751/651.

  • Page 37: 16. Test Points

    Test Points | ACS 751/651 | 37 ACS 751/651 | 37 | 37 16. Test Points HMI board Test point name Expected voltage (V) Remarks Minimum Typical Maximum 11.4 12.6 If the voltage is out of range, check the SMPS.

  • Page 38: 17. Hydraulic Circuit Diagram

    38 | ACS 751/651 | Hydraulic circuit diagram 17. Hydraulic circuit diagram Applicable only for POE option UV DYE CHARGE SEPARATOR COMBO FILTER HEATED SUCTION COUPLING ACCUMULATOR COMPRESSOR HIGH CXOL VISO CTRL OIL DRAIN VACUUM PUMP PRIN ORIFICE To atmosphere...

  • Page 39: 18. Electrical Terminal Diagram

    Electrical terminal diagram | ACS 751/651 | 39 ACS 751/651 | 39 | 39 18. Electrical terminal diagram Lout Fig. 36: Electrical terminal diagram ACS 751/651 Robert Bosch GmbH 1 689 975 223 2013-10-21...
  • Page 40 Robert Bosch GmbH Franz-Oechsle-Str. 4 73207 Plochingen DEUTSCHLAND www.bosch.com AADG.Service@in.bosch.com 1 689 975 223 | 2013-10-21...

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Acs 651

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