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Bosch ACS 653 Repair Instruction
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Bosch ACS 653 Repair Instruction

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ACS 653 - ACS 653-P - ACS 663 - ACS 663-P
ACS 663-RI
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A/C Service Unit

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Summary of Contents for Bosch ACS 653

  • Page 1 ACS 653 - ACS 653-P - ACS 663 - ACS 663-P ACS 663-RI en Repair instruction A/C Service Unit...
  • Page 2 ACS 653, ACS 663 Service Manual Robert Bosch GmbH Franz-Oechsle-Straße 4 1119D-73201 Plochingen SERVICE: bosch.prueftechnik@bosch.com © Robert Bosch GmbH SP00D00624 2021-04-08 Robert Bosch GmbH...

  • Page 3: Table Of Contents

    ACS 653, ACS 663 Service Manual Table of Contents Safety Warnings ....................4 Protective devices ......................7 Door switch ........................7 PED directive 2014/68/EU ....................7 Machine handling ......................7 Target group ........................8 Introduction ......................9 Introduction ........................10 Unit Specifications ......................

  • 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 653, ACS 663 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 663) or R134a (ACS 653) 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: Protective Devices

    • High pressure switch. • Recovery group. • Piping. Call Bosch service center to get technical specifications for each part listed. Machine handling The unit should normally be moved on flat surfaces with a maximum slope of 15 ° and on the four wheels, avoiding excessive shaking.

  • Page 8: Target Group

    ACS 653, ACS 663 Service Manual Target group Repair of the ACS 653, ACS 663 may only be performed by service technicians, trained in handling of refrigerants, personal protective equipment, refrigerant leakage prevention, handling of charging, leak detection and proper disposal.

  • Page 9: Introduction

    Introduction ACS 653, ACS 663 Service Manual I n troduct i o n Introduction .......................10 Control Panel Functions ....................11 Icon Legend ........................11 Glossary .......................... 12 Setup Menu ........................12 General Maintenance ..................... 15 Electrical Protection ....................... 15 Tank Fill ........................... 15 Filter Maintenance ......................

  • Page 10: Introduction

    Introduction ACS 653, ACS 663 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 11: Control Panel Functions

    Introduction ACS 653, ACS 663 Service Manual 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.

  • Page 12: Glossary

    • Select Functions to access the following refrigerant disposable capacity of 17.4 kg, functions. except the ACS 653 has a disposable capacity of 19.4 kg. A/C Perfomance Test Machine: Model No. ACS 653 or ACS 663.
  • Page 13 Select a language for screen prompts. English To upgrade the firmware through a USB stick or is the default language. via WiFi (with Bosch WiFi dongle - optional -). Select Units The display shows five selection options: Program the machine to display metric or √...
  • Page 14 Introduction ACS 653, ACS 663 Service Manual WiFi Configuration Pump Maintenance To configure the WiFi connection to the machine. Displays the amount of time remaining until The display shows five selection options: the next vacuum pump oil change is needed.

  • Page 15: General Maintenance

    Introduction ACS 653, ACS 663 Service Manual General Maintenance 8. Select OK icon to start the tank fill process. 9. The machine (for ACS 663-RI only) checks Do not use abrasive cleaning agents, solvents the refrigerant in the source tank to verify (petrol, diesel, etc.) and coarse workshop cloths...

  • Page 16: Filter Maintenance

    Introduction ACS 653, ACS 663 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 17: Internal Refrigerent Identifier Maintenance (For Acs 663-Ri Only)

    Introduction ACS 653, ACS 663 Service Manual Internal Refrigerent Identifier LED legend of the refrigerant identifier Maintenance (for ACS 663-RI only) Working status A refrigerant identifier samples refrigerant Flashing Red Warm up phase going into the ISV to verify it is R1234yf and...

  • Page 18: Edit Print Header

    Introduction ACS 653, ACS 663 Service Manual Edit Print Header 12. Slowly add vacuum pump oil to the pump through the oil fill port until the oil reaches To make changes to the printer text (available the center of the sight glass (1).

  • Page 19: Calibration Check

    This procedure should be repeated at regular internal scale is always calibrated. To perform intervals, as it allows to correct any zero offsets this check make use of Bosch calibration kit in the oil drain scale. (optional) including sample weight and magnet.

  • Page 20: Pressure Decay Leak Test (For R1234Yf Only)

    Introduction ACS 653, ACS 663 Service Manual Pressure Decay Leak Test Lockout (for R1234yf only) Never leave the machine live if an immediate use is not scheduled. To ensure that unauthorized This function is available on Maintenance menu. personnel cannot run the machine, use the To ensure a safe, environmentally friendly, Lockout as shown in Figure 1-10.

  • Page 21: Printer Kit Installation (Act1234-Pik)

    Introduction ACS 653, ACS 663 Service Manual Printer kit installation (ACT1234-PIK) 4. Remove the control panel (2) of the unit to have access inside. WARNING: Disconnect the unit from 5. Connect the RS232 cable (4) and the power the power source before beginning supply cable (5) to the suitable connectors service work.
  • Page 22 Introduction ACS 653, ACS 663 Service Manual 11. Remove the brass cap from the manifold (7) and place the solenoid body (6). Tighten at 9 Nm torque. 12. Tighten the solenoid coil (6) at 4 Nm torque. 13. Fix the refrigerant identifier (12) by 2 screws as per Figure 1-14.

  • Page 23: N2H2 Manifold Kit Installation (Act1234-Nik)

    Introduction ACS 653, ACS 663 Service Manual 27. Switch on the machine. 28. Call up the Main Menu. 29. Select NEXT icon. 30. Select MENU icon. 31. Select Maintenance Service menu " " Identifier Type and Internal Identifier 32. Select Maintenance "...

  • Page 24: Calibration Check Kit Installation (Optional)

    Introduction ACS 653, ACS 663 Service Manual Figure 1-18. N2H2 Manifold hoses connection 13. Close the service rear door. 14. Reinstall the plastic frontal cover and fix it by 6 screws (1) and the 2 ones (2) (see Figure 1-16).

  • Page 25: Refrigerant R134A To R1234Yf Conversion Kit

    Introduction ACS 653, ACS 663 Service Manual Refrigerant R134a to R1234yf NOTE: In case of recovery machine without deep-recovery capabilities, perform vacuum for conversion kit definitive emptying. WARNING: Disconnect the unit from the power source before beginning 8. Disconnect the recovery machine and service work.
  • Page 26 Introduction ACS 653, ACS 663 Service Manual 17. Remove the service hoses with quick couplers. 18. Remove the front plastic cover. Figure 1-22. Air Flow Sensor (1 of 2) Figure 1-21. Ports assembly -Unit outside view- 19. Remove the HP (red) and LP (blue) flush ports.
  • Page 27 Introduction ACS 653, ACS 663 Service Manual 34. Remove the cap (13) and the visible screw 44. Follow the instructions on display to replace from the hole (see Figure 1-23). filter (refer to “Filter Maintenance” in the 35. R e m o v e t h e c o n t r o l p a n e l ( 1 4 ) Maintenance section) and vacuum pump oil (see Figure 1-23).

  • Page 28: Unit Specifications

    Introduction ACS 653, ACS 663 Service Manual UNIT SPECIFICATIONS ACS 663 ACS 663-RI ACS 653 Refrigerant R1234yf R1234yf R134a ISV total capacity 22 l 22 l 22 l (water capacity) Internal Vessel Maximum 19.655 kg of R1234yf 19.655 kg of R1234yf 21.671 kg of R134a...
  • Page 29 Introduction ACS 653, ACS 663 Service Manual ACS 663 ACS 663-RI ACS 653 N2H2 Optional Optional Optional Wireless Optional with Wifi/BT Optional with Wifi/BT Optional with Wifi/BT usb dongle usb dongle usb dongle External source cylinder R1234yf LS MALE R1234yf LS MALE...

  • Page 30: Maintenance Schedule

    Introduction ACS 653, ACS 663 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 68 kg (alert 56 kg)

  • Page 31: Diagnostics And Testing

    Diagnostics and Testing ACS 653, ACS 663 Service Manual D i a g n o s t i c s and Testing Functional Check ......................32 Updating System Software Instruction ................32 Recover Function ....................... 33 Charge Function ......................... 34 Diagnostics and Testing .....................

  • Page 32: Functional Check

    Diagnostics and Testing ACS 653, ACS 663 Service Manual FUNCTIONAL CHECK Prior to performing a functional or diagnostic 14. The unit will go through a file updating period check, make sure the software version is (it can take several minutes) to finalize the current.

  • Page 33: Recover Function

    Diagnostics and Testing ACS 653, ACS 663 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 34: Charge Function

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Machine is asking to input: Charge Function • Oil inject (Yes or No). If select No unit don’t inject any oil. 1. Connect (or verify) both service hoses to • Oil amount: xxx ml (is possible set as ml, the test tank and turn the quick couplers oz or lb).
  • Page 35 Diagnostics and Testing ACS 653, ACS 663 Service Manual 9. If the amount of refrigerant is sufficient 12. If the charge was cancelled, Charge to charge the system to completion, the complete will change to Charge cancelled display will show hoses compensation a...

  • Page 36: Diagnostics And Testing

    Diagnostics and Testing ACS 653, ACS 663 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 37: Calibrate Load Cells

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Calibrate load cell NOTE: DO NOT DISTURB unit during weight calibration. All units include load cell scales: ISV Load Cell and Drain Load Cell. After 5 seconds: ISV Load Cell Calibration 1.
  • Page 38 Diagnostics and Testing ACS 653, ACS 663 Service Manual 8. 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 39: Output Test

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Output Test OUTPUT TEST The Output Test checks the electrical outputs Tank liquid solenoid S22 from the power board and wiring harnesses to the various solenoids, fan, vacuum pump, Vacuum Pump and compressor.

  • Page 40: Input Test

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Input Test Calibrate air flow (for R1234yf only) The input test displays the current state of The air flow inside the unit must be present at the measurable parts of the unit such as the...

  • Page 41: A/C Unit Internal Clearing

    Diagnostics and Testing ACS 653, ACS 663 Service Manual A/C unit internal clearing 5. The vacuum pump should turn on and the time begins to count down. Process will stop The A/C unit internal clearing is used to early if sufficient vacuum level is achieved.

  • Page 42: End User Install

    Diagnostics and Testing ACS 653, ACS 663 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 43 Diagnostics and Testing ACS 653, ACS 663 Service Manual 7. Scroll to the next desired Maintenance Counter. If none is desired, select BACK icon to return to the Service Menu. The list of available items follows in the table: Display...

  • Page 44: Keypad Test

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Keypad Test Set Boot Mode The Keypad Test is used to determine if the Setting the Boot Mode makes it possible to keys on the control panel are functioning when boot into a mode other than Normal (default).

  • Page 45: Reset Board

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Reset Board Identifier Type (for R1234yf only) Unless absolutely necessary, resetting the It is used to set the internal or external refrigerant board is not recommended. Resetting the board identifer. will erase any calibration/customization and restore the factory defaults.

  • Page 46: Default Precharge Leak Test Time

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Default Precharge Leak Test Time Customer configuration The Default Precharge Leak Test Time is To set some special features requested by a editable. Default 5 min. specific customer or dealer. CAUTION: this time is editable to make...

  • Page 47: Depressurizing The Unit

    Diagnostics and Testing ACS 653, ACS 663 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 48: Troubleshooting

    Diagnostics and Testing ACS 653, ACS 663 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 49: Will Not Power-Up, No Display

    Diagnostics and Testing ACS 653, ACS 663 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 50: Will Not Fill Tank

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Will Not Fill Tank Stuck In Clearing NOTE: The compressor should be running NOTE: The recover process begins with during this test. If it does not run, refer to low-side clearing. Low-side clearing activates...

  • Page 51: Will Not Recover

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Will Not Recover 10. Verify the oil drain solenoid isn’t leaking 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 52: Will Not Deep Recover

    Diagnostics and Testing ACS 653, ACS 663 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 damage or corrosion.

  • Page 53: Will Not Drain Oil

    Diagnostics and Testing ACS 653, ACS 663 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. 2. Is an Oil Drain Error Message displayed? •...

  • Page 54: Will Not Evacuate (Vacuum)

    Diagnostics and Testing ACS 653, ACS 663 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), clear during this test. If the pump does not run, hoses.

  • Page 55: Fails Leak Test

    Diagnostics and Testing ACS 653, ACS 663 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 injection bottles is imperative that a thorough recovery and are securely attached and contains an evacuation of the system be performed.

  • Page 56: Will Not Charge

    Diagnostics and Testing ACS 653, ACS 663 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 57: Will Not Print (Only For Variants With Printer)

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Will Not Print (only for variants with Replace the Printer Paper 1. Pull the cover open by inserting a finger into printer) the pocket in the cover and pull. 1. Does the printer have power? 2.

  • Page 58: Power Board Troubleshooting

    Diagnostics and Testing ACS 653, ACS 663 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 59: Compressor Troubleshooting

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Compressor Troubleshooting 8. Connect the unit to the power source. 9. Enter the service menu, scroll to the Output 1. Check for proper power source, circuit test and select the Compressor test.

  • Page 60: Vacuum Pump Troubleshooting

    Diagnostics and Testing ACS 653, ACS 663 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 61: Error Messages

    Diagnostics and Testing ACS 653, ACS 663 Service Manual ERROR MESSAGES PROCEDURE ERROR/WARNING DESCRIPTION OF ERROR/WARNING Calibrate Load Cells Calibration failed! Difference between upper and lower Slope is out of range. limits is too great. Select RETRY or ESC icon...
  • Page 62 Diagnostics and Testing ACS 653, ACS 663 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 63: Error Messages For Refrigerant Identifier (If Available)

    Diagnostics and Testing ACS 653, ACS 663 Service Manual Error messages for refrigerant identifier (if available) PROCEDURE ERROR/WARNING DESCRIPTION OF ERROR/WARNING Refrigerant Identification Identifier Unstable Reading Possible reasons: Error 1 1. Sampling path problem: • Brass filter clogged and/or sample hose clogged.
  • Page 64 Diagnostics and Testing ACS 653, ACS 663 Service Manual PROCEDURE ERROR/WARNING DESCRIPTION OF ERROR/WARNING Refrigerant Identification Identifier Unstable Reading Possible reason: Error 3 1. Radio transmitters and arc welders. Refrigerant Identification Identifier Air Calibration Error Possible reasons: 1. Sampling path problem: •...
  • Page 65 Diagnostics and Testing ACS 653, ACS 663 Service Manual PROCEDURE ERROR/WARNING DESCRIPTION OF ERROR/WARNING Refrigerant Identification Identifier Temperature Out of Possible reasons: Range 1. Ambient temperature below 10 °C. 2. Ambient temperature above 50 °C. Refrigerant Identification Identifier Pressure Out of...

  • Page 66: Electrical System Operation And Repair

    Electrical ACS 653, ACS 663 Service Manual Electrical System Operation and Repair Electrical System Operation .................67 Power Board and Power Supply Operation ..............67 Power Board Connector Assignments ................67 Control Board Operation ....................68 Control Board Connector Assignments ................68 Control Board Functions ....................

  • Page 67: Electrical System Operation

    Electrical ACS 653, ACS 663 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 and S17 operate effectively. The power board, power (is used on ACS 663-RI unit only).

  • Page 68: Control Board Operation

    Electrical ACS 653, ACS 663 Service Manual Control Board Operation Control Board Functions The Control Board, Figure 3-3, is mounted in 1. Reads Keypad the control panel and provides the control for • If a key does not respond, it’s most likely...

  • Page 69: Sensors And Transducers

    Electrical ACS 653, ACS 663 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 70 Electrical ACS 653, ACS 663 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 663-RI unit only.
  • Page 71 Electrical ACS 653, ACS 663 Service Manual ss01904 ISV TANK ISV TANK ACCUMULATOR TEMPERATURE PRESSURE PRESSURE SENSOR TRANSDUCER TRANSDUCER (TT) (TP) (AP) P7 P11 REFRIGERANT IDENTIFIER (ID) CONTROL BOARD AIR FLOW SENSOR (AF) LOW-SIDE PRESSURE OIL DRAIN SCALE TRANSDUCER LOAD CELL...
  • Page 72 Electrical ACS 653, ACS 663 Service Manual ss01905 S1 Air purge S22 Tank liquid INJECTION MANIFOLD S2 Oil inject 1 (PAG) S14 Oil inject 2 (POE) S15 Dye MAIN MANIFOLD POWER BOARD S3 Oil drain S4 Low-side inlet S5 High-side inlet...
  • Page 73 Electrical ACS 653, ACS 663 Service Manual ss01907 P7 P11 CONTROL BOARD PRINTER ASSEMBLY (if present) VACUUM PUMP POWER BOARD COMPRESSOR Figure 3-4. Electrical Connections (Sheet 4 of 4) Robert Bosch GmbH SP00D00624 2021-04-08...

  • Page 74: Electrical System Repair

    Electrical ACS 653, ACS 663 Service Manual ELECTRICAL SYSTEM REPAIR Replacement Power Board Remove Existing Power Board 1. Disconnect unit from the power source. WARNING: Disconnect the unit from 2. Open the service rear door. the power source before beginning 3.

  • Page 75: Replacement Control Board

    Electrical ACS 653, ACS 663 Service Manual Replacement Control Board Install Replacement Control Board NOTE: All control boards are shipped from the WARNING: Disconnect the unit from the factory without any software on board. Service power source before beginning service centers must follow these installation procedures work.

  • Page 76: Replacement High-Pressure Cut-Out Switch

    Electrical ACS 653, ACS 663 Service Manual Replacement High-Pressure Cut-Out 12. Unit ask for firmware update, press YES. 13. Unit ask to RESET the board erasing all the Switch data and calibrations stored, press YES and please wait. After that service routine starts WARNING: Disconnect the unit from the with required settings.

  • Page 77: Replacement Fan Assembly

    Electrical ACS 653, ACS 663 Service Manual Replacement Fan Assembly 12. Close the service rear door. 13. Connect the unit to a power source and WARNING: Disconnect the unit from place the power switch on. The fan should the power source before beginning run.

  • Page 78: Replacement Air Flow Sensor (For R1234Yf Only)

    Electrical ACS 653, ACS 663 Service Manual Replacement Air Flow Sensor 11. Close the service rear door. 12. Reinstall the plastic frontal cover. (for R1234yf only) 13. Connect the unit to a power source and WARNING: Disconnect the unit from place the power switch on.

  • Page 79: Replacement Scale Assembly

    Electrical ACS 653, ACS 663 Service Manual Replacement Scale Assembly Installing Replacement Scale Assembly 1. Install the scale into the unit fastening WARNING: Disconnect the unit from securely with four nuts. the power source before beginning 2. Connect the scale assembly wire to the service work.

  • Page 80: Replacing Load Cell

    Electrical ACS 653, ACS 663 Service Manual Installing the Load Cell ss01362 1. Connect the new load cell to the adapter block and secure in place with screws CBP8 (arrow going down see picture). 2. Be sure adapter or load cell don’t toching the external frame.

  • Page 81: Replacement Refrigerant Identifier (If Present)

    Electrical ACS 653, ACS 663 Service Manual Replacement Refrigerant Identifier (if present) WARNING: Disconnect the unit from the power source before beginning service work. Incorrect use or connections can cause electrical shock. WARNING: Wear safety goggles when working with refrigerants.
  • Page 82 Electrical ACS 653, ACS 663 Service Manual 14. Insert the rear cover so that the 4 holes on 7. Disconnect USB cable, power cable and the sides the cover fit into the 4 clips on the sample hose from refrigerant identifier (4).

  • Page 83: Plumbing And Mechanical System Operation And Repair

    Plumbing and Mechanical ACS 653, ACS 663 Service Manual Plumbing and Mechanical System Operation and Repair Plumbing and Mechanical System Operation ............84 Compressor ........................84 Vacuum Pump ........................84 Internal Storage Vessel (ISV) ..................... 84 Main Manifold ........................84 Cooling Fan ......................... 85 Injection Manifold .......................

  • Page 84: Plumbing And Mechanical System Operation

    Plumbing and Mechanical ACS 653, ACS 663 Service Manual PLUMBING AND MECHANICAL SYSTEM OPERATION Internal Storage Vessel (ISV) The plumbing and mechanical system is controlled by electrical impulses from The ISV stores the refrigerant from the the electrical system. There are four main...
  • Page 85 Plumbing and Mechanical ACS 653, ACS 663 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 86: Plumbing And Mechanical System Repair

    Plumbing and Mechanical ACS 653, ACS 663 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. IInstall the rubber mounts into the base of the power source before beginning the compressor.
  • Page 87 Plumbing and Mechanical ACS 653, ACS 663 Service Manual MAIN MANIFOLD ASSEMBLY ss01942 COMPRESSOR OIL DRAIN ASSEMBLY NOTES: 1. Apply Loctite 222 to equivalent to threads. 2. Torque hose fittings to 8.5 ±0.5Nm. Figure 4-1. Compressor Interconnection Diagram Robert Bosch GmbH...
  • Page 88 Plumbing and Mechanical ACS 653, ACS 663 Service Manual Replacement Vacuum Pump 5. Remove the two plastic lines from the vacuum pump. WARNING: Disconnect the unit from 6. Remove the four bolts fastening the vacuum the power source before beginning pump to the pump shelf.
  • Page 89 Plumbing and Mechanical ACS 653, ACS 663 Service Manual High-side gauge ss01943 Low-side gauge Main Manifold (Side View) ISV Assembly Liquid Vapor Main Manifold (Top View) Flush Manifold (Reference Only) Vacuum pump Injection Manifold (Reference Only) Figure 4-3. Plumbing Interconnection Diagram...
  • Page 90 Plumbing and Mechanical ACS 653, ACS 663 Service Manual Replacement ISV Assembly Installing Replacement ISV Assembly 1. Place the tank on the scale. WARNING: Disconnect the unit from 2. Secure the tank to the scale with two bolts. the power source before beginning 3.
  • Page 91 Plumbing and Mechanical ACS 653, ACS 663 Service Manual Replacement Main Manifold Removing Main Manifold 1. Clear service hoses and remove them. WARNING: Disconnect the unit from 2. Disconnect unit from the power source. the power source before beginning 3. Remove the front plastic cover.
  • Page 92 Plumbing and Mechanical ACS 653, ACS 663 Service Manual NOTE: All wires must be clear of moving parts, pinch points, and sharp edges. High Side Inlet Low Side Inlet Solenoid (S4) Solenoid (S5) Low Side Charge Solenoid (S7) High-Pressure Switch...
  • Page 93 Plumbing and Mechanical ACS 653, ACS 663 Service Manual Replacement Injection Manifold Installing the Injection Manifold 1. Install the injection manifold and secure with WARNING: Disconnect the unit from two screws. the power source before beginning 2. Connect all hoses to the injection manifold.
  • Page 94 Plumbing and Mechanical ACS 653, ACS 663 Service Manual Replacement Flush Manifold Installing the Flush Manifold 1. Install the flush manifold and secure with WARNING: Disconnect the unit from two screws. the power source before beginning 2. Insert the rear cover so that the 4 holes on service work.
  • Page 95 Plumbing and Mechanical ACS 653, ACS 663 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 96 Plumbing and Mechanical ACS 653, ACS 663 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 97: Component Application Charts

    4. Vacuum Process: The unit may purge air 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 653, ACS 663-RI and ACS 663 Function Component...
  • Page 98 Plumbing and Mechanical ACS 653, ACS 663 Service Manual Fluid Flow Diagram Locations Function Figure No. Tank Fill Low side Clearing Refrigerant Identification (for ACS 663-RI only) Recover 4-10 Deep Recover 4-11 Oil Drain 4-12 Vacuum 4-13 Vacuum Leak Test...

  • Page 99: Flow Diagrams

    Plumbing and Mechanical ACS 653, ACS 663 Service Manual FLOW DIAGRAMS TANK FILL PROCESS During the Tank Fill process the compressor, fan, HS and LS inlet solenoids, recover solenoid and oil return solenoid are activated (see application chart). The output state of the recovery solenoid is controlled to maintain 2.4 bar (35 psi) in the accumulator.
  • Page 100 Plumbing and Mechanical ACS 653, ACS 663 Service Manual LOW SIDE CLEARING PROCESS During the Low side Clearing process, the compressor is activated. The process continues until -0.45 bar (13 in Hg) is reached, plus 15 seconds. Figure 4-8. Low side Clearing...
  • Page 101 Plumbing and Mechanical ACS 653, ACS 663 Service Manual REFRIGERANT IDENTIFICATION PROCESS (for ACS 663-RI 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...
  • Page 102 Plumbing and Mechanical ACS 653, ACS 663 Service Manual RECOVERY PROCESS During the first stage of the recovery process, the fan, compressor, HS and LS inlet solenoids, recovery solenoid, oil return solenoid are activated (see application chart). Recover and oil return solenoids are activated intermittently.
  • Page 103 Plumbing and Mechanical ACS 653, ACS 663 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, vacuum and deep recover solenoids are activated. The output state of the oil return and recycle solenoids are controlled to maintain 0 to 207 mbar (3 psi) in the accumulator.
  • Page 104 Plumbing and Mechanical ACS 653, ACS 663 Service Manual OIL DRAIN PROCESS During the Oil Drain process, the unit pressurize the accumulator until 1.1 bar. Then oil drain solenoid opens and release pressure and oil (see application chart). The oil amount is measured by load cell.
  • Page 105 Plumbing and Mechanical ACS 653, ACS 663 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 106 Plumbing and Mechanical ACS 653, ACS 663 Service Manual VACUUM LEAK TEST PROCESS HS and LS 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 pressure rise within 5 minutes time, the vacuum leak test will fail..
  • Page 107 Plumbing and Mechanical ACS 653, ACS 663 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 before charge.
  • Page 108 Plumbing and Mechanical ACS 653, ACS 663 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, viscosity, type of oil wanted and the ambient temperature. The machine injects the oil automatically (with HP port only) adding the amount discharged with amount input by user.
  • Page 109 Plumbing and Mechanical ACS 653, ACS 663 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, viscosity, type of oil wanted and the ambient temperature. The machine injects the oil automatically (with HP port only) adding the amount discharged with amount input by user.
  • Page 110 Plumbing and Mechanical ACS 653, ACS 663 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 111 Plumbing and Mechanical ACS 653, ACS 663 Service Manual PRE-CHARGE PROCESS (for R1234yf only if enabled) During the pre-charge process (before to perform the charge), the unit charges a small amount of refrigerant in the A/C system and performs a pressure test to check any leaks.
  • Page 112 Plumbing and Mechanical ACS 653, ACS 663 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 113 Plumbing and Mechanical ACS 653, ACS 663 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 Robert Bosch GmbH...
  • Page 114 Plumbing and Mechanical ACS 653, ACS 663 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 and tank liquid solenoid are activated.
  • Page 115 Plumbing and Mechanical ACS 653, ACS 663 Service Manual PERIODIC LEAK TEST (for 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 116: Main Component Descriptions

    Parts and Components ACS 653, ACS 663 Service Manual MAIN COMPONENT DESCRIPTIONS 12V POWER SUPPLY— Provides 12 Volts FAN— Keeps the compressor from exceeding to power the circuit boards, all solenoids, and its normal operating temperature. The fan runs sensors requiring 12V power.
  • Page 117 Parts and Components ACS 653, ACS 663 Service Manual FLUSH MANIFOLD ASSEMBLY— Internal SOLENOID (S7), LOW-SIDE CHARGE— manifold assembly that serves as the attachment When energized, allows refrigerant from ISV to ports for the high- and low-side service hoses. enter low side of system being serviced.
  • Page 118 Parts and Components ACS 653, ACS 663 Service Manual S Y S T E M O I L S E PA R AT O R / H E AT TRANSDUCER, AIR PURGE— Measures the EXCHANGER— Heat exchanger with high-side pressure within the ISV.

  • Page 119: Notes

    Notes ACS 653, ACS 663 Service Manual Notes Robert Bosch GmbH SP00D00624 2021-04-08...
  • Page 120 Robert Bosch GmbH Automotive Service Solutions Franz-Oechsle-Straße 4 73207 Plochingen DEUTSCHLAND www.bosch.com bosch.prueftechnik@bosch.com SP00D00624 | 2021-04-08...

This manual is also suitable for:

Acs 653-pAcs 663Acs 663-pAcs 663-ri

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