ACS 753 - ACS 763 - ACS 863: A/C Service Unit

ACS 753 - ACS 763 - ACS 863
en Repair instruction
A/C Service Unit
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 2 Robert Bosch GmbH

Table of Contents
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................................................................................................... 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
Robert Bosch GmbH 3 SP00D00609 2018-03-26

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.
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.

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. 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 overfill the internal

storage vessel (ISV), because overfilling may cause explosion resulting in personal injury
or death. Do not recover refrigerants into a nonrefillable container; use only type-approved
refillable 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 flammable substances.
TO REDUCE THE RISK OF FIRE, do not use an extension cord. An extension cord may
overheat and cause fire. 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 flames 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 classified zones
or areas. Protect the machine from conditions that may cause electrical failure or other
hazards relating to ambient interaction.

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 fire 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.
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 classified as flammable
or hazardous according to EN 1272/2008 (CLP).
CAUTION : To prevent equipment damage,

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 flat surface and in sufficient 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.
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 specified in the “Unit specifications” 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

Official 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 flat 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 firm 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.

Introduction ACS 753, ACS 763, ACS 863 Service Manual
I n troducti 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 Identifier Maintenance (ACS 863 only)V�� 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 Specifications.............................................................................................20

Maintenance Schedule.......................................................................................22

ACS 753, ACS 763, ACS 863 Service Manual 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 specifications 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 first 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 specifications.
1 23
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14
16
13 4 23 17
12 18
11 5
10 19
9 6
20
7
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21
22
Figure 1-1. Description of machine
1. Gauge low pressure (LP) 15. N2H2 or N2 inlet port max 14 bar (1.4 MPa)
2. Visual alert 16. Flush port (high pressure*)
3. Gauge high pressure (HP) 17. Flush port (low pressure*)
4. 2 x USB 2.0 slot 18. Service hose port (high pressure*)
5. Identifier Filter 19. Service hose port (low pressure*)
(ACS 863 only) 20. Contaminant recovery outlet port
6. Master switch (ACS 863 only)
7. Circuit breaker 21. Front wheels with locking brake
8. Power supply socket 22. Rear wheels
9. UV dye bottle 23. Hoses wraping support
10. Fresh oil bottle 2 (POE) (*) max 25 bar (2.5 MPa)
11. Fresh oil bottle 1 (PAG)
12. Used oil bottle
13. Printer
14. Display and control panel (HMI)

Control Panel Functions Main Menu

Standby
09:36
V 076.026.050
3.544 kg
ARROW UP moves selection of a Refrigerant
7.34 bar
menu item to the previous item. PAG POE Dye

205 ml 205 ml 205 ml
ARROW DOWN moves selection of

a menu item to the following item.
ARROW RIGHT scrolls to next
screen.
Figure 1-2. Control Panel Keyboard
ARROW LEFT scrolls to previous
screen. NEXT to move to the next screen
SELECTION KEYS (function keys) or step.
to select the functions shown on BACK to return to the previous
display (bottom icons). screen or step.
0...9 The input keys can be used to ON/OFF to enable or disable the
A...Z enter letters, numbers and special selected function.
characters in the input boxes.
OK to confirm, proceed or save
settings.
Icon Legend
ESC to cancel the operation and
DATABASE supplies information return to the previous function or the
regarding charge capacity by vehicle Main menu.
model.
UP to move menu selection upward.
AUTOMATIC activates a menu that
helps the user set up an automatic DOWN to move menu selection
recover / vacuum / leak test / charge downward.
sequence. PRINT to perform a print.
RECOVER activates the sequence
to recover refrigerant from the vehicle BACKSPACE to erase the character
A/C system. to the left of the cursor.
VACUUM activates the sequence PAUSE to pause a process.

that pulls a deep vacuum on the
vehicle A/C system to remove air PLAY to resume a paused process.
and moisture.
CHARGE activates the sequence RETRY to repeat the last step.
that charges the vehicle A/C system
with a programmed amount of DELETE to delete a selected entry
refrigerant. from the memory of the machine.
HELP displays information related to WIFI indicates that the WiFi

the current display. connection is enabled.
MENU accesses additional functions BLUETOOTH indicates that the

and parameters. Bluetooth connection is enabled.

HS LS to set which side to charge Setup Menu
thru (high pressure, low pressure or The machine launches into the initial Setup
both sides). mode (the first time the machine is powered up).
ml oz to set the unit of measurement NOTE: It is needed to complete all the setup
(ml or oz). procedure sequence before to use the A/C unit.
kg oz lb to set the unit of measurement Carry out the following setup:

(kg, oz or lb). 1. Language selection.
2. License agreement review.
USB to export data onto a USB key. 3. Units (Metric/Imperial) selection.
4. Date and Time adjustment.
5. Print Header Editor.
Glossary 6. Identifier setting (ACS 763 only).
7. Service Vacuum.
A/C System: The vehicle air conditioning 8. Internal Tank Fill.
system being serviced. At the end of the initial setup procedure it is
suggested to:
Evacuation: Moisture and other incondensables
• Perform check scale.
are removed from an A/C system by using a
• Perform air flow calibration.
vacuum pump.
Functions Menu
Internal Storage Vessel (ISV): The tank
designed specifically for this machine has 1. Call up the Main Menu.
refrigerant disposable capacity of 17.4 kg, 2. Select NEXT icon.
except the ACS 753 have a disposable capacity 3. Select MENU icon.
of 19.4 kg. • Select Functions to access the following
functions.
Machine: Model No. ACS 753, ACS 763 or
ACS 863. A/C Perfomance Test
Performs a pressure test on an A/C system of
PAG/POE: Different oil types in the vehicle air- a vehicle with a refrigerant already present.
conditioning system depending on the vehicle N2H2 or N2 Test
manufacturer. To search the leaks of the A/C system of a ve-
Recovery/Recycling: Refrigerant is recovered hicle by means of an external bottle of Nitrogen
from an A/C system, filtered, and stored in the or a mixture of nitrogen and hidrogen.
ISV. Flush Hoses
Flushes residual oil from the machine to pre-
Refrigerant: R134a (ACS 753) or R1234yf.
pare for the service of next vehicle.
Source (or External Tank): A disposable tank System Flush
of new refrigerant used to refill the ISV; not Provides a method of removing oil and impu-
included. rity by forcing liquid refrigerant through an A/C
system or components of an A/C system. After
flushing, the refrigerant is recovered by the
machine and filtered by the recycling circuit.
Tank Fill
Use this function to transfer refrigerant from a
source tank to the ISV. The tank fill value may
be adjusted up or down to suit the user’s needs.
Refer to Tank Fill in the Maintenance section.

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.
Refrigerant Tracking Refrigerant Identifier (ACS 763 only)
Function to memorize the refrigerant amount To enable or disable the purity test of the
recovered and charged for every vehicle. The external refrigerant identifier connected to the
display shows five selection options: USB port of the machine. The display shows
√√ Display: to show data of recovered and three selection options:
charged refrigerant. √√ Always display identifier prompts: Dis-
√√ Export to USB: to extract the report with plays the steps required to perform the
recovered and charged refrigerant amount purity test.
in the vehicle. Data extraction via USB √√ Skip display identifier prompts: Not
stick, recommended size 2 GB and FAT displays the steps required to perform the
format (support is not part of scope deliv- purity test.
ery). Data are transferred as .csv file. √√ Ask user to connect identifier: Ask a
√√ Erase all records: to erase all data stored user, with a special message, to confirm
on the machine. whether or not to perform the purity test.
√√ Print all records: to print all data stored
on the machine. Default Vacuum Leak Test Time
√√ Disable Tracking: to disable the Refriger- Program the machine to change duration of the
ant tracking function. vacuum leak test time.
Set Buzzer
• Select BACK icon to return to the Setup
Program the machine to turn the buzzer on or
Menu.
off.
Settings Menu
Firmware Update
• Select Settings to access the following To upgrade the firmware through a USB stick
functions. or via WiFi. The display shows three selection
options:
Select Language
Select a language for screen prompts. English √√ Check for Update: To check if new firm-
is the default language. ware updates are available.
√√ USB Update: To upgrade the firmware
Select Units
through a USB stick.
Program the machine to display metric or
√√ Wi-Fi Update: To upgrade the firmware
imperial values. The default display is in a
through a WiFi network. If the unit is con-
metric system.
nected to WiFi network and the WiFi net-
Date and Time work is connected to Internet, it will auto-
Program the machine for current date and time. matically start searching for new updates.
Edit Print Header
Programs information that will appear on the
printout each time a print function is used.
Unit Activation
Failure to register and activate the machine
within 30 days of initial startup will cause the
machine to lock out and not function. Select
this Settings Menu item and follow the prompts
before the trial period expires.

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.
√√ Search WiFi Networks: To search for For maximum vacuum pump performance,
available WiFi networks. change vacuum pump oil every time the
√√ WiFi status: To display some WiFi con- filter is replaced. Refer to the Vacuum Pump
nection data used. Maintenance in the Maintenance section.
√√ Test WiFi connection: to perform a WiFi ISV Purge Condition
network connection test used by the ma- Displays internal storage vessel (ISV) pressure
chine. and temperature. It is used to eliminate
√√ Disconnect current network: To disable incondensables gas and helps to limit the
the WiFi network connection stored on the pressure in the ISV.
machine. Calibration Check
Asanetwork Use to verify internal scale calibration. Refer to
To enable or disable the asanetwork function. Calibration Check in the Maintenance section
For further information contact Customer Ser- of this manual.
vice. Adjust Zero Offset
Connected Repair [CoRe] To reset the fresh oil PAG, fresh oil POE, used
To enable or disable the CoRe function. oil and UV dye scales.
For more information see Connected Repair Display Tittle Info
[CoRe] chapter on the user manual. To activate or deactivate the pressure and
• Select BACK icon to return to the Setup temperature values display of the machine.
Menu. System Information
Displays the revision level of the software in
Maintenance Menu
the unit.
• Select Maintenance to access the follow-
Service Menu
ing functions.
For service center use only.
Filter Maintenance Production Menu
The filter removes acid, particulates, and mois- For production use only.
ture from the refrigerant. To meet requirements,
it is mandatory to replace the filter after (SEE • Select BACK icon to return to the Setup
TABLE) of refrigerant has been filtered. Menu.
Model Replacement filter at: 68 kg

R134a (alert 56 kg)
Model Replacement filter at: 150 kg
R1234yf (alert 138 kg)
This menu item displays the filter capacity re-

maining until the machine locks down and no
longer functions. Refer to Filter Maintenance in
the Maintenance section.

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. Clean only using a soft is R1234yf and not contaminated. The
cloth and neutral cleaning agents. machine displays the following screens:
NOTE: In cases of refrigerant leaks, such INITIALIZING REFRIGERANT IDENTIFIER
as during installation, maintenance or repair ANALYZING REFRIGERANT SAMPLE
of machine, or even during normal use after REFRIGERANT PURITY PASSED
machine rest, there will be no refund by the 10. The machine begins filling the internal
manufacturer. storage vessel (ISV) and automatically
stops when the preset tank fill level is
CAUTION: Disconnect the power reached. To stop the tank fill before the
supply before any maintenance. preset level is reached, select PAUSE icon.
Electrical Protection
The machine is equipped with a circuit breaker
to the side of the machine below the ON/OFF
switch. If the breaker trips, its button will pop
out. A tripped circuit breaker will cause the
machine to lose all power. Press the circuit
breaker button to reset. If the circuit breaker
does not reset or continues to trip, there is a
fault in the unit electrical system. Troubleshoot
and repair the affected component(s). 1
Tank Fill
This menu (available on Function menu) is
Figure 1-3. Contaminant recovery outlet port
used to transfer refrigerant from a source tank
to the ISV. 11. Close the liquid valve and remove the hose
1. Call up the Main Menu. from the source tank.
2. Select NEXT icon. 12. Select OK icon to return to the Function
3. Select MENU icon. Menu.
4. Select TANK FILL from the Functions Operating Tips (ACS 863 only)
Menu. The machine displays:
1. If the machine displays
FILL AMOUNT: xx.xxyy
REPLACE IDENTIFIER FILTER
RECOVER CAPACITY: xx.xxyy
CHARGE CAPACITY: xx.xxyy • the refrigerant identifier filter must be
5. Enter the fill amount (at least 5 kg) to ensure replaced. Select OK icon to confirm, and
enough liquid refrigerant is available for refer to the Refrigerant Identifier chapter
charging and select OK icon. Unit is set of this manual for instructions.
with 2.2 kg dead space (first 2.2 kg are not 2. If the machine displays
shown on display anymore). If the source REFRIGERANT PURITY FAILED
tank is empty, or has insufficient refrigerant RECOVER CONTAMINATED
for transfer, tank fill will stop. REFRIGERANT FROM SYSTEM AND HOSES
6. Connect the low pressure service hose • the refrigerant in the source tank is either
(blue) to the liquid connector on a full source not R1234yf or it is contaminated. In either
tank. case, it should not be added to the internal
7. Position the source tank in such a way storage vessel in the machine. The refrig-
that liquid refrigerant is supplied to the erant purity is 95%.
connection. Open the source tank valve.
• 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. Remove the old filter (1) by turning it clock-
to remove the refrigerant sampled by the wise. Refer to Figure 1-4.
refrigerant identifier in the machine. 6. Look at the new filter. Verify both O-rings
Filter Maintenance are lubricated and correctly located in the
grooves as shown in Figure 1-5.
The filter is designed to trap acid and particulates, 7. Install the new filter by threading it counter-
and to remove water from refrigerant. To meet clockwise into place. Verify the filter is posi-
this mandate, the filter must be replaced after tioned correctly. Tighten the filter to 20 Nm.
(SEE TABLE) of refrigerant has been filtered. 8. Close the service rear door.
The unit gives a warning when (SEE TABLE) of 9. Switch on the machine.
the filter capacity has been used; the unit locks 10. Machine starts with vacuum pump oil
down when the (SEE TABLE) filter capacity has change (Refer to the “Vacuum Pump Main-
been reached and will no longer function. tenance” in this section).
11. Recycle the filter that was removed from
Check Remaining Filter Capacity the machine according to the laws in your
1. Call up the Main Menu. jurisdiction.
2. Select NEXT icon.
3. Select MENU icon. CAUTION: Use only authentic Bosch filters
4. Select Filter Maintenance from the in this machine. All performance tests and
Maintenance Menu or when the machine claims are based on using this specific filter.
prompts. The machine displays:
REMAINING FILTER CAPACITY: XXX.XYY Model Replacement filter at: 68 kg
REPLACE FILTER NOW? R134a (alert 56 kg)
• The machine displays amount of filter ca- Model Replacement filter at: 150 kg
pacity remaining until the machine locks R1234yf (alert 138 kg)
down. This message may occur at anytime
during the course of an A/C system main-
tenance action.
5. Select OK icon to change the filter; Select
ESC icon to resume using the machine.
Replace the Filter
1. If OK icon was selected to change the filter,
the unit will clear the filter, then prompts for
the new filter code to be entered: 1
ENTER NEW FILTER SERIAL NUMBER
NOTE: If SERIAL NUMBER WRONG is
displayed, the serial number has been incorrectly
entered or the filter has already been used in this
machine. Figure 1-4. Filter Location
2. Use the keypad to enter the serial number
that appears on the new filter and select OK O-rings
icon to continue.
• The machine clears the existing filter and
displays:
TURN POWER OFF
AND REPLACE FILTER Figure 1-5. O-ring Location

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.
not contaminated. Replace the sample hose 1. Call up the Main Menu.
assembly during every filter change and also if 2. Select NEXT icon.
prompted by an error message saying the hose 3. Select MENU icon.
is clogged. See Figure 1-6. 4. Select Pump Maintenance from the
1. Switch off the machine. Maintenance Menu or when prompted. The
2. Open the service rear door. display shows how long the vacuum pump
3. Remove the rear cover (above the service has operated since the last oil change.
door) by pushing it up and extract it by pull-
REMAINING OIL LIFE XXX:XX (hhh:mm)
ing it out.
CHANGE OIL NOW?
5. Select OK icon to change vacuum pump oil.
6. If the the machine displays:
WARMING OIL FOR DRAIN
• allow the vacuum pump to run for two
minutes to warm up the oil.
7. If the oil is already warm, the display shows:
DRAIN USED OIL FROM PUMP AND REPLACE
1 2 WITH 550 ML OF NEW OIL REMOVE CAP TO
Figure 1-6. Internal refrigerent identifier location SPEED DRAINING OF OIL
8. Switch off the machine.
4. Disconnect the existing sample hose as- 9. Open the service rear door.
sembly (2) between the rear side of the 10. Slowly open the oil fill port cover (2) to verify
manifold and the refrigerant identifier, and there is no pressure in the machine. Then
install a new sample hose assembly. If the carefully remove the cover. See Figure 1-7.
filter is any color but white, the filter must 11. Remove the oil drain fitting cap (3) and drain
be replaced. the oil into a suitable container for disposal.
5. Pull the filter barbs from the rubber hoses. Install the cap and close tightly.
Snap the filter (1) out of the clip. 12. Slowly add vacuum pump oil to the pump
6. Install a new filter with the arrow pointing through the oil fill port until the oil reaches
downward as shown on the refrigerant iden- the center of the sight glass (1).
tifier. Do not kink the rubber hoses. Push 13. Install the cap on the oil fill port and close
the rubber hoses back into the refrigerant tightly.
identifier housing until they are straight. 14. Close the service rear door.
7. Insert the rear cover so that the 4 holes on 15. Switch on the machine.
the sides the cover fit into the 4 clips on the 16. Select OK icon to continue.
machine. Push down to hook the rear cover. 17. The display show a message that indicate
8. Close the service rear door. to the user to check that the oil level is at
the center of the sight glass pump.
NOTE: In case it is necessary to add more oil,

repeat steps 8, 9, 10, 12, 13, 14 and 15 for
add oil.

18. Select ESC icon to return to the Mainte- Edit Print Header
nance Menu. To make changes to the printer text (available
in Setting menu) appearing in the header on
each printout:
1. Call up the Main Menu.
2. Select NEXT icon.
3. Select MENU icon.
4. Select Edit Print Header in the Settings
Menu. The cursor is in the first field.
5. Update the text by using the arrows and the
multi-tap interface on the numeric keypad:
2 • BACKSPACE icon acts as a backspace
key.
• Right or left arrow moves the cursor to the
3 1 right or to the left.
Figure 1-7. Oil Ports • Zero (0) key also acts as a spacebar.
• Up and Down arrows navigate between
the rows.
CAUTION: To prevent personal injury, 6. Select OK icon to save the changes and
do NOT operate the machine at any return to the Settings Menu.
other time without the oil fill port 7. Select ESC icon to exit and return to the
cap installed, because the vacuum Settings Menu.
pump is pressurized during normal Replace Printer Paper
operation. To install a new paper roll in the printer:
1. Remove the cover on the printer by pulling
NOTE: Review the laws and regulations in your out on the tab (2) as shown in Figure 1-8.
jurisdiction to determine correct disposal proce- 2. Remove the paper core.
dures for pump oil. It is the responsibility of the 3. Install the new roll of paper with the end of
user to determine if a material is a hazardous the paper at the top of the roll.
waste at the time of disposal. The user must 4. Assemble the cover onto the printer with the
ensure compliance with all applicable laws and leading edge of the paper over the roller (1).
regulations.
Figure 1-8. Replace Print Paper

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.
with the machine. 1. Call up the Main Menu.
1. Verify the magnet on the bottom of the ma- 2. Select NEXT icon.
chine is clean. Refer to Figure 1-9. 3. Select MENU icon.
2. Call up the Main Menu. 4. Select Adjust Zero Offset from the Main-
3. Select NEXT icon. tenance Menu.
4. Select MENU icon. 5. Select the scale type to reset and confirm
5. Select Calibration Check from the Mainte- with OK icon.
nance Menu. The machine displays: 6. A message appears on the display to re-
PLACE CALIBRATION WEIGHT ON MAGNET move the oil bottles and/or the UV dye bottle
LOCATED ON THE BOTTOM OF MACHINE (according the selected scale type).
7. Carefully remove the bottle shown on the
6. Attach the calibration weight to the magnet display.
(1) on the bottom of the machine.
7. Select OK icon to continue. NOTE: To remove the “PAG”, “POE” and “UV
Dye” bottles, you must pull the lever on the
ALERT: Unit shown “Reading, do not colored covers of the bottles slightly to unlock
disturb”. and pull them outward. Instead to remove the
oil drain bottle it is enought pulling it straight
The machine displays: outwards.
REMOVE CALIBRATION WEIGHT
FROM MAGNET LOCATED ON THE BOTTOM 8. Select OK icon to confirm and reset the
OF MACHINE selected scale.
9. Repeat the same procedure to reset the
8. Remove calibration weight from magnet other scales.
located on the bottom of machine. 10. Zero position of the 4 scales will be set.
9. Select OK icon to continue.
ALERT: Do not touch the unit in this
phase!
• If the display shows Calibration passed
the scale is calibration. Select OK icon to
return to the Maintenance Menu.
• If the display shows Calibration failed the
scale is out of calibration. Select RETRY
icon to retry. If calibration continues to fail,
contact an authorized service center for
assistance.
Figure 1-9. Magnet Location

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-
and economic operation, the unit performs a ized personnel cannot run the machine, use the
ghi
abc
def
software-controlled self-test in regular intervals Lockout as shown in Figure 1-10.

jkl
mno
pqrs
tuv
wxy
z
every 10 days (for R1234yf only). 1. Turn the Lockout lever (1) counterclockwise
1. Follow the on-screen prompts to connect (CCW).
the hose service couplers to the storage 2. Insert a padlock or other item through the
connectors on the side of the machine. aligned holes so the lever cannot be turned
Open the hose couplers by turning the col- clockwise (CW) to start the machine.
lars clockwise.
2. Select OK icon to start the test.
3. The machine performs a self-recovery and 1
displays:
RECOVER IN PROGRESS
4. The machine performs a 30-second vacuum
test and displays:
VACUUM CHECK IN PROGRESS
• If the vacuum test fails, the machine will
prompt to check for leaks.
5. Once the machine passes the vacuum test, Figure 1-10. Lockout
a controlled pressure is applied to its internal
components. The machine displays:
PRESSURE CHECK IN PROGRESS
6. Pressure is held for five minutes and moni-
tored for decay. Minutes and seconds count
down on the display.
• If an acceptable pressure decay is de-
tected, the machine recovers refrigerant
and returns to the Functions Menu, ready
for normal operation.
• If an unacceptable pressure decay is de-
tected, the machine will prompt to check for
leaks. Take the machine to an authorized
service center for repair.
NOTE: Leak Check may also be selected at

any time from the Functions Menu. If you de-
cline to run the Leak Check when prompted,
the machine will continue to prompt for the test
at each power-up until the test is completed
(for R1234yf only).

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
Storage Capacity (kg of (17.4 kg manageable (17.4 kg manageable (19.4 kg manageable
refrigerant) by operator) by operator) by operator)
Fluid Maximum Working 25 bar (2.5 Mpa) 25 bar (2.5 Mpa) 25 bar (2.5 Mpa)
Pressure (PS)
Fluid Operating Tempera- -10 °C ÷ +120 °C -10 °C ÷ +120 °C -10 °C ÷ +120 °C
ture Range (TS)
Maximum Recovery Speed - - -
(liquid phase)
Overall Leak Rate <80g/year <80g/year <80g/year
Power Supply 230 Vac/1 50/60 Hz 230 Vac/1 50/60 Hz 230 Vac/1 50/60 Hz
Overvoltage category II II II
Power Consumption 1100 W 1100 W 1100 W
Unit Storage Temperature -20 °C ÷ +60 °C -20 °C ÷ +60 °C -20 °C ÷ +60 °C
Range
Unit Operating Tempera- +10 °C ÷ +50 °C +10 °C ÷ +50 °C +10 °C ÷ +50 °C
ture Range
Humidity (non-condensing) 32.2°C (90°F), 86% 32.2°C (90°F), 86% 3°C (90°F), 86% RH
RH RH
Maximum Altitude 2000 m (6561.66 ft) 2000 m (6561.66 ft) 2000 m (6561.66 ft)
IP Protection Rating IP20 IP20 IP20
Pollution dregree 2 2 2
Noise <70 dB(A) <70 dB(A) <70 dB(A)
Dimensions 105 x 75 x 77 cm 105 x 75 x 77 cm 105 x 75 x 77 cm
with HMI on shipping with HMI on shipping with HMI on shipping
position position position
Weight 112 kg 112 kg 112 kg
(empty tank + accessories)
Display 7in. TFT WVGA 7in. TFT WVGA 7in. TFT WVGA
(800x480) color LCD (800x480) color LCD (800x480) color LCD
with LED backlight with LED backlight with LED backlight
Filter 700 cc dessicant 700 cc dessicant 700 cc dessicant
Manometer Ø 100 mm Ø 100 mm Ø 100 mm
EN 837-1 Class 1 EN 837-1 Class 1 EN 837-1 Class 1
Bottles (Oils and Dye) 3 x 250 ml 3 x 250 ml 3 x 250 ml
sealed sealed sealed
Service hoses 250 cm / SAE J2888 250 cm / SAE J2888 250 cm / SAE J639
Quick Couplers For R1234yf, For R1234yf, For R134a,
SAE J2888 SAE J2888 SAE J639

ACS 763 ACS 863 ACS 753

Flush Port Yes Yes Yes
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 Yes, embedded port
for external tank for external tank for external tank
Wireless Wifi/BT usb dongle Wifi/BT usb dongle Wifi/BT usb dongle
into scope of delivery into scope of delivery into scope of delivery
External source cylinder 1234YF LS J639 1234YF LS J639 QUICK COUPLER
adapters MALE TO MALE TO FOR COMMERCIAL
W21.8-1/14LH W21.8-1/14LH TANK 1/4” SAE
ADAPTER ADAPTER
ADAPTER 1234YF ADAPTER 1234YF TANK ADAPTER

LS J639 MALE LS J639 MALE R134a - 21,8-14
M26.2x1.8 M26.2x1.8 G/1/4
ADAPTER 1234YF ADAPTER 1234YF

LS J639 MALE LS J639 MALE
12.7 mm ACME16 12.7 mm ACME16
Compressor
Power 1/4 HP 1/4 HP 1/4 HP
Displacement 8.85 cm3 8.85 cm3 8.85 cm3
Recovery performance - - -
(maximum, liquid phase)
Vacuum Pump
Free Air Displacement 170 l/min (6 CFM) 170 l/min (6 CFM) 170 l/min (6 CFM)
Ultimate Vacuum (min) 40 microns 40 microns 40 microns
Oil Capacity 700 ml 700 ml 700 ml
Type 2 stages oil bath 2 stages oil bath 2 stages oil bath
Scales
ISV scale accuracy ±15 g ±15 g ±15 g
Bottle scales accuracy ±2 g ±2 g ±2 g

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.
Change filter Model Replacement filter at:

R134a 68 kg (alert 56 kg)
Model Replacement filter at:
R1234yf 150 kg (alert 138 kg)
When the filter is replaced or every 100 hours.

Change vacuum pump oil Refer to Change Vacuum Pump Oil in the
Maintenance section of this manual.
Check casters and wheels for ease of
Monthly.
operation
Monthly. Refer to Calibration Check in the
Maintenance section of this manual. Every year
Check internal scale calibration
all scales must be calibrated by an authorized
service center.
Reset of PAG and POE Injection Oil, drain Whenever it is necessary. Refer to Scales Reset
oil and UV dye scales in the Maintenance section of this manual.
Automatic every 10 days (for R1234yf) or every
yearly (for R134a). Refer to Pressure Decay
Check machine for leaks
Leak Test in the Maintenance section of this
manual.
Clean air intake panels Monthly. Use a clean cloth.
Clean cabinet and control panel Monthly. Use a clean cloth.
Inspect power cord and hoses for cuts
Daily.
and abrasions
Lubricate wheel bearings and brake
Monthly.
components
Every yearly — performed by an authorized
Solenoid valves inspection
service center.
Check the internal refrigerant identifier
Daily.
filter (ACS 863 only)
Every six months or whenever it is dirty and / or
Change filter and sample hose of the clogged. Replace the sample hose assembly
internal refrigerant identifier (ACS 863 during every filter change. Refer to Refrigerant
only) Identifier Maintenance in the Maintenance
section of this manual.
Due to normal wear and tear, these units require regular maintenance to ensure safe operation
and optimum performance. The above chart provides a schedule of the minimum recommended
maintenance tasks.

ACS 753, ACS 763, ACS 863 Service Manual Diagnostics and Testing
D i a g n o s tic s and Testing

Functional Check...................................................................................................24
Updating System Software Instruction............................................................................. 24
Recover Function................................................................................................................ 25
Charge Function.................................................................................................................. 26
Diagnostics and Testing........................................................................................28
Service Center Menu........................................................................................................... 28
Diagnostics and Troubleshooting...................................................................................... 28
Calibrate Load Cells............................................................................................................ 28
Output Test........................................................................................................................... 32
Input Test.............................................................................................................................. 33
Calibrate air flow.................................................................................................................. 33
A/C unit Internal Clearing................................................................................................... 34
Service Vacuum................................................................................................................... 34
End User Install................................................................................................................... 35
Maintenance Counters........................................................................................................ 35
Keypad Test......................................................................................................................... 37
Set Serial Number................................................................................................................ 37
Set Manufacturing Date...................................................................................................... 37
Set Boot Mode..................................................................................................................... 38
Reset Board......................................................................................................................... 38
Refrigerant Identifier (ACS 863 only)C�� 39
Charge Leak Test................................................................................................................. 39
10 Days Leak Test (R1234yf only)...................................................................................... 39
Default Vacuum Time.......................................................................................................... 39
Default Vacuum Leak Test Time......................................................................................... 39
Default Precharge Leak Test Time..................................................................................... 39
Service hose length............................................................................................................. 39
Depressurizing the Unit.........................................................................................40
Unit is Functional................................................................................................................ 40
Unit is Not Functional......................................................................................................... 40
Troubleshooting.....................................................................................................41
Grounding, Noise, and Power Issues................................................................................ 41
Will Not Power-Up, No Display........................................................................................... 42
Will Not Fill Tank.................................................................................................................. 43
Stuck In Clearing................................................................................................................. 43
Will Not Recover.................................................................................................................. 44
Will Not Deep Recover........................................................................................................ 45
Will Not Drain Oil................................................................................................................. 46
Will Not Air Purge................................................................................................................ 46
Will Not Evacuate (Vacuum)............................................................................................... 47
Fails Leak Test..................................................................................................................... 48
Will Not Inject Oil or Dye..................................................................................................... 48
Will Not Charge.................................................................................................................... 49
Slow Charge......................................................................................................................... 49
Will Not Hose Flush............................................................................................................. 49
Will Not Print........................................................................................................................ 50
Power Board Troubleshooting........................................................................................... 51
Control Board Troubleshooting......................................................................................... 51
Compressor Troubleshooting............................................................................................ 52
Vacuum Pump Troubleshooting......................................................................................... 53
Error Messages......................................................................................................54
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. This is especially true if the control the entire update procedure, then will dis-
and/or power boards have been replaced. If play the Main Menu.
the software version is not current, corrupt, Install Current Software with WiFi
or unknown, follow the procedure in Updating Once WiFi connection has been established
System Software Instruction. select Wi-Fi Update (Call up the Main Menu and
Updating System Software Instruction select Next " Menu " Settings " Firmware
update " Wi-Fi Update).
To upgrade the firmware through a USB stick 1. Manual path:
or via WiFi (see Firmware update in the Setup Select Wi-Fi Update and check the new
Menu function section). software availability then select HELP
Download and install current Software icon to look into release note or OK icon
with USB stick to start the update procedure that is
Equipment Requirements: composed by the following steps:
(1) USB stick • Downloading compressed software pack-
This item may be purchased from most retail age.
office supply/electronics stores or from any • Decrypt the software package and vali-
online retailer that carries computer accessories. date it to be sure that is a not corrupted.
In case of Firmware update with USB stick • Decompress the content.
follow the instruction: • Install all new files.
• Request user to reboot unit and complete
1. Insert the USB stick to your computer. the install procedure.
2. Format as FAT32. • When the unit reboot confirm the instal-
3. Download the current software from: lation procedure by press <Yes> button
\EDIS\software\systemsw\acs6xx_7xx\. when the bootloader black and white
4. Put the zip package as is into the root folder screen is shown.
of the USB stick. • The unit will go through a file updating
5. Insert the USB stick into the USB port on period (it can take several minutes) to
the unit. finalize the entire update procedure, then
6. Turn ON the unit. will display the Main Menu.
7. Call up the Main Menu. 2. Automatic path:
8. Select NEXT icon. After the connection to internet network is
9. Select MENU icon. available, when the ACS unit is switched
10. Select Settings " Firmware update and on, it’s automatically connect to the same
USB Update. network and immediately (before to show
11. Allow the unit to install the software com- the Main Menu) it will search for new soft-
pletely and then remove the USB stick, this ware is available of not, if yes it will show
operation may requires several minutes. a message to process as above (point 1).
12. Wait the screen that ask to reboot the unit at
the end of the update process and so recyle
the unit power.
13. When the unit reboot confirm the installation
procedure by press <Yes> button when the
bootloader black and white screen is shown.

NOTE: Refer to Scale Calibration at 11. 2 th stage recovery. Unit perform special
Replacement Scale Assembly/Magnet in the deep recovery function where pump and
Electrical section, if necessary. compressor are working togheter to intake all
refrigerant small parts still in the A/C vehicle
The Recover and Charge function tests must be system. Deep recover min tiem is 5 minutes.
performed sequentially, in the order presented Then Oil drain process to evacuate the
here. accumulator from used oil recoverd by vehicle.
12. After the oil drain is complete, a summary
of the amount of refrigerant recovered and
Recover Function oil drained is displayed. The unit displays:
During the Recover process, the system will
initiate a filter check, service data entry, and
inlet pressure check.
1. Empty the oil drain bottle before starting a
recovery.
2. Connect the high-side (red) and/or low-side
(blue) hoses to the test tank.
3. Open the coupler valves on the hoses by
turning the collars clockwise.
4. Select the RECOVER icon from the main
menu.
5. The screen will message display: “Connect Or:
both service hoses to AC system being
serviced and open both coupler valves”.
6. Select OK icon and unit perform:
• inlet pressure check.
• A/C unit internal clearing process.
• 1st recovery stage.
• 2 st recovery stage (deep recover).
7. Select OK icon to continue or ESC icon to
cancel.
8. The machine (ACS 863 only) checks the
refrigerant in the source tank to verify it
is R1234yf and not contaminated. The
machine displays the following screens: 13. Select Print icon to print out recovery
information and pre-recover diagnostics or
INITIALIZING REFRIGERANT IDENTIFIER
select OK icon to return the main menu.
ANALYZING REFRIGERANT SAMPLE
The displayed recovered weight can vary
REFRIGERANT PURITY PASSED
depending on ambient conditions and
9. The unit will run low-side clearing then enter should not be used as an indicator of
into a 1st stage Recovery. scale accuracy. The amount of oil that was
10. When the system has recovered to removed from the A/C system is the amount
-0.4 bar, the vacuum pump starts and runs of new oil that can be charged into the A/C
until recover is complete. system after evacuation is complete.
• Use only new oil to replace the oil removed
during the recycling process.
• Dispose of used oil according to government
laws and regulations.
Recovery is complete.

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. To avoid false failures, one).
the temperature of the vehicle system and the • Oil amount: xxx ml (is possible set as ml,
temperature of the recovery machine should be oz or lb).
within ±5 degrees °C of each other. • Oil type: 2 option (PAG or POE).
1. Connect (or verify) both service hoses to • Dye inject amount: xxx ml (is possible set
the test tank and turn the quick couplers as ml, oz or lb).
clockwise. 4. Confirm with OK icon and begin the charge
2. Select the CHARGE icon from the main process. Moving or bumping the unit at this
menu. Unit show the ENTER VEHICLE point may result in an inaccurate charge.
DATA input page, confirm with OK icon. Charging please wait displays:
The following display may show:
5. When the charge cycle gets close to the

desired weight value, the machine slows
down. It will charge, settle, charge again,
If there is sufficient vacuum available, this
settle, etc.
displays: 6. If there is not sufficient refrigerant in the tank
to charge the system, the display shows:
Machine is asking to input:

• Charge amount (min is 10 g).
• Select charge hoses (3 option: High, Low 7. Select ESC icon to exit. May require tank fill.
and Both side).
3. Select OK icon to continue.

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 and the values on the display will disappear:
few seconds and then close coupler valves
and disconenct service hoses from vehicle.
The charge is complete:
12. Select OK icon to exit.

13. The unit will begin a hose clearing process
to remove refrigerant from the hoses,
9. Select OK icon then the unit will begin a followed by a short recovery.
hose clearing process to remove refrigerant Charge is complete.
from the hoses, followed by a short recovery.
10. At the end unit show the charged data and
print out option.

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.
WARNING: Never change the default settings unless directed by the factory.
Otherwise the unit may fail to operate properly.
WARNING: Never give the programming or service codes to customers.
Service Center Menu Service Menu

NOTE: Consult the Technical Service Bulletins • Calibrate Load cell
for the latest software version as applicable. To
navigate through the Service Menu, use the • Output test
keypad and arrow keys. • Input Test
• Calibrate air flow
Diagnostics and Troubleshooting • A/C unit internal clearing
• Service vacuum
1. Turn unit on and allow it to run through the
• End user install
boot sequence.
2. Select NEXT icon. • Maintenance counters
3. Select MENU icon. • Keypad test
4. Select MAINTENANCE. • Set serial number
5. From the maintenance menu, scroll up and
find SERVICE MENU. • Set Manufacturing date
6. Enter yearly password then select OK icon. • Set boot mode
The following displays: • Reset Board
• Refrigerant identifier
• Charge leak test
• 10 days leak test
• Default vacuum time
• Default vacuum leak test time
• Default precharge leak test time
• Service hose length
Calibrate load cell
• To perform any of the checks in the Service All units include load cell scales: ISV Load Cell,
Menu, use the up and down arrows to scroll Drain Load Cell, PAG Load Cell, POE Load Cell
to the desired test listed and select OK icon. and Dye Load Cell.
• To exit the Service Menu, select BACK icon. ISV Load Cell Calibration
1. After selecting Calibrate Load Cell from
the Service Menu by pressing OK icon, the
following displays:

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.
When finished, select OK icon to save the
entered weight value.
6. If the calibration is accepted, the offset and
slope will be calculated. If either calculation
fails, a fail screen for the offset or slope will
be displayed.
Offset Failure:
3. Select OK icon to begin the calibration.
Slope Failure:
4. Use the calibration weight as displayed for

this step. (The first weight should be 0 as
displayed on the screen.) Select OK icon to
save the displayed weight value.
NOTE: DO NOT DISTURB unit during weight
calibration.
The operator is given the opportunity to

retry the calculation or to exit the calibration
function.

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. The following
displays:
8. Typically adding 1.00 kg (2 lb) is sufficient

to perform this test.
9. If OK icon is selected and the calibration is
accepted, the following displays: 2. Select OK icon to enter the Drain Load Cell
calibration menu. The following displays:
10. Select OK icon to terminate.

11. If the calibration is not accepted, a Calibration 3. Select OK icon to begin the calibration.
Failed screen is displayed as shown in Step 6. Selecting ESC icon returns to the Calibrate
12. Selecting ESC icon returns to Calibrate Load Cell service menu.
Load Cell in the service menu.
Follow all remaining calibration instructions
displayed.
• First point calibration without nothing.
• Second point calibration with 500 g (edit-
able).
• Check with 250 g (not editable) and con-
firm with OK icon.
NOTE: DO NOT DISTURB unit during weight

calibration.

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. The following POE Load Cell service menu. The following
displays: displays:
2. Select OK icon to enter the PAG Load Cell 2. Select OK icon to enter the POE Load Cell
calibration menu. The following displays: calibration menu. The following displays:
3. Select OK icon to begin the calibration. 3. Select OK icon to begin the calibration.
Selecting ESC icon returns to the Calibrate Selecting ESC icon returns to the Calibrate
Load Cell service menu. Load Cell service menu.
Follow all remaining calibration instructions Follow all remaining calibration instructions
displayed. displayed.
• First point calibration without nothing. • First point calibration without nothing.
• Second point calibration with 500 g (edit- • Second point calibration with 500 g (edit-
able). able).
• Check with 250 g (not editable) and con- • Check with 250 g (not editable) and con-
firm with OK icon. firm with OK icon.
NOTE: DO NOT DISTURB unit during weight NOTE: DO NOT DISTURB unit during weight
calibration. calibration.

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. The following
to the various solenoids, fan, vacuum pump,
displays:
and compressor. This test is useful as a
troubleshooting method to determine if a device
is operating properly or not.
1. From the Service Menu, scroll to Output
Test.
2. Select OK icon. The following displays:
2. Select OK icon to enter the Dye Load Cell

calibration menu. The following displays:
Placeholder X indicates the state of the output

device. A 1 or 0 indicates whether the device
is ON or OFF. A list of the tests is provided in
the table below:
OUTPUT TEST
Air Purge Solenoid S1
3. Select OK icon to begin the calibration. PAG Solenoid S2
Selecting ESC icon returns to the Calibrate Oil Drain Solenoid S3
Load Cell service menu. Low-Side Inlet Solenoid S4
High-Side Inlet Solenoid S5
Follow all remaining calibration instructions
displayed. High-Side Charge Solenoid S6
• First point calibration without nothing. Low-Side Charge Solenoid S7
• Second point calibration with 500 g (edit- Recycle Solenoid S8
able).
Vacuum Solenoid S9
• Check with 250 g (not editable) and con-
firm with OK icon. Recover Solenoid S11
Deep Recover Solenoid S12
NOTE: DO NOT DISTURB unit during weight Oil Return Solenoid S13
calibration.
POE Solenoid S14
Dye Solenoid S15
Identifier solenoid S17
N2H2 inlet solenoid S19
N2H2 vent solenoid S20

OUTPUT TEST INPUT TEST

Tank liquid solenoid S22 Sensor or Value
Property
Fan Device Format
ISV Weight X.XXXYY ISV Weight
Vacuum Pump
PAG Weight X.XXXYY PAG Weight
Compressor
POE Weight X.XXXYY POE Weight
Beacon
Dye Weight X.XXXYY Dye Weight
Alert Beeper Drain Weight X.XXXYY Drain Weight
3. As the tests are highlighted, select LS Press X.XYYY Low-Side Pressure
ON/OFF icon. The state will change from 0 AC Press X.XYYY Accumulator
to 1. There should be a click heard as the Pressure
solenoids are energized, the motors of the ISV Press X.XYYY ISV Pressure
fan, vacuum pump, and compressor should ISV Temp X.X0Y ISV Temperature
start, the beacon, if installed will flash once, Amb Temp X.X0Y Ambient Temperature
and the beeper will sound.
HP Sw X High-Pressure Switch
4. When the test is complete, select BACK
icon to return to the Service Menu. Overfill X ISV Liquid Quantity
Air Flow XXXXrpm Fan Air Flow
Input Test 3. Scroll through the sensors or devices to

The input test displays the current state of observe their values. When finished, select
the measurable parts of the unit such as the BACK icon to return to the Service Menu.
amount of refrigerant, temperatures, and the
Calibrate air flow
various pressures present within the unit. The
values shown are absolute and indicate what is The air flow inside the unit must be present at
happening within the unit at any given moment the correct volume to make sure enough air
during operation. The values are observable is present to prevent the buildup of refrigerant
only and cannot be changed or deleted. They and to keep the compressor temperature below
can indicate whether a sensor or device is its upper limit.
operating within the required limits for proper 1. From the Service Menu, scroll to Calibrate
unit operation. air flow.
1. From the Service Menu, scroll to Input Test. 2. Select OK icon. The following displays:
2. Select OK icon. The following displays:
3. Check :
Placeholders X and Y represent numbers • Unit is with covers.
displayed during this test. A list of the sensors • Fun is clean and running.
and devices and what the values represent 4. Select OK icon, and wait unit is performing
follows: calibration automatically.

5. If Ok unit come back to service menu. 5. The vacuum pump should turn on and the
6. If failed unit ask to retry. time begins to count down (5 minutes).
To pause at any point during the process
A/C unit internal clearing select PAUSE icon. At the Pause function,
The A/C unit internal clearing is used to the Service Vacuum can either be resumed
evacuate service hoses, distillator and dryer or cancelled.
filter (after compressor discharge pressure is
still in). Components ON:
1. LS inlet Solenoid S4.
2. HS Inlet Solenoid S5.
3. Recover Solenoid S11.
4. Compressor.
Service Vacuum
Service vacuum is a manually operated test
used to pull a vacuum on the machine to
remove air from the manifold and ISV prior to
refilling the ISV after service. The inlet pressure should stay below 0.35 bar
1. From the Service Menu, scroll to Calibrate throughout the Service Vacuum. The Vacuum
air flow. Pump, Vacuum Solenoid, HS Charge Solenoid,
2. Select OK icon. The following displays: Oil Return Solenoid, LS Inlet Solenoid, Tank
Liquid Solenoid and Recover Solenoid will turn
ON during this test.
6. When the vacuum Time Remaining falls
to 00.00, the outputs will turn OFF and the
following displays:
3. Enter a new time using the keypad and

select OK icon to begin the vacuum. If
the pressure is greater than 0.35 bar, this
screen displays:
7. Select OK icon to return to the Service

Menu.
4. Select RETRY icon to repeat, or ESC icon

to return to the Service Menu.

8. If the Inlet pressure rises above 0.35 bar Maintenance Counters
during the Service Vacuum, any outputs
that are ON will turn OFF and the vacuum Maintenance Counters record the number
time will stop counting down. The following of times a maintenance function has been
displays: performed. The counters also record the amount
of refrigerant recovered, refrigerant filtered,
refrigerant charged, refrigerant replenished,
and how many times the compressor and
vacuum pump have run.
These counters run in the background.
1. F r o m t h e S e r v i c e M e n u , s c r o l l t o
Maintenance Counters and select OK
icon. The following displays:
9. Selecting OK icon may restart the vacuum

process if the Inlet pressure has dropped
below 0.35 bar. If restart is achieved, the
vacuum pump will restart and the outputs
(see Step 5) will turn ON again completing
the Service Vacuum.
10. Select OK icon to return to the Service
Menu.
2. Scroll through the list and select the counter
End User Install to be viewed.
The End User Install allows the service 3. Select PRINT icon to print the entire list of
technician to access, review and/or change Maintenance Counter items and associated
the parameters set during the initial setup of values. Select BACK icon to return to the
the machine. The functions include: Service Menu.
• Language selection. 4. To reset an amount, select ON/OFF icon
• License agreement review. then enter 28712347 in the space provided.
• Units (Metric/Imperial) selection. Select OK icon.
• Date and Time adjustment. 5. If the password is valid, the following
• Print Header Editor. displays:
• Identifier setting (ACS 763 only).
• Service Vacuum.
• Internal tank fill.
These functions can be accessed to customize
the unit for the end user, or to check the
customization when the unit is activated for the
first time after shipment. The End User Install
would not normally be needed.

The second line of the display, above, represents 7. Scroll to the next desired Maintenance
the item to be reset. Counter. If none is desired, select BACK
6. Select OK icon to reset the amount. Select icon to return to the Service Menu.
ESC icon to leave the amount current and
return to the Service Menu.
The list of available items follows in the table:
Display Item Description

Rec Cyc Recover Cycles displays the recovery cycles number performed
from the station
Recd Recovered Refrigerant displays the recovered refrigerant total quantity
Lifetime from the station
Drn Cyc Oil Drain Cycles displays the used oil total quantity drained from the station
Comp Compressor Run Time displays the total operating hours of the compressor
Filtd Filtered Refrigerant displays the filtered refrigerant total quantity from the station
Filt Cyc Filter Change Cycles displays the number of times the dryer filter
has been changed
Vac Cyc Vacuum Cycles displays the vacuum cycles number performed
from the station
Pump Vacuum Pump Run Time displays the total operating hours of the vacuum pump
Oil Cyc Vacuum Pump Oil displays the number of times the vacuum pump oil
Change Cycles has been changed
VP Oil Vacuum Pump Oil Time displays the vacuum pump operating hours
from the last oil change
Chg Cyc Charge Cycles displays the charge cycles number performed
from the station
Chgd Charged Refrigerant displays the charged refrigerant total quantity in kg/lb
Lifetime
HF Cyc Hose Flush Cycles displays the hoses flush cycles number performed
from the station
Repld Replenished Refrigerant displays the replenished refrigerant total quantity in kg/lb
Lifetime with the “Tank filling” function

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.
pressed. The keys affected by this test are listed 1. From the Service Menu, scroll to Set Serial
in the table below: Number and select OK icon. The following
• F1 •1 •6 • Up Arrow displays:
• F2 •2 •7 • Down Arrow
• F3 •3 •8 • Left Arrow
• F4 •4 •9 • Right Arrow
• F5 •5 •0 -----
1. From the Service Menu, scroll to Keypad

Test and select OK icon. The following
displays:
2. Enter the serial number using the keypad

and select OK icon.
• If the number is valid, it will be saved and
return to the Service menu.
• If the number is not valid, the beeper will
sound three times.
Set Manufacturing Date

Setting the manufacturing date is usual after
main board replacement only.
1. From the Service Menu, scroll to Set
Manufacturing Date and select OK icon.
The following displays:
The X displayed represents the key to be
tested. The first key is F1, followed by F2 and
so on. After each key is tested, the next key will
scroll up automatically.
This test cannot be aborted. Once complete, the
display will automatically return to the service
menu.
2. Enter the manufacturing date using the

keypad and select OK icon.
3. Select ESC icon to return to the Service
Menu without saving the new manufacturing
date.

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
The choices to boot are Normal, Filter Change will erase any calibration/customization and
Required, Leak Test Required, and End-User restore the factory defaults.
Install. 1. From the Service Menu, scroll to Reset
1. From the Service Menu, scroll to Set Boot Board and select OK icon. The following
Mode and select OK icon. displays:
2. Enter password 28768347 then select OK
icon. If the password is valid, the following
displays:
2. To reset the board to the default values,

select OK icon.
3. Scroll to the boot mode desired and select 3. To leave the board configuration as is, select
OK icon. The unit will boot to the selected ESC icon to return to the Service Menu.
mode at the next power up cycle.
4. To leave set boot mode without change,
select BACK icon to return to the Service
Menu.

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).
Charge Leak Test CAUTION: this time is editable to make

easier diagnostic and repair, change the
The Charge Leak Test is used to enable/disable timing as default could reduce the unit
pre-charge leak test. performance.
10 Days Leak Test (R1234yf only) Default Precharge Leak Test Time
The 10 Days Leak Test is used to enable/ The Default Precharge Leak Test Time is
disable periodical leak test. editable (default 5 min).
CAUTION: this time is editable to make

Default Vacuum Time easier diagnostic and repair, change the
T h e D e f a u l t Va c u u m Ti m e i s e d i t a b l e timing as default could reduce the unit
(default 5 min). performance.
Service hose length

CAUTION: this time is editable to make
easier diagnostic and repair, change the It is used to set the service hose length (2.5 m
timing as default could reduce the unit or 5 m).
performance.

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.
WARNING: Always unplug the machine from the power source before removing
any of the shrouding or beginning any service work.
Unit is Functional Unit is Not Functional

1. Perform recovery function. 1. Disconnect the high- and low-side service
2. Turn unit off when Oil Draining is displayed. hoses from vehicle or service tank, whichever
3. Refrigerant will be present in the vapor is applicable. Make sure the coupler valves
hose, liquid hose, and accumulator. are closed.
2. Connect an auxiliary recovery unit to the
To evacuate the tank: lateral contamination port (ACS 863 only)
1. Connect an external recovery unit to the or by quick coupler adapter connection.
lateral contamination port (ACS 863 only) 3. Start the separate recovery unit and allow
or by quick coupler adapter connection. it to pull the unit into a 0.4 bar (33 cm-Hg)
2. Open service menu and goes into Output vacuum.
test. Refer to Output test in the Diagnostics 4. When the unit is pulled down to this level,
and Testing section. turn off the auxiliary recovery unit and
3. Enable: disconnect from the lateral contamination
• Tank liquid solenoid S22, port (ACS 863 only) or by quick coupler
• Low-Side Charge Solenoid S7 and/or, adapter connection.
• High-Side Charge Solenoid S6. 5. Carefully disconnect or remove components
as there may be refrigerant present.

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
grounding, shielding, and AC and DC power voltage. For a nominal 230 V line, the limits are
supply issues. 207 V to 253 V. The unit will operate above and
Grounding Issues below the voltage limits. However, problems
Grounding must be looked at first, for without in operation may appear if the voltage drops
a low-impedance ground; all noise protection (sags) below or rises above (surges) these
measures built into the electronic components limits. The life expectancy of the components
and assemblies are rendered useless. in the unit may be shortened significantly.
Grounding equipment is done for two reasons. The impedance controls the ability of the line to
The first and most important is safety. To meet supply a constant voltage with a changing load.
safety requirements, any exposed conductive Noting the line voltage with the unit off, then
surface of the equipment must be within the noting the voltage with the unit on, a technician
safe touch-voltage range of under 30 Volts can determine the impedance of the line from
RMS. Any voltage greater may result in a life the unit to the power transformer. If there is a
threatening electrical shock, under the right greater than 10% change, the line has too much
conditions. resistance or the load is too great. The solution
is a dedicated line.
The second reason is the process by which
the case and any extensions of the case are The line cord must be wired correctly. When
connected to earth ground. If the ground is replacing the line cord, make sure the terminals
open or has a high resistance, electrical noise at the plug have the high, neutral, and ground
will not be shorted to ground and can radiate connections in their proper location. A ground
into the unit. circuit tester can be used to test wiring.
Noise (Shielding) Issues Verify the Power Outlet

Proper shielding prevents noise from entering 1. Ensure the outlet is in good working order.
the unit. Two types of noise can affect the 2. With no load on the circuit, use a ground
operation of a unit; noise coming in on the AC circuit tester to verify proper polarity and
line and external noise (such as ignition noise) presence of earth ground.
radiated directly into the unit. 3. Using a digital volt meter, with no load on
the circuit, verify there is less than 0.3 V
AC Noise - any signal on the power line other from neutral to ground and the voltage is
than the advertised voltage and frequency; this stable. Be suspicious of a 0 V reading. This
includes spikes, surges, and sags. may indicate a short between neutral and
ground.
External Noise - (such as ignition noise) is 4. With no load on the circuit, verify the output
generally radiated into the unit. Other types voltage is nominally 230 V and stable.
of radiated noise sources are light ballasts, 5. With the unit connected to the circuit
transmitting towers, power lines, etc. External (loaded) verify the voltage varies less than
noise can cause the unit to lock-up, reset, or 4 VAC measured from neutral to ground.
behave erratically. The effect varies with the 6. Using an oscilloscope, monitor the waveform
type and intensity of the noise. output from the outlet for any distortion. The
signal should be a sine wave.

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. If the unit
power source with a good ground and not is still inoperative, perform the following
through an extension cord. voltage checks.
2. Verify the power cable is wired correctly a. Measure the voltage at the output of the
and the connector has not been damaged. power supply from PSJ2 pin 2 (+) to pin
Replace or repair as required. 3 (-). Voltage should be 12 VDC.
3. If unit does not power up, check to make • If 12V is not present, go to step 5.
sure the circuit breaker hasn’t tripped. • If 12V is present, replace control board.
4. Turn on the main power switch. 5. Connect the unit to a proper AC power
5. If the display does not activate, verify line source and place the unit power switch on.
voltage is present at the input and output a. Disconnect the cable from power board
terminals of the switch. PBP4.
• If line voltage is not present at power b. Measure the voltage at PBP3 pins 2
switch input, check connections between and 3.
the power switch and AC connector. • Voltage should be 230 VAC (nominal).
• If line voltage is present at power switch If voltage is correct, replace power
input, but not at output with switch turned supply.
on, replace the power switch. • If voltage is less than 207 VAC, replace
• If line voltage is present at both input and power board.
output of switch, proceed to next step.
Circuit Breaker Tripped
Circuit Breaker Not Tripped 1. Place unit power switch off and reset the
1. Turn off unit and disconnect AC power cord circuit breaker.
from receptacle. 2. Place unit power switch on. If the circuit
2. Check the circuit breaker for continuity. breaker remains engaged, the unit should
• If there is no continuity, replace circuit operate normally and no further action is
breaker. required. Otherwise, proceed to step 3.
• If there is continuity, continue to next step. 3. If the circuit breaker trips again after being
NOTE: Before replacing any component, make reset, place the power switch off.
sure the interconnecting harnesses are in good 4. Disconnect PBP3 and perform continuity
condition and proper electrical contact is made checks of the power switch. If no faults are
between the connectors. found, replace the circuit breaker.
5. Connect PBP3 and disconnect remaining
3. Perform the following continuity checks:
connectors from the power board.
a. Disconnect the cable from power supply
6. Place unit power switch on.
PSJ1.
7. If the reset circuit breaker trips again,
b. Jumper all input power cable pins
replace the power board.
together at the plug end.
8. If the circuit breaker doesn’t trip after being
c. Check for continuity across power
reset, place the power switch off.
supply input cable pins 2 and 3.
9. Connect one connector at a time into the
• If continuity exists, remove jumpers
power board, placing the power switch on
from the input power cable and connect
after each additional connection.
PBP3.
10. Perform step 9 until the circuit breaker trips
• If no continuity, check the power switch
when placing the power switch on.
for proper operation. Repair or replace
11. Check all components associated with the
as required.
last connector to be attached to the power
board when the power switch was placed
on.

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. Low-side clearing activates the
compressor troubleshooting in the Compressor compressor only and runs until the accumulator
section of this manual. transducer reads -0.45 bar (13 in HG) plus
1. Verify the low-side service hose is properly 15 seconds. The unit will then go into the
connected and threaded completely onto first stage of recovery. There is no high-side
the source tank fitting. Check quick-seal on clearing in these units. If a unit gets stuck in the
low-side service hose and make sure virgin clearing process, use the following procedure
tank valve is open. to troubleshoot this condition.
2. Is there a message on the display stating 1. Attach a calibrated gauge to the accumulator
the source tank is empty? If so, verify the test port on the side of the manifold block.
source tank has liquid refrigerant and the 2. Disconnect the fan by unplugging it at
source tank valve is open. the relay board. Do this with the machine
3. Verify the source tank and the tank is disconnected from its power source.
positioned to supply liquid refrigerant to the 3. Turn on the display pressures feature
low-side service hose. Disposable tanks (display tittle info available in maintenance
should be inverted. Attach the low-side menu) so the transducer readings are
service hose to the liquid port on a refillable displayed on the screen while operating
tank. the machine.
NOTE: The recover solenoid (S11) is controlled 4. Verify the problem by attempting to recover
to maintain a maximum of 2.5 bar (35 psi) in the hoses or a test tank.
the accumulator. NOTE: There must be pressure in the unit to
4. Monitor accumulator pressure. If reading verify stuck in clearing.
is low, check for restriction upstream of the 5. Verify the transducers are the correct
accumulator. If pressure is normal, check pressure rating and wired correctly.
compressor oil return solenoid (S13). 6. Verify all lines going to and from the
5. Check the recover (S11), compressor oil compressor are tight and leak free. Retest
return (S13), deep recover (S12), and oil if any loose/leaking lines are found.
drain (S3) solenoids for bleed-through. 7. Close the valve on the source tank if
Repair as needed. attached and valve is open, and retest. If the
6. Check the compressor for suction and unit completes clearing, replace the tank fill
discharge performance. Refer to the solenoid and retest.
Compressor Testing procedure in this 8. Verify the accumulator test gauge and
section. transducer readings match. If the test gauge
7. Remove the filter and inspect all fittings shows the vacuum level in the accumulator is
and gaskets to verify that no obstructions below the minimum level and the transducer
exist. Replace/repair gaskets as needed reading doesn’t match (the accumulator
and reinstall filter. transducer reading and the calibrated test
8. Verify the scale is calibrated and free to gauge reading should match), replace the
move. accumulator transducer and retest.
9. Check Tank Liquid solenoid, evacuating the
tank with a recovery service unit in advance.
Give the process a little time to run, to allow
the refrigerant in the system to be cleared. If
the pressure drops and the clearing process
completes, replace the Recycle solenoid
and retest.

10. Verify the oil drain solenoid isn’t leaking Will Not Recover
the vacuum. Place a finger over the end of
the oil drain tube and check for suction. If NOTE: The compressor should be running
a suction is detected, replace the oil drain during this test. If it does not run, refer to
solenoid. Retest. Compressor troubleshooting in the Compressor
11. Disconnect the manifold end of the section of this manual.
compressor oil return line and check for 1. Verify there is pressure reading on the
pressure coming from the manifold (with gauges.
compressor running). If pressure is detected • If pressure is present, the service hoses
at the compressor oil return line connection are connected correctly.
on the manifold, replace the compressor oil • If pressure is absent, the service hoses
return solenoid. Retest. are connected improperly or there is a
12. Verify the accumulator/oil separator bowl is restriction. Clear and reconnect service
tight. Tighten and retest if loose. hoses.
• If not loose, remove the accumulator/oil 2. Display the accumulator pressure (enable
separator bowl and check the condenser display tittle info in maintenance menu).
coil connections to ensure they are tight. • If there is no pressure, inspect inlet
• If loose, tighten, reassemble, and retest. valves, recover solenoid, and check
13. Verify the compressor oil separator bowl is valves.
tight and the O-ring is installed. • I f p r e s s u r e s e e m s n o r m a l a t t h e
• If the compressor oil separator bowl is accumulator, inspect oil return solenoid
loose, retighten and retest. (S13), and compressor.
• If the O-ring is missing, install a new
O-ring, reassemble, and retest. NOTE: The recover solenoid (S11) is controlled
14. Reinstall the condenser coil and compressor to maintain a maximum of 2.5 bar (35 psi) in
oil separator bowl; do not reinstall the the accumulator.
system oil separator bowl. 3. Verify operation of the recover check valve.
15. Access the service menu and select the Replace as needed.
Output Test option. 4. Check the compressor for suction and
16. Scroll to the compressor and turn it on. discharge performance.
Once the compressor is running check the 5. Remove the filter and inspect all fittings
condenser coil connections, condenser coil and gaskets to verify that no obstructions
tubing, and compressor oil separator threads exist. Replace/repair gaskets as needed
for leakage with a soapy water solution or and reinstall filter.
other leak detection fluid. Remove the 6. Verify the accumulator transducer is
leaking component and verify the O-rings functioning properly by attaching a calibrated
are in place and not cut or damaged. gauge to the service port and compare
The O-rings and mating parts should be readings to those on the manual gauge. The
lubricated prior to assembly. Repair any readings should be within the specifications
leaks found and retest. on the transducer ID plate.
NOTE: Limit the amount of time the compressor 7. Check the oil return (S13) solenoid for
is running, as it will be pulling in air and adding bleed-through and proper operation. Repair
it to the ISV. Be sure to purge the air from the as needed.
ISV once the machine is repaired. 8. Check Tank Liquid solenoid, evacuating the
tank with a recovery service unit in advance.
17. If the unit doesn’t complete clearing, test the 9. If problem still exists, check the vacuum (S9)
compressor as reccomended procedure. solenoid, as applicable.
Refer to Compressor Troubleshooting in the
Compressor section of this manual. NOTE: If the compressor fails to operate, refer
to Compressor Troubleshooting.

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. Replace or repair as
way valve in tank vapor side). required.
2. Verify the ISV contains a minimum of 454 g 2. Connect the unit power cable directly to
(1 lb) of chargeable refrigerant. the power source. Do not use an extension
3. Verify the vacuum (S9), deep recover (S12), cord.
and oil return (S13) solenoids are receiving 3. Check for 230 V at the vacuum pump
power and opening properly. connector, pins 2 and 3.
• If not receiving power, check the • If voltage is present, replace vacuum
continuity of the wiring between solenoid pump assembly.
and power board. Repair as needed. • If voltage is not present, continue to next
• If the wiring is correct and no power is step.
being applied to the solenoid, replace
the power board. NOTE: When checking voltage to the vacuum
• Verify the accumulator transducer pump, it is normal to read low voltage at the
is functioning properly and reading connector when it’s disconnected and the power
accurately. to the vacuum pump is off.
• Verify the solenoid coil is opening the 4. Check for 230 V from the power board on
solenoid properly. connector P6.
NOTE: The oil return (S13) solenoid is controlled NOTE: If the fan is operating, power is present
to maintain 0 to 0.2 bar (3 psi) in the accumulator. at the power board. The fan, vacuum pump, and
Only this solenoid will be activated at a time and compressor use the same power source. The
it will be pulsed intermittently. fan shall operate whenever the power switch
4. Test the pump per the test procedure in the is turned on.
Vacuum Pump section. If it fails, replace 5. Perform functional check.
the pump.

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? • If not receiving power, check the
• Error 1 - Oil drain halted. Pressure error. continuity of the wiring between solenoid
Retry or exit? and power board. Repair as needed.
a. Verify operation of the compressor oil • If the wiring is correct and no power is
return solenoid (S13). being applied to the solenoid, replace
b. C h e c k Ta n k L i q u i d s o l e n o i d , the power board.
evacuating the tank with a recovery NOTE: Verify the tank temperature sensor and
service unit in advance. pressure transducer are functioning properly.
c. Verify there is 454 g (1 lb) minimum To verify tank pressure transducer, perform
chargeable refrigerant in the ISV. the following:
• Error 2 - Oil drain halted. Flow error. Retry • Open service menu and goes into
or exit?. Output test.
Verify the oil drain solenoid (S3) is • Open Tank solenoid and high-side
receiving power and opening properly. charge solenoid, check the value on
a. If not receiving power, check the high gauge.
continuity of the wiring between 2. Manually purge air.
solenoid and power board. Repair • Verify air purge transducer and
as needed. temperature sensor are reading
b. If the oil drain solenoid is receiving correctly.
power and is opening, verify the oil • The air purge function will time out after
drain line isn’t plugged. four minutes if the ISV pressure doesn’t
c. If the wiring is correct and no power is reach the calculated pressure within
being applied to the solenoid, replace that time. This may indicate excessive
the power board. air in the ISV that must be purged.
d. If the unit continues to drain oil for four 3. If the air doesn’t purge, check the 0.028-in.
minutes, Oil Drain Error 2 will display. orifice between the ISV pressure transducer
The accumulator may be filled with oil and air purge solenoid (S1) for debris.
that must be drained manually. • Check Tank Liquid solenoid, evacuating
NOTE: Determine the reason the oil separator the tank with a recovery service unit in
isn’t draining properly. Improper draining advance. If the orifice is contaminated or
could be caused by a faulty component or defective, repair or replace as needed.
improper operation by the user. Access the • If the orifice is operating properly,
maintenance counters in the service menu. proceed to the next step.
Comparing the recover cycles to the oil drain 4. To test the temperature sensor, determine
cycles may indicate user operational errors. If the ISV temperature and compare it to the
the procedure, in step a above, does not resolve temp probe reading in the air purge info
the problem, replace the control board. screen.
5. To verify pressure transducer, perform the
following:
• Open service menu and goes into Output
test to enable the tank liquid solenoid
S22, high-side charge solenoid S6 and
low-side charge solenoid S7.
• Compare the data with the one readable
in input test or in the tool bar (enable
display title info in maintenance menu).

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. If the pump does not run, hoses. If unit won’t maintain vacuum, check
refer to Vacuum Pump Troubleshooting in the the following for leakage:
Vacuum Pump section of this manual. • High-side charge solenoid (S6) and low-
1. Verify the service hoses are properly side charge solenoid (S7).
attached to the unit (valves open) without • Hose couplers.
any restrictions. • Hoses.
2. Make sure the two plastic vacuum lines • Gauge tubing.
are snug at both ends and not obstructed. • Injection manifold.
Check the pneumatic fittings for leaks. • S u c t i o n s i d e v a c u u m h o s e s a n d
3. Check for proper vacuum oil level in the connections.
vacuum pump sight glass (oil level should 3. If there is no pressure on gauges and
be in the center of the sight glass while the display says Pressure Exists, enter the
pump is running). Replace vacuum pump service menu and verify low-side inlet
oil if necessary. transducer reading. If it is reading pressure
4. Check for suction at the intake of the pump. where none exists, replace transducer. If
If there is none, replace the pump. replacing the transducer doesn’t correct the
5. Verify the vacuum solenoid (S9) is receiving reading, replace the power board.
power and that the low-side (S4) and high- 4. Refer to Vacuum Pump Does Not Run in
side (S5) inlet solenoids are open. electrical troubleshooting.
• If not receiving power, check continuity
of the wiring between the solenoids and
power board. Repair as needed.
• If the wiring is correct and no power is
being applied to the solenoid, replace the
power board.
6. Check the PAG (S2), POE (S14) and dye
(S15) solenoids for bleed-through and
proper operation. This can be done by
checking for suction at the oil/dye inject tube
in the oil/dye inject bottle. Remove the oil/
dye inject bottle during the vacuum process
and check for suction at oil/dye inject tube
or watch for oil/dye movement in the tube
towards the manifold. Repair as needed.
7. Verify the low-side pressure transducer is
functioning properly.

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. During appropriate amount of oil or dye.
the recovery process, cold spots can develop 2. Verify a vacuum has been pulled on the
in an automotive system. Pockets of refrigerant system.
in desiccant and in system oil will continue 3. Verify the high-side service hose is properly
to vaporize as the A/C system temperature attached to the unit without any restrictions
equalizes toward ambient. As this occurs, A/C and coupler valve is open.
system pressure will increase, which may be 4. Open service menu and goes into Output
interpreted by the unit as a leak. This will vary test to activate the PAG (S2) or POE (S14)
somewhat with ambient temperature conditions. or dye (S15) solenoids.
1. Verify the service hoses are properly 5. Verify power to the oil/dye inject solenoids
attached to the unit (valves open) without (S2, S14, S15).
any restrictions. 6. Verify the solenoid coil is opening the
2. If vacuum can not be maintained, using solenoid properly.
Service Leak Check in the service menu, • With the system pulled into a vacuum,
pressurize the unit and use a leak detector remove the oil/dye bottle, place a finger
to check all hoses, fittings, and components over the end of the oil/dye inject tube
for leaks. Repair as needed. and activate the oil/dye inject solenoid.
3. Check the PAG (S2), POE (S14) dye (S15), Suction should be felt at the oil/dye inject
high- (S6) and low-side (S7) charge, and tube.
vacuum (S9) solenoids for bleed-through. • If no suction is felt, the oil inject solenoid
Repair as needed. may not be receiving power. Check the
continuity of the wiring between solenoid
NOTE: A leaking high- (S6) or low-side (S7) and power board. Repair as needed.
charge solenoid may be identified by an internal • If the wiring is correct and no power is
pressure rise above zero. A leaking vacuum being applied to the solenoid, replace
(S9) or PAG (S2) or POE (S14) or dye (S15) the power board.
solenoid would not normally rise above zero. 7. Verify operation of the oil/dye inject check
4. Verify the low-side pressure transducer is valves. Replace as needed.
functioning properly. Enter service menu
and verify low-side inlet transducer reading.
• Compare the low-side transducer reading
shown in the service menu with the
reading on the low-side panel gauge. The
readings should match, assuming the
low-side panel gauge is accurate.
• If the low-side inlet transducer is reading
pressure while the system is in a vacuum,
replace the transducer. Verify the
replacement transducer reads zero at
atmosphere by plugging it into the wiring
harness prior to installation.
• If replacing the transducer doesn’t correct
the reading, replace power board.

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. The refrigerant flows due to a pressure and temperature. It will attempt to power charge
differential. If the system is not in a vacuum, three times before displaying:
unit will not charge. Charge Stalled.
1. Verify the service hoses are properly Retry, ESC, or select Charge icon to use
attached to the unit without any restrictions vehicle A/C system to complete charge.
and coupler valves are open. 1. Check and ensure there is a good vacuum
2. Verify a deep vacuum has been pulled on in the vehicle being tested.
the system being charged. 2. Verify sufficient pressure in the ISV to
3. Check that all ISV hoses are properly transfer refrigerant.
installed and check Tank Liquid solenoid, NOTE: During the charge process, there
evacuating the tank with a recovery service must be a transfer of at least 23 g (0.05 lb)
unit in advance. of refrigerant within 30 seconds. If not, the
4. Verify the scale has been calibrated. compressor is switched on and off to build tank
5. INSUFFICIENT REFRIG AVAILABLE will pressure. This process may be repeated twice.
be displayed if the weight entered leaves
less than 2.2 kg of refrigerant in the internal 3. Ensure chargeable weight is greater than
tank after charge. If there is enough refriger desired charge.
ant in the tank, check scale calibration and 4. Verify the charge couplers are completely
recalibrate if necessary. open and the vehicle ports are actuated.
6. Verify the high-side charge (S6) and low- 5. Check for debris in any of the charging circuit
side charge (S7) solenoids are receiving solenoids. Clean or replace if necessary.
power and opening properly. 6. If slow charge persists, there may be a pin
• If not receiving power, check the continuity hole leak in the ISV dip tube. Substitute a
of the wiring between solenoid and power known good ISV tank.
board. Repair as needed.
• If the wiring is correct and no power is
being applied to the solenoid, replace the Will Not Hose Flush
power board.
Flushing the hoses is required if the next vehicle
NOTE: If the unit does not complete a full to be serviced contains a different type of A/C
charge, the compressor is switched on and off system oil than the previous vehicle serviced.
to build tank pressure. 1. Verify the service hoses are properly
attached to the unit storage ports without
any restrictions and coupler valves are
open.
2. Check Tank Liquid solenoid, evacuating the
tank with a recovery service unit in advance
and tank hoses are properly connected to
the ISV.
3. If there is no pressure on the gauges, refer
to the Will Not Charge troubleshooting
procedures earlier in this section.
4. If the pressure does not clear on the gauges,
refer to the Will Not Recover troubleshooting
procedures earlier in this section.

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.
2. Does the printer have paper? Verify the 2. Remove the paper core.
paper is installed correctly in the printer. 3. Install the new roll of paper with the end
The paper should be rolling off the back of of the paper at the top of the roll, unrolling
the roll. from the back.
3. If the machine is operating in direct sunlight, 4. Feed the paper out the top of the opening,
move it or cover the face of the printer and and close cover.
try again.
Printer Has Power
If the printer has power, check the continuity of
the printer harness between the printer (P30)
and the control board (P15).
• If harness tests good, replace the printer
assembly and retest. If the harness test
fails, replace printer harness.
• Check the output of the power supply at
PSJ2. If there is 12 VDC at PSJ2, check
the power input to the control board at
CBP19.
• If printer still does not print, replace the
control board.
Printer Does Not Have Power
Verify the printer is receiving power at harness
connector P45. Test for +5 VDC across the
RED (pin 1) or YELLOW (pin 2), and BLACK
(pins 3 & 4) wires.
• If voltage is present at P30, replace the
printer assembly and retest. If not, check
for printer power at CBP15.
• The control board receives power from
the power board PBP2, through connector
P19. If the control board is not receiving
power, the printer will not function.
• If printer power is present at CBP15,
check for continuity of the printer harness.
Repair or replace if necessary. If printer
power is not present at CBP15, replace
the control board.

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. • Repeated Communication errors.
• A solenoid won’t open. • Keys don’t read (after verifying keypad).
• Compressor and fan won’t start. NOTE: Before reflashing, make sure the unit
• Vacuum pump won’t start. has the latest software version installed. If
• A function does not start or finish a the software version is current. Do not reflash
process. controller if updating the software solves the
2. Do not replace the power board for these problems, unless a TSB indicates reflashing
issues: is needed.
• Display has lines, missing characters,
etc. 2. Do not replace the control board for these
• Repeated read errors. issues:
• Repeated communication errors. • A solenoid will not open.
• Display is blank at power up, contrast • A motor won’t start.
can’t be adjusted, and power has been • Scale is out of calibration, (overcharge/
verified. undercharge etc).
The best way to troubleshoot is to go into the • The display is dim or dark (unless it can
diagnostic menu: not be adjusted).
• If you are able to switch a solenoid or • A pressure reading is wrong.
relay on and off, the output portion of the • High pressure, air purge time out, etc.
board is likely okay. • A function doesn’t start or complete
• If the fan, compressor, or vacuum pump (Recovery, Charge Tank Fill etc).
is selected it should receive power.
Pressures can be verified with a gauge at
the accumulator port, low-side hose, and
by accessing the tank. The tank pressure
transducer can be checked by charging a hose
and comparing to the low-side transducer or
the gauges. They should be reasonably close
initially, but the gauge or low-side reading
should drop quickly if the tank is warm.

Compressor Troubleshooting
ss00649
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.
3. Verify the ground wire between the
compressor electrical box and chassis
ground is securely fastened.
4. Check for 230 VAC to the compressor.
• If there is no voltage to the compressor’s
start components, proceed to the next
step.
• If voltage is present at the compressor,
replace the compressor thermal protector
and start relay assembly. If compressor
runs, verify the compressor amp draw is
within specs. If the compressor doesn’t
run and/or is drawing locked rotor amps, Figure 2-1. Compressor Assembly
replace the compressor. 7. Start the compressor.
CAUTION: If using the output step test to 8. The first time the compressor is tested, the
run compressor, the oil return solenoid must gauges may read approximately 7 bar (100
be open before the compressor is started. psi) and 540 mBar (16 in-Hg).
9. Turn off the compressor and release
5. Check for 230 VAC from the power board pressure from manifold.
on connector P6, pins 1 and 2.
• When checking voltage to the compressor, Testing the Compressor a Second Time
it is normal to read a low voltage at the NOTE: Studies have shown the first test may
connector when it’s disconnected and the give false compressor values due to embedded
power to the compressor is off. refrigerant in the oil.
• If voltage is present, check wiring between
1. Close the valves on the manifold and start
the power board and the compressor start
the compressor.
components. Repair as needed.
2. A good compressor will produce 14 bar (200
• If voltage is not present, replace the relay
psi) discharge and 472 mBar (14 in-Hg) on
board.
the suction side, minimum.
6. Perform functional check.
3. Release all pressure and vacuum from the
Compressor Testing Procedure manifold set, close both valves and repeat
1. Remove shrouding from the unit. the test a third time to verify readings.
2. Remove all three lines attached to the 4. If the suction or discharge of the compressor
compressor. is under specifications, replace the
3. Cap off the compressor oil return port. compressor.
4. Connect a manifold set to the compressor,
high side to the compressor discharge and
the low side to the suction port. Remove
hose from center port of manifold.
5. Close both valves on the manifold.
6. Enter the service menu, scroll to the Output
test and select the Compressor test.

Vacuum Pump Troubleshooting Vacuum Pump Does Not Run
1. Check gauges for vacuum. breaker, and electrical connectors for
2. If pressure is over 0.7 bar (10 psi), recover damage or corrosion. Replace or repair as
hoses. required.
3. If unit won’t maintain vacuum, check 2. Connect the unit power cable directly to the
high- and low-side charge solenoids, power source. Do not use an extension cord.
hoses, couplers, gauges, and other related 3. Check for 230 V at the vacuum pump
components, for leakage. connector, pins 2 and 3.
4. If there is no pressure on the gauges and • If voltage is present, replace vacuum
the display says Pressure Exists, enter pump assembly.
the Service Menu and verify low-side inlet • If voltage is not present, continue to next
transducer reading. If it is reading pressure step.
where none exists, replace transducer. If
replacing the transducer doesn’t correct the NOTE: When checking voltage to the vacuum
reading, replace the control board. pump it is normal to read low voltage at the
5. If the compressor is not running or appears connector when it’s disconnected and the power
to be running poorly, refer to Vacuum Pump to the vacuum pump is off.
Does Not Run. 4. Check for 230 V from the power board on
connector P6 pins 3 and 4.
• If voltage is present, check wiring between
the power board and the vacuum pump.
Repair as needed.
5. Use the output test and verify fan operation.
• If the fan is not functioning, check/verify
wiring, switches, and circuit breaker.
• If the fan is functioning, replace the power
board.
• If voltage is not present, replace the
power board.
NOTE: If fan works, power is present at the
power board. The fan, vacuum pump, and
compressor use the same power source.
Figure 2-2. Vacuum Pump Assembly
6. Perform functional check.

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
or ESC icon
Calibrate Load Cells Calibration failed! Verification Weight too high or low.
weight X. XXXYY. Select RETRY or ESC icon.
Calibration Check Calibration failed. Select RETRY icon to return to the
beginning of the calibration check,
or ESC icon to return to the service
menu.
Charge Insufficient vacuum for System vacuum to low to draw in
charge. enough refrigerant. Select AUTO-
MATIC, RETRY or ESC icon.
Charge Insufficient refrigerant Refrigerant in ISV too low. Select
available for charge. ESC icon. May require tank fill.
Charge Leak Test Leak test failed! Check for leaks and retest.
Select ESC icon.
Drain Oil Oil drain halted. Pressure Pressure insufficient to push oil out
error. of separator. Select RETRY or ESC
icon.
Drain Oil Oil drain halted. Flow error. Oil drain timed out. Select RETRY or
ESC icon.
Enter Password Invalid password! Password entered is incorrect. Verify
function password is correct. Select
RETRY or ESC icon.
Fast Charge Charge stalled! Check Check panel valve position and
connections and valves. couplers. Select RETRY or ESC
XX.XXXYY of XX.XXXYY icon.
charged.
Filter Change Invalid serial number! Filter serial number must be different
from any other filter serial number
previously installed. Select RETRY or
ESC icon.
Filter Change Serial number has already Filter serial number must be different
been used. from any other filter serial number
previously installed. Select RETRY or
ESC icon.
Helium Leak Test Transducer error. For production only. Exit test.
Leak Check Pressure test failed. Check Locate and repair any leaks. Select
for leaks. RETRY or ESC icon.
Leak Check Vacuum test failed. Check for Locate and repair any leaks. Select
leaks. RETRY or ESC icon.


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.
3. Check for oil inject solenoid failure.
4. Check for Oil inject stuck check
valve.
Recover No pressure on inlets. Select OK (Yes) or ESC icon (No).
Recover Anyway?
Service Vacuum Vacuum halted! The inlet Select RETRY or ESC icon.
pressure is too high for
vacuum.
Set Tank Tare Invalid entry. Must be Tank tare range is either too low or
between XXYY and XXYY. too high. Select Retry to re-enter
tank tare value or ESC icon.
Slow Charge Charge stalled! Check Check panel valve position and
connections and valves. couplers. Select RETRY or ESC
XX.XXXYY of XX.XXXYY icon.
charged.
Startup System Fault. RTC Fault. System missing date/time
information. Select ESC icon to run
RTC routine.
System Flush Insufficient refrigerant. 6.00kg Select ESC icon, then perform tank
required for system flush. fill.
System Flush Pressure too high for flush. Select ESC icon, then perform
System must be recovered. recovery.
Tank Fill Source tank is empty. Filled: Source tank emptied during the tank
XX.XXYY. fill process. Connect new source
tank, then select RETRY or ESC
icon.
Vacuum The inlet pressure is too Run a recovery by selecting Recover
high for vacuum. Recover or or ESC icon to quit.
Cancel.
Vacuum Vacuum Halted! The inlet Select RETRY or ESC icon.
pressure is too high for
vacuum.
Vacuum Test Test failed! Select RETRY or ESC icon.
Recovery Refrigerant purity acceptable Refrigerant analysis test passed:
(if the refrigerant identifier is refrigerant purity acceptable
present)


WARNING
Recovery Purity test failed. Recover Refrigerant analysis test failed
contaminated refrigerant from (generic error). Select RETRY or
system and hoses (if the re- ESC icon
frigerant identifier is present)
Recovery Communication problems Warning the user that is unable to
Refrigerant Identifier (if the communicate with the refrigerant
refrigerant identifier is pres- analyzer. Select OK icon to terminate
ent)
Recovery Identifier error 1, unstable Analysis refrigerant test failed
output. Move unit away from (known error 1)
any EMF or RFI sources Select RETRY or ESC icon
(if the refrigerant identifier is
present)
Recovery Identifier error 2, high output. Analysis refrigerant test failed
Move unit away from any (known error 2)
EMF or RFI sources (if the re- Select RETRY or ESC icon
frigerant identifier is present)
Recovery Identifier error 3, air calibra- Analysis refrigerant test failed
tion low. Check ventilation (known error 3)
(if the refrigerant identifier is Select RETRY or ESC icon
present)
Recovery Identifier error 4, temperature Analysis refrigerant test failed
out of range (if the refrigerant (known error 4)
identifier is present) Select RETRY or ESC icon
Recovery Identifier error 5, no flow. Analysis refrigerant test failed
Identifier filter and sample (known error 5)
tube may need replacement Select RETRY or ESC icon
(if the refrigerant identifier is
present)
RPM Calibration Air Flow Calibration Error Error that appears when the differ-
(except ACS 753 units) ence between speed fan on and
speed fan off is less than 200 RPM.
Select RETRY or ESC icon

ACS 753, ACS 763, ACS 863 Service Manual Electrical
Electrical System Operation and Repair

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.................................................................................................... 59
Sensors and Transducers................................................................................................... 60
Control Board Software Updating Methods...................................................................... 60
Electrical System Repair.......................................................................................65

Replacement Power Board................................................................................................. 65
Replacement Control Board .............................................................................................. 66
Replacement High-Pressure Cut-Out Switch ................................................................... 67
Replacement Fan Assembly .............................................................................................. 68
Replacement Scale Assembly/Magnet ............................................................................. 69
Scale Calibration (Load Cells)............................................................................................ 70
Replacing Load Cells.......................................................................................................... 71

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 (is used on ACS 863 unit only), S19 and S20
supply, and control board work together to P9: Solenoids S4, S5, S6, S7, S8, S9, S11,
condition the input voltage by removing voltage S12, S13 and S22
spikes and noise, transforming the input
voltage to 12 VDC (power supply) for operating The Power Board (PB) receives AC voltage at
relays and voltage regulators (power board), PBP3 from the power switch and circuit breaker
to power the unit cooling fan, engage the to PBP3 pins:
compressor and vacuum pump when required. • Pin 1 – Unit ground (on center divider)
Inputs from the sensors and transducers are • Pin 2 – AC low
processed (control board), to ultimately power • Pin 3 – AC high
the manifold solenoids (power board) for The input voltage is immediately applied to
recovering, recycling, and recharging vehicle the Power Supply (PS) through PBP4 and
A/C systems. the interconnecting cable to PSJ1. The output
Power Board and Power Supply Operation of the power supply is 12 V ± 0.1 VDC. This
The Power Board is shown in Figure 3-1. The is the main system control voltage and used
Power Supply is shown in Figure 3-2. Refer to throughout the unit for its various functions
these figures as needed. through PSJ2 to PBP1 and Control Board
(CB) receives 12 VDC from power board PBP2
Power Board Connector Assignments through an interconnecting cable to CBP19
See Figure 3-1, Power Board for connector (See Control Board Functions). Relay K3 is
locations: used to couple the 12 V output from the power
J1: Control Board J1 supply to the power board through PBP1.
P1: Power Supply J2
P2: Control Board P19 Input AC voltage within the power board is
P3: AC Input also routed to relays K2, K3, and K4. Relay
P4: Power Supply J1 functions are:
P5: Fan • K2 – Fan
P6: Vacuum Pump, Compressor • K3 – Compressor
• K4 – Vacuum Pump
P8 P9 Power for the unit fan, vacuum pump, and

P4 compressor is routed to those units through
PBP5 and PBP6 and wiring harnesses.
P3
P6 J1 1
J1
J2
P7 P1
6
K3 F1
K4 V Adj.
P5 K2 P2 Figure 3-2. 12 VDC Power Supply
Figure 3-1. Power Board

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. A fourth regulated power
the entire operation of the unit based upon the source supplies voltage to the optional printer.
signals from sensors, transducers, and manual
operator inputs via the keyboard. Control Board Functions
1. Reads Keypad
Control Board Connector Assignments • If a key does not respond, it’s most likely
See Figure 3-3 for connector locations. that:
J1: Power Board J1 1. it isn’t supposed to respond at that
J5: USB port time
J6: Refrigerant Identifier (if present) 2. the keypad is faulty (replace keypad)
P1: Air Flow Sensor (present but disabled on 3. Operates Display
ACS 753) • The display contrast changes with
P2: Oil Drain Load Cell temperature and light conditions.
P3: Dye Load Cell • Always try to adjust the contrast before
P6: Accumulator Pressure Transducer, Low- replacing the control board (Up/Down
Side Pressure Transducer, ISV Tank Pressure Arrows).
Transducer, ISV Tank Temperature Sensor, and • After adjustment, if there are missing
Ambient Temperature Sensor segments, characters, etc., in the lines
P8: Scale Assembly of the display, replacement is required.
P9: POE Load Cell 4. Contains Programming
P10: PAG Load Cell • Normally, if a unit runs at all, the program
P11: Led Board and the control board are okay. Reflashing
P13: USB Port does nothing unless a valid upgrade
P15: Printer Power program is available.
P17: Keypad 5. Communicates with USB ports.
P18: Printer Data • This occurs during software updates.
P19: 12 VDC from Power Board P2 6. Contains calibration and other stored
The Control Board (CB) receives power from variables
the Power Board PBP2 to CBP19. This voltage • Normally if a variable is corrupt an error
is used to power the sensor circuits, processors, will appear.
and is provided as an output signal to the Power • Never replace the control board to try to
Board to energize manifold solenoids, and the correct a reading inaccuracy.
compressor and vacuum pump relays. • If the calibration data is repeatedly
corrupt and causing calibration errors or
P17 J8 P7 P11 won’t hold calibration, the board could
be suspect.
P15
J2
P12 7. Communicates with the Power Board
J6
• Never replace the control board to correct

P19
J5
an input reading or output failure.

P13 • If any part of the program works the
controller is not the problem (it will not
J3 fail to operate any one output or input).
P1
P6
P18
J7
J1
P3 P2 P9 P10 P8
Figure 3-3. Control Board

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. computer (or network), or to update the
software as required occasionally to keep the
Sensors include: unit current. See Firmware update in the Setup
1. Air Flow Sensor (AF): senses whether the Menu Function section.
unit cooling fan is operating (present but
disabled on ACS 753). Refer to Figure 3-4 (Sheets 1 through 4), for a
2. Scale Assembly: weighs the refrigerant graphical representation of the interconnection
in the ISV as a baseline for determining of the electrical components.
the amount of refrigerant withdrawn from
the vehicle A/C system, the amount of
refrigerant added to the system, and how
much refrigerant is available in the ISV for
use.
3. ISV Tank Temperature (TT): supplies the
temperature of the refrigerant stored in
the ISV for adjusting fluid weight based on
density.
4. Ambient Temperature (AMBT): supplies
the base temperature reference for the
refrigerant control.
5. Oil Drain Load Cell: senses the weight of
the oil being drained (separated) from the
vehicle A/C system.
6. PAG or POE Load Cells: senses the
weight of the oil available for use by the
unit servicing the vehicle A/C system and
provides information to the unit as to how
much oil was injected into the vehicle A/C
system.
7. Dye Load Cell: same as PAG or POE Load
Cells, but for dye.
8. Refrigerant Identifier: identifies R1234yf
refrigerant and tests refrigerant for purity
(internal on the ACS 863; external through
the USB port on the ACS 763, function
disabled on ACS 753).
Transducers include:
1. Low-side Pressure (LSP): measures the
pressure in the low side of the vehicle A/C
system.
2. Accumulator Pressure (AP): measures
the pressure in the oil separator to ensure
proper oil separation from the refrigerant.
3. ISV Tank Pressure (TP): measures the
pressure in the ISV tank.

ss01906
P17 J8
Power Socket J2
P12
PS2 PS1
P19
PS3 P2
P13
GND
GRN/YEL CONTROL
J3
BOARD
P6
BLU BRN
Main J7
Switch J1
S/L2 R/L1
POWER 1
P2 J1 SUPPLY J2 P1
6
V/T2 U/T1
V
ADJ.
BLU BRN
Door Switch
GRN/YEL
P2
8 4 3 7
J1
P1
P9
P2
P1
BLU
P8
P7
Circuit Breaker
BRN CB1 POWER P3
BRN BOARD
P6
CB2
P5
P1
P4
P3
Internal Refrigerant
Identifier
Figure 3-4. Electrical Connections (Sheet 1 of 4)
NOTE: Internal refrigerant indentifier is included on ACS 863 unit only.

ss01904
ISV TANK ISV TANK AMBIENT ACCUMULATOR

TEMPERATURE PRESSURE TEMPERATURE PRESSURE
SENSOR TRANSDUCER SENSOR TRANSDUCER
(TT) (TT) (AMBT) (AP)
P3 P4 P2 P5
P17 J8 P7 P11
P15
P12 J2 REFRIGERANT
J6 IDENTIFIER
(ID)
J5 P19
P13 CONTROL
BOARD
J3
P1 P6 P1
P18
P2 AIR FLOW
P5 SENSOR
(AF)
J7
J1
P8
P3 P2 P9 P10
P6
LOW-SIDE
PRESSURE DYE OIL DRAIN POE PAG SCALE
TRANSDUCER LOAD CELL LOAD CELL LOAD CELL LOAD CELL ASSEMBLY
(LSP)
NOTE:
• Air Flow Sensor is disabled on ACS 753 unit only.
• Internal refrigerant indentifier is included on ACS 863 unit only.

ss01905
FLUSH + N2H2 ISV

MANIFOLD
S19 N2H2 Inlet BLK BRN S1 Air purge

P57 P9
S20 N2H2 Vent RED VIO S22 Tank liquid
P58 P11
INJECTION MANIFOLD
P2 P1 WHT S2 Oil inject 1 (PAG)

P8
P8 P9 VIO S14 Oil inject 2 (POE)

P54
P4
YEL S15 Dye
P55
P3
P6 J1
MAIN MANIFOLD
POWER P7 P1
BOARD
BLU S3 Oil drain
P51
BRN S4 Low-side inlet
P22
RED S5 High-side inlet
P21
P5 P2 WHT S6 High-side charge
P15
ORG S7 Low-side charge
P18
P3
RED S8 Recycle
P17
BLU S9 Vacuum
P16
RED S11 Recover
P12
ORG S12 Deep recover
P13
P14 YEL S13 Oil return

RED S17 Identifier
P56
WHT High pressure switch
NOTE: S17 is used on ACS 863 unit only.

ss01907
P2
LED
P17 J8 P7 P11 P1 BOARD
P15 P4
P12 J2
P19
P13
CONTROL
BOARD
J3
P3 PRINTER
P6 ASSEMBLY
P18 P2 P1
J7
J1
P8
P3 P2 P9 P10
P8 P9
P4
P3
P6 J1
P7 P1 P1 VACUUM
^^
PUMP
POWER
BOARD
GND
P5 P2
P4 P3
BRN
BLU
FAN
P2
COMPRESSOR
^^
GND

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
service work. Incorrect use or Remove Existing Power Board
connections can cause electrical NOTE: It may be necessary to remove the
shock. power supply to gain access to the bottom
attaching screws of the power board.
WARNING: Wear safety goggles
when working with refrigerants. 1. Disconnect unit from the power source.
Refrigerants can cause eye injury. 2. Remove shroud.
3. Disconnect all wires from power board.
WARNING: Use extreme caution 4. Remove screws securing power board in
when disconnecting hoses. place and remove power board.
Pressurized refrigerant may be
present in hoses. Point hoses away Install Replacement Power Board
from you and anyone nearby. 1. Install new power board and secure in place
with screws.
2. Connect wires as shown in power board
wiring diagram. See Figure 3-5.
3. Power up the unit and perform a functional
test.
P8 P9
P4
P3
J1 PBP9
PBP4 P6
P7 P1
PBP8
PBP3
PBJ1
PBP6 P5 P2
PBP1
PBP5 PBP2 PBP7
Figure 3-5. Power Board Connector Identification

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.
service work. Incorrect use or
connections can cause electrical Install Replacement Control Board
shock. NOTE: All control boards are shipped from
WARNING: Wear safety goggles the factory in the Production Boot Mode.
when working with refrigerants. Service centers must follow these installation
Refrigerants can cause eye injury. procedures to set the boot mode to Normal.
1. Attach the display and keypad ribbon cables
WARNING: Use extreme caution to the control board.
when disconnecting hoses. 2. Connect wires as shown in Figure 3-6.
Pressurized refrigerant may be 3. Tilt the control panel down and secure with
present in hoses. Point hoses away two screws.
from you and anyone nearby. 4. Power up the unit. The unit will be in the
NOTE: TANK TARE is a fixed value already Production Test Mode.
memorized in the main board spare parts. 5. Check the software version. If necessary,
download the new software and follow the
Instructions Install Current Software procedure under
These instructions outline the basic steps to Updating System Software Instruction in the
replace the control board. Refer to Figure 3-6. Diagnostics and Testing section.
Remove Existing Control Board 6. Access the Service Menu and enter yearly
1. Disconnect unit from the power source. password.
2. Remove shrouding. 7. Scroll to the Set Boot Mode option and
3. Remove the upper right- and left-hand enter access code 28768347.
screws from the control panel, then tilt the 8. If necessary, scroll to Normal and select OK
control panel towards the front of the unit. icon, for normal machine operation.
CBP17 CBJ6 CBP11
P17 J8 P11
CBP15
P15
LS1
J2
P12
J6
P19
CBP1 P13
CBP19
J3
P1
P6
P18
CBP6 J7
J1 CBP18
P2
P8
P3 P9 P10
CBP3 CBP2 CBP9 CBP10 CBP8 CBJ1
Figure 3-6. Control Board Connector Identification

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. Carefully remove the faulty cut-out switch.
number decal on the machine. 6. Clean the fitting by wiping away dirt, grease,
11. Select OK icon to save the serial number. and oil.
12. Perform the Scale Calibration. NOTE: DO NOT apply thread sealant to any
13. Enter the software registration code in the internal threads. Apply thread sealant to only
registration screen. If you don’t know the the external pipe threads of the fittings.
code, contact Bosch tech support.
14. Perform a functional check of the unit. WARNING: Thread sealant contains
ADHHM-128 anaerobic adhesive and
Replacement High-Pressure Cut-Out methacrylic ester. If there is skin
contact with the sealant, thoroughly
Switch wash the skin with soap and water.
WARNING: Disconnect the unit from 7. Install the new high-pressure cut-out switch.
the power source before beginning 8. Connect the wires to the new switch.
service work. Incorrect use or 9. Connect the unit to the power source.
connections can cause electrical 10. Operate the unit and check for leaks.
shock. 11. Replace the shroud.
when working with refrigerants.
Refrigerants can cause eye injury.
WARNING: Use extreme caution
when disconnecting hoses.
present in hoses. Point hoses away
from you and anyone nearby.
Replacement Instructions
Follow these steps to replace the high-pressure
cut-out switch on the unit. See Figure 3-7. Attach control wires
1. Evacuate the unit with a recovery service to these terminals
unit.
2. Turn off the power switch and disconnect Figure 3-7. High-Pressure Cut-Out Switch
the unit from the power source.
3. Remove the shroud to access the manifold
block.

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. Connect the unit to a power source and
service work. Incorrect use or place the power switch on. The fan should
connections can cause electrical run. If the fan does not run, refer to the
shock. Diagnostics and Testing section.
when working with refrigerants.
Refrigerants can cause eye injury.
Upper mounting hole
WARNING: Use extreme caution ss01994

Replacement Instructions
Follow these steps to replace the fan assembly.
Refer to Figure 3-8.
1. Clear service hose and remove them.
2. Disconnect Voltage.
3. Remove front panel and open service rear
door.
4. Remove oil return and discharge compressor
hose. Lower mounting hole
5. Remove 2 screws outside the frame to free
the fan. Figure 3-8. Fan Assembly
6. Note the orientation of the fan blades.
7. Disconnect the FAN connectors and fan
ground connector from the fan assembly.
8. Remove the fan assembly.
9. Fasten the fan ground connector to the
ground screw on the replacement fan body.
10. With the fan blades properly oriented as
noted in step 6, install the replacement fan
assembly by securing it to the lateral panel
assembly with two sheet metal screws.
11. Connect the FAN connectors to the fan
assembly. Use tie-wraps to secure the fan
wires
NOTE: There is no polarity requirement for
these connections.
12. Connect the power cord wire harness to
the vacuum pump shelf assembly, while
supporting the back panel to relieve stress
on the power cord after connecting.

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. Incorrect use or from the tank.
connections can cause electrical 4. Disconnect the wires from the air purge
shock. solenoid, tank temperature sensor, and
WARNING: Wear safety goggles pressure transducer.
when working with refrigerants. 5. Remove the two bolts securing the tank to
Refrigerants can cause eye injury. the scale.
6. Remove the tank from the scale.
WARNING: Use extreme caution 7. Remove the two bolts holding the scale in
when disconnecting hoses. place.
Pressurized refrigerant may be 8. Remove the ground wire connected to the
present in hoses. Point hoses away center divider of the unit and the harness
from you and anyone nearby. connected to the control board.
9. Slide scale forward and remove.
WARNING: If scale assembly circuit
are not calibrated, the tank can Installing Replacement Scale Assembly
overfill, causing possible explosion 1. Slide the rear flange of the scale under the
and/or vehicle overcharge. retaining lip of the chassis.
2. Connect the ground wire from the scale to
Instructions the center divider.
These instructions outline the steps to replace 3. nstall the scale into the unit fastening
the scale assembly. See Figure 3.9. securely with two bolts.
4. Connect the scale assembly wire to the
control board.
5. Connect the unit to the power source.
6. Perform scale calibration (next chapter).

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.

2. Disconnect the liquid hose and vapor hose CBP8
from the tank.
3. Disconnect the electrical wires from the air
purge solenoid, tank temperature sensor,
and pressure transducer.
4. Remove the bolts securing the tank to the
GND
scale assembly.
5. Remove the tank from the scale and verify Figure 3-9. Scale Assembly/Magnet
there is no weight on the scale or anything
interfering with the operation of the scale.
6. Access the SERVICE MENU.
7. Enter yearly password.
8. Complete the necessary steps to select
CALIBRATE LOAD CELLS.
NOTE: Calibration can be performed in Imperial
or Metric units. The unit of measure displayed
is determined at machine set-up.
9. Perform Calibrate Load Cells procedure in
the Diagnostics and Testing section.
10. Remove the weights and place the tank on
the scale.
11. Reconnect tank temperature sensor, air
purge solenoid, and pressure transducer
wires.
12. Reconnect liquid and vapor hoses to tank.
13. Secure the tank to the scale with two bolts.
14. Perform a functional test, check for leaks,
and replace shrouding.

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).
service work. Incorrect use or 2. Be sure adapter or load cells don’t toching
connections can cause electrical the external frame.
shock. 3. Connect the load cell wire harness to the
WARNING: Wear safety goggles control board.
when working with refrigerants. 4. Close the HMI back panel and put the frame.
Refrigerants can cause eye injury. 5. Connect the unit to its power source and
turn the unit on. Press the MENU icon.
WARNING: Use extreme caution 6. Select the SERVICE MENU.
when disconnecting hoses. 7. Enter yearly password and select OK icon.
Pressurized refrigerant may be 8. Select the Up or Down arrow key to scroll
present in hoses. Point hoses away to CALIBRATIONS and select OK icon.
from you and anyone nearby. 9. Scroll to the load cell requiring calibration
and and select OK icon.
Instructions 10. The process of calibrating the load cells
These general instructions outline the steps to involves two weights. The first is the un-
replace the oil drain, PAG or POE, or dye load loaded load cell (0.0 grams), the second
cells. See Figure 3.10. is with a weight hanging from the load cell
(500 grams) Pause between each calibra-
Removing the Load Cell
tion step to make sure the values are loaded
into the data set.
2. Remove the oil (PAG and POE), dye, and
11. Double check with sample weight of
drain bottles from the load cells.
250 grams is needed to complete calibra-
3. Remove the HMI frame and back panel.
tion After entering, select OK icon.
4. Disconnect the wire harness connecting the
load cell(s) being replaced from the control
board.
5. Remove the 4 screws securing the load cell
to adapter block (internal side of the panel
and outside the panel, see picture).
6. Remove the load cell.
Cell mounting Screws

direction
Figure 3-10. Load cells

Plumbing and Mechanical ACS 753, ACS 763, ACS 863 Service Manual
Plumbing and Mechanical System Operation and Repair

Plumbing and Mechanical System Operation.....................................................73
Compressor......................................................................................................................... 73
Vacuum Pump...................................................................................................................... 73
Main Manifold....................................................................................................................... 73
Internal Storage Vessel (ISV).............................................................................................. 73
Cooling Fan.......................................................................................................................... 74
Injection Manifold................................................................................................................ 74
Flush + N2H2 Manifold........................................................................................................ 74
Oil Drain Bottle.................................................................................................................... 74
High- and Low-Side Gauges............................................................................................... 74
High- (Red) and Low-Side (Blue) Service Hoses.............................................................. 74
Plumbing and Mechanical System Repair .......................................................... 75

Replacement Compressor ................................................................................................. 75
Replacement Vacuum Pump ............................................................................................. 77
Replacement Manifold Block ............................................................................................. 79
Replacement Injection Manifold ........................................................................................ 81
Replacement Flush + N2H2 Manifold ............................................................................... 82
Repairing or Replacing a Solenoid ................................................................................... 83
Replacing Check Valve ...................................................................................................... 84
Component Application Charts.............................................................................85
Flow Diagrams........................................................................................................87
Tank Fill................................................................................................................................ 87
Internal Clearing.................................................................................................................. 88
Refrigerant Identification.................................................................................................... 89
Recovery.............................................................................................................................. 90
Deep Recovery..................................................................................................................... 91
Oil Drain................................................................................................................................ 92
Vacuum................................................................................................................................. 93
Vacuum Leak Test............................................................................................................... 94
Air Purge.............................................................................................................................. 95
Oil Inject 1 (PAG)................................................................................................................. 96
Oil Inject 2 (POE)................................................................................................................. 97
UV Dye Inject........................................................................................................................ 98
Pre-charge............................................................................................................................ 99
Charge .................................................................................................................................. 100
Recycle/Power Charge........................................................................................................ 101
Hose Flush........................................................................................................................... 102
Periodic Leak Test............................................................................................................... 103
N2H2 Injection...................................................................................................................... 104
N2H2 Venting....................................................................................................................... 105

ACS 753, ACS 763, ACS 863 Service Manual Plumbing and Mechanical
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 • Oil Return (S13)
components to the plumbing system: • Identifier (S17)
• Compressor Also included are transducers:
• Vacuum Pump • Low Side Pressure (LSP) transducer
• Main Manifold Assembly • Accumulator Pressure (AP) transducer
• Internal Storage Vessel (ISV) The manifold assembly permits efficient,
Along with these components are several reliable operation of the unit. The oil separator
ancillary components: and heat exchanger are a single unit. That and
• Cooling Fan the filter/dryer are attached below the manifold.
• Injection Manifold Assembly This manifold assembly is not interchangeable
• Flush + N2H2 Manifold Assembly with any other manifold assembly.
• Oil Drain Bottle Repair or replacement of the manifold should
• High- and Low-Side Gauges be performed under clean conditions so
• High- (red) and Low-Side (blue) Service particulates do not enter the assembly from
Hoses any open ports. Particulates can clog the small
All components are interconnected with various chambers and cause solenoid and check valve
lengths and diameters of flexible tubing or malfunctions, as well as contaminate a vehicle
copper tubing. The copper tubing connects air conditioning system.
the compressor discharge port to the manifold
assembly. All lines connected to the compressor Internal Storage Vessel (ISV)
are high-pressure lines. The ISV stores the refrigerant from the
vehicle A/C system and from the external
Compressor refrigerant source tank. Sensors, solenoids,
When replacing the compressor, heed all and transducers on the ISV include:
warnings, cautions, and any other related safety • Air Purge (S1)
information. For compressor specifications, see • Tank liquid (S22)
Unit Specifications chapter of this manual. • ISV Pressure (TP) transducer
• ISV Temperature (TT) sensor
Vacuum Pump
The vacuum pump is used in this unit for the
recovery and vacuum processes. For vacuum
pump specifications, see Unit Specifications
chapter of this manual.
Main Manifold
The main manifold assembly consists of
solenoids:
• Oil Drain (S3)
• Low-Side Inlet (S4)
• High-Side Inlet (S5)
• High-Side Charge (S6)
• Low-Side Charge (S7)
• Recycle (S8)
• Vacuum (S9)

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. Operators should drain this bottle prior to
to keep the compressor below its maximum each use of the unit to make sure unit operation
ambient operation temperature of 50°C (140°F) is not interrupted.
or less.
High- and Low-Side Gauges: These gauges
Injection Manifold: This assembly serves as monitor the high- and low-side pressures when
the attachment ports for the high- and low-side the unit is operating.
service hoses, as the oil injection point through
PAG Solenoid (S2) and POE Solenoid (S14), High- (Red) and Low-Side (Blue) Service
and as the dye injection point through Dye Inject Hoses: These hoses connect the unit to the
Solenoid (S15). vehicle A/C system.
Flush + N2H2 Manifold: This assembly serves
as the attachment ports for the high- and low-
side service hoses, as the N2H2 or N2 injection
point through N2H2 Inlet Solenoid (S19).

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. Place two
service work. Incorrect use or metal sleeves in the front mounts only.
connections can cause electrical 2. Place the compressor into the unit. It may be
shock. necessary to lubricate the rear compressor
WARNING: Wear safety goggles mounts. If needed, apply a small amount of
when working with refrigerants. light oil, such as compressor oil, to the top
Refrigerants can cause eye injury. and bottom of the rubber mount.
3. Connect the compressor pigtail to the
WARNING: Use extreme caution COMP connector on the main wire harness.
when disconnecting hoses. 4. Refer to the illustration and install the hoses
Pressurized refrigerant may be connecting the compressor to the manifold
present in hoses. Point hoses away block. Replace the O-rings where used on
from you and anyone nearby. the hoses.
5. Secure the compressor into place with the
Instructions hardware in the RA kit.
These instructions outline the steps to replace 6. With the O-rings in place, connect the
the existing compressor. See Figure 4-1, copper line to the discharge side of the unit.
Plumbing Interconnection Diagram. Refer to this 7. Close the service rear door.
schematic of the unit plumbing and mechanical 8. Connect the unit to the power source,
system when performing all removals and perform a function test, and check for leaks.
replacements of plumbing or other mechanical
parts and assemblies.
Removing Compressor
1. Disconnect the unit from its power source.
2. Open the service rear door.
3. Disconnect the copper line from the
compressor.
WARNING: There may be pressure in
the copper line.
4. Remove the compressor mounting bolts and
washers and slide the compressor away
from the rear retainer.
5. Disconnect the hoses from the compressor.
6. Disconnect the compressor pigtail from the
COMP connector on the main harness.
7. Remove the compressor from the unit.
CAUTION: To prevent personal injury,
use caution when removing the
compressor. The capacitor may still
be energized.

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.
2. Apply Loctite 242 to equivalent to threads.
3. Torque hose fittings to 8.5 ±0.5Nm.
4. Route replacement hoses and tubes in the same positions and places as the original securing
with tie-wraps where appropriate.
Figure 4-1. Compressor Interconnection Diagram

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.
service work. Incorrect use or 6. Disconnect the vacuum PUMP connector
connections can cause electrical from the main harness.
shock. 7. Remove the vacuum pump from the unit.
WARNING: Wear safety goggles Installing Replacement Vacuum Pump
when working with refrigerants. 1. Place the vacuum pump into the unit.
Refrigerants can cause eye injury. 2. Secure the vacuum pump to the unit with
WARNING: Use extreme caution two screws.
when disconnecting hoses. 3. Connect the electrical connector (PUMP)
Pressurized refrigerant may be from the vacuum pump to the main harness.
present in hoses. Point hoses away 4. Connect the two plastic lines.
from you and anyone nearby. 5. Remove the cap from the vacuum pump
oil fill port.
Instructions 6. Add 140 g (5 oz) of oil into the vacuum
These instructions outline the steps to replace pump.
the existing vacuum pump. See Figures 4-2 7. Place the cap on the fill port.
and 4-3. 8. Close the service rear door.
9. Perform the steps to start the pump.
Removing Vacuum Pump 10. While the vacuum pump is running, check
1. Disconnect the unit from the power source. the correct fill level through the sight glass.
2. Open the service rear door. 11. Perform a function test and check for leaks.
3. Remove the screw holding the control panel
to its support and rotate the control panel
toward the front of the unit.
ss01940
Oil fill port
Sight
Oil drain glass
port
Figure 4-2. Vacuum Pump

ss01943 High-side gauge 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. Plumbing Interconnection Diagram

Replacement Manifold Block Removing Manifold Block
WARNING: Disconnect the unit from 2. Remove the front plastic covers.
the power source before beginning 3. Disconnect all hoses from the manifold
service work. Incorrect use or block.
connections can cause electrical 4. Disconnect all wires from the block
shock. components.
WARNING: Wear safety goggles 5. Remove the manifold block.
when working with refrigerants. Installing Replacement Manifold Block
Refrigerants can cause eye injury. See Figure 4-4 while performing the following
WARNING: Use extreme caution procedures.
when disconnecting hoses. 1. Connect the hoses and lines to the manifold
Pressurized refrigerant may be block. Refer to Figures 4-1, 4-3, and 4-4 for
present in hoses. Point hoses away the proper location of the hoses.
from you and anyone nearby. 2. Reconnect all wiring as shown in Figure 4-4.
3. Mount the front plastic covers.
Instructions 4. Connect the unit to the power source,
These instructions outline the steps to replace perform a function test, and check for leaks.
the existing manifold block. See Figure 4-4.
In most cases, the manifold block does not
have to be removed from the unit for repair.
Solenoids and check valves can be replaced
without complete removal of the block from the
unit. When this is possible, remove and replace
the faulty component in place, after following
steps 1 through 2 in Removing Manifold Block.
The remaining steps (3-5) outline the procedure
for removing the entire manifold block. See
Figure 4-4.
If the injector manifold is being repaired, refer
to the Replacement Manifold Solenoid or
Replacement Manifold Check Valve as needed.
When installing hoses, solenoids, and check
valves, replace the O-rings and use thread
sealant where necessary.

NOTE: All wires must be clear of moving parts, pinch points, and sharp edges.
Low Side Inlet High Side Inlet

High-Pressure Solenoid (S4) Solenoid (S5) N2H2 Inlet
Switch Solenoid (S19) N2H2 Vent
Solenoid (S20)
Low Side Charge
Solenoid (S7)
High Side Charge

Recover Solenoid (S6)
Solenoid (S11)
Accumulator Pressure
Transducer (AP)
Flush + N2H2
Manifold Assembly
Deep Recover
Vacuum
Solenoid (S12) POE Solenoid PAG Solenoid
Solenoid (S9)
Oil Return Recycle Identifier (S14) (S2)
Solenoid (S13) Solenoid (S8) Solenoid (S17) Dye Solenoid
Manifold Assembly (Top View) (S15)
Low Side Pressure

Transducer (LSP)
Injection Manifold Assembly
Tank Temperature Tank Liquid Air Purge

Sensor (TT) Solenoid (S22) Solenoid (S1)
4psi Relief
Check Valve for
Vacuum Pump
Tank Pressure
Transducer (TP)
Oil Drain
Solenoid (S3)
Manifold Assembly
(Side View)
ISV Assembly
(Side View)
Figure 4-4. Assembly Component Names

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. Connect the wiring to the injector block
service work. Incorrect use or solenoid(s).
connections can cause electrical 3. Install the injection manifold to the panel
shock. and secure with two screws.
WARNING: Wear safety goggles 4. Attach the high- and low-side inlet hoses to
when working with refrigerants. the manifold block.
Refrigerants can cause eye injury. 5. Attach the outside high- (red) and low-side
(blue) service hoses to the injection manifold
assembly.
7. Connect the unit to the power source,
perform a function test, and check for leaks.
PAG Solenoid Bottle Hose
Instructions (S2) Connections
These instructions outline the steps to replace
POE Solenoid
the injection manifold. See Figures 4-3 through (S14)
4-5. If an injection block is being repaired,
refer to Repairing or Replacing a Solenoid
or Replacing a Check Valve on the following
two pages, as applicable, once the block is
removed.
High and Low
When installing hoses, solenoid(s), or check Service Hose Ports
valve, replace the O-rings and use thread
sealant where necessary.
Removing the Injection Manifold
2. Remove the front plastic covers and the
service hoses. Dye Contaminant recovery
3. Remove the two screws securing the Solenoid (S15) outlet port
injection manifold to the panel of the unit. (ACS 863 only)
4. Disconnect the high- and low-side inlet lines
from the manifold block. Figure 4-5. Injection Manifold
5. Remove the injection manifold from the unit.
6. Remove the wiring from the oil injection
solenoid(s).
7. Remove the inside high- and low-side inlet
lines.

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. Connect the wiring to the injector block
service work. Incorrect use or solenoid(s).
connections can cause electrical 3. Install the flush + N2H2 manifold to the
shock. panel and secure with two screws.
WARNING: Wear safety goggles 4. Mount the front plastic covers.
when working with refrigerants. 5. Connect the unit to the power source,
Refrigerants can cause eye injury. perform a function test, and check for leaks.
WARNING: Use extreme caution Hose
High and Low Flush
when disconnecting hoses. Connections
Ports
Instructions
These instructions outline the steps to replace
the flush + N2H2 manifold. See Figures 4-3
through 4-6.
When installing hoses, solenoid(s), or check
valve, replace the O-rings and use thread N2H2 or N2
sealant where necessary. inlet port
Removing the Flush + N2H2 Manifold

1. Disconnect the unit from the power source. N2H2 Inlet
2. Remove the front plastic covers and the Solenoid (S19)
service hoses. N2H2 Vent
Solenoid (S20)
3. Remove the two screws securing the flush
+ N2H2 manifold to the panel of the unit. Figure 4-6. Flush + N2H2 Manifold
4. Disconnect the plastic hose inlet lines from
the manifold block.
5. Remove the coils cables from the manifold.
6. Remove the complete block.

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. Incorrect use or assembly and hand tighten.
connections can cause electrical 3. Using a torque wrench, torque the solenoid
shock. assembly to 8-9 Nm (70-89 in-lb).
WARNING: Wear safety goggles 4. Install the coil on the solenoid assembly,
when working with refrigerants. and secure with the fastener holding the
Refrigerants can cause eye injury. coil in place.
5. Using a torque wrench, torque the coil
retaining bolt to 3-4 Nm (25-35 in-lb).
6. Reconnect the wires that were disconnected
earlier when removing the faulty solenoid
assembly.
Instructions 8. Connect the unit to the power source,
These instructions outline the steps to repair perform a function test, and check for any
solenoids found throughout the unit. leaks.
Removing Solenoid
2. Remove the front plastic covers.
3. Depressurize the unit.
4. Disconnect the two wires connected to the
solenoid being repaired or replaced.
5. Remove the fastener holding the coil on the
solenoid, and remove the coil.
6. Remove the solenoid assembly from the
manifold block.
7. Check the manifold block for any debris
before installing a repaired or replacement
solenoid.

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. Incorrect use or tighten.
connections can cause electrical 3. Torque the check valve to 8-9 Nm (70-80
shock. in-lb).
WARNING: Wear safety goggles 4. Mount the front plastic covers.
when working with refrigerants. 5. Connect the unit to the power source,
Refrigerants can cause eye injury. perform a function test, and check for leaks.
WARNING: Use extreme caution Removing Solenoid Check Valve

when disconnecting hoses. 1. Disconnect the unit from the power source.
Pressurized refrigerant may be 2. Remove the front plastic covers.
present in hoses. Point hoses away 3. Depressurize the unit.
from you and anyone nearby. 4. Refer to Removing Solenoid on the previous
page.
Instructions 5. Remove the check valve from the manifold
These instructions outline the steps to replace after removing the solenoid.
manifold, injection manifold, and solenoid
Installing Replacement Solenoid Check
check valves. In some cases, the manifold
Valve
must be removed from the unit to gain access
1. Lubricate the O-rings on the new check
to solenoids or other components.
valve.
Removing Check Valve 2. Install the new check valve and hand-
1. Disconnect the unit from the power source. tighten.
2. Remove the front plastic covers. 3. Torque the check valve to 8-9 Nm (70-80
3. Depressurize the unit. in-lb).
4. Remove the faulty check valve. 4. Perform the Installing Solenoid procedures
on the previous page.

COMPONENT APPLICATION CHARTS

NOTES FOR COMPONENT APPLICATION CHARTS
1. Tank Fill Process: The output state of the Recover solenoid is controlled to maintain 2.4 bar
(35 psi) in the accumulator.
2. Recover Process: The output state of the recover solenoid is controlled to maintain 0.55 bar
(8 psi) to 4.27 bar (62 psi) max. in the accumulator. The output state of the oil return solenoid
is initially activated for three seconds, and reactivated every 10 minutes thereafter depending
on the length of the recovery process.
3. Deep Recover Process: The output state of the oil return and recycle solenoids are controlled
to maintain 0 to 207 mbar (3 psi) in the accumulator.
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
Periodic Leak Test

Vacuum Leak Test
Oil Inject 2 (POE)

Oil Inject 1 (PAG)
Recycle/ Power
N2H2 Injection
Deep Recover
N2H2 Venting
UV Dye Inject
Identification
Pre-Charge
Hose Flush
Refrigerant
Function
Air Purge
Oil Drain
Clearing
Tank Fill
Recover
Vacuum
Internal
Charge
Charge
Component
Air Purge solenoid (S1) I

Oil Inject 1 (PAG) ON
solenoid (S2)
Oil Drain solenoid (S3) ON
Low-Side Inlet solenoid ON ON ON ON ON I ON ON ON
(S4)
High-Side Inlet solenoid ON ON ON ON ON I ON ON ON
(S5)
High-Side Charge ON I I I
solenoid (S6)
Low-Side Charge ON I I I
solenoid (S7)
Recycle solenoid (S8) I ON
Vacuum solenoid (S9) ON ON
Recover solenoid (S11) I I I ON
Deep Recover solenoid ON
(S12)
Oil Return solenoid (S13) I I I I ON
Oil inject 2 (POE) ON
solenoid (S14)
Dye solenoid (S15) ON
Identifier solenoid (S17) ON

N2H2 inlet solenoid (S19) ON
N2H2 vent solenoid (S20) ON
Tank liquid solenoid (S22) ON ON ON ON
Legend ON ON I ON Intermittently

Fluid Flow Diagram Locations

Function Figure No.
Tank Fill 4-7
Internal Clearing 4-8
Refrigerant Identification 4.9
Recover 4-10
Deep Recover 4-11
Oil Drain 4-12
Vacuum 4-13
Vacuum Leak Test 4-14
Air Purge 4.15
Oil Inject 1 (PAG) 4-16
Oil Inject 2 (POE) 4.17
UV Dye Inject 4.18
Pre-charge 4.19
Charge 4.20
Recycle/Power charge 4.21
Hose Flush 4-22
Periodic leak test 4.23
N2H2 Injection 4.24
N2H2 Venting 4.25

ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge

Refrigerant Solenoid
Identifier
Tank Liquid
Liquid Solenoid
Robert Bosch GmbH

TANK FILL PROCESS
LS Charge Main Manifold Vapor
ID Solenoid
Solenoid Pressure
LS Charge Vapor Relief
ID Orifice
Check Valve Check Valve Temp.
Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
Check Valve High Pressure
Cutout Swtich
Accumulator
Transducer
Low Side
Transducer LS Inlet Recover
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
HS Inlet Heat Exchanger /
LS Solenoid Deep Recover Compressor Oil
System Oil
Gauge Solenoid Separator
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
87
Gauge
Oil Drain
Solenoid
reaches the “target” weight, all components are deactivated.

Pump Exhaust
Check Valve
Figure 4-7. Tank Fill

Vacuum Pump
Exhaust
Compressor
Vacuum Pump
FLOW DIAGRAMS
Oil Drain
Bottle
Injection
Manifold Oil Inject 1
Solenoid
N2H2 Port
Oil Inject 1
Check Valve Oil 1 Inject
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil Inject 2 Low Side
Check Valve Pressure Storage Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
SP00D00609
Dye Inject
Bottle
Low Side High Side

Service Hose High Side Storage Port
Service Hose
Plumbing and Mechanical
2018-03-26
temperature which can vary depending on the temperature reading from the temperature sensor. When the ISV
of the tank fill solenoid is controlled to maintain 2.4 bar (35 psi) in the accumulator, and is based on the ambient
During the Tank Fill process the compressor, fan, tank fill, and oil return solenoids are activated. The output state
ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge
SP00D00609
Identifier
Tank Liquid
Liquid Solenoid

ID Solenoid
Solenoid Pressure
2018-03-26
ID Orifice
Sensor
is reached, plus 15 seconds.

HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
INTERNAL CLEARING PROCESS

Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
88
Oil Drain
Pump Exhaust Solenoid
Check Valve
Vacuum Pump
Exhaust
Compressor
Vacuum Pump
Figure 4-8. Internal Clearing

Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
Low Side High Side

Service Hose
During the Internal Clearing process, the compressor is activated. The process continues until -0.45 bar (13 in Hg)
Robert Bosch GmbH

ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge

Identifier
Robert Bosch GmbH

Tank Liquid
Liquid Solenoid

ID Solenoid
Solenoid Pressure
ID Orifice
Sensor
repeat at least two more times.

HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Tank
Recover Check
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
89
Oil Drain
Check Valve
REFRIGERANT IDENTIFICATION PROCESS (ACS 863 only)

Vacuum Pump
Exhaust
Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Figure 4-9. Refrigerant Identification

Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
SP00D00609
Low Side High Side
Service Hose

2018-03-26
the recovery process, or a “FAIL” message will display. If the refrigerant fails to pass the ID test, the machine will
orifice. After analyzing the refrigerant, the identifier will either send a “PASS” message to the control board to begin
open intermittently, allowing refrigerant to flow to the refrigerant identifier, through the 0.028-inch internal diameter
pressure is verified the machine will initiate identification of the refrigerant. The low side identifier solenoid (S17) will
print the results, and ask if you want to repeat the ID test. If the refrigerant ID test, fails, the test will automatically
When the recover or tank fill function is selected, the machine will check pressures on the service hoses. Once
ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge
SP00D00609
Identifier
Tank Liquid
Liquid Solenoid

ID Solenoid
RECOVERY PROCESS
Solenoid Pressure
2018-03-26
ID Orifice
reached, plus 15 seconds.

Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
90
Oil Drain
Check Valve
Figure 4-10. Recover

Vacuum Pump
Exhaust
Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
Low Side High Side

Service Hose
During the first stage of the recovery process, the fan, compressor, high side and low side inlet solenoids are
Robert Bosch GmbH

activated. Recover and oil return solenoids are activated intermittently. Recovery stops when 135 mbar (4 in Hg) is
ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge

Identifier
Tank Liquid
Liquid Solenoid
Robert Bosch GmbH

ID Solenoid
Solenoid Pressure
ID Orifice
Sensor
HS Charge Recycle
DEEP RECOVERY PROCESS

Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
91
Oil Drain
Check Valve
Vacuum Pump
Exhaust
Figure 4-11. Deep Recover

Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
SP00D00609
Bottle
Low Side High Side

Service Hose
the oil return and power charge solenoids are controlled to maintain 0 to 207 mbar (3 psi) in the accumulator.
During the Deep Recovery process, the recover solenoid is deactivated, high side, and low side inlet solenoids
2018-03-26
remain activated. The vacuum pump, compressor, and deep recover solenoids are activated. The output state of
ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge
SP00D00609
Identifier
Tank Liquid
Liquid Solenoid
in the accumulator.
OIL DRAIN PROCESS
ID Solenoid
Solenoid
2018-03-26
Pressure
ID Orifice
Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge Oil Drain
92
Solenoid
Pump Exhaust
Check Valve
Figure 4-12. Oil Drain

Vacuum Pump
Exhaust
Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
Low Side High Side

Service Hose
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)
Robert Bosch GmbH

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
ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge

Identifier
Tank Liquid
Liquid Solenoid
Robert Bosch GmbH

VACUUM PROCESS
ID Solenoid
Solenoid Pressure
ID Orifice
Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
0 (zero), the vacuum process will stop.

Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve

System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
93
Oil Drain
Check Valve
Figure 4-13. Vacuum

Vacuum Pump
Exhaust
Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
SP00D00609
Bottle
Low Side High Side

Service Hose
2018-03-26
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
ISV Pressure
Air Transducer
Diffuser
RI Filter
SP00D00609
Air Purge
Identifier
Tank Liquid
Liquid Solenoid

ID Solenoid
2018-03-26
Solenoid Pressure
ID Orifice
Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
VACUUM LEAK TEST PROCESS

Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
94
Oil Drain
Check Valve
time, the vacuum leak test will fail (this is not a service menu test.)
Vacuum Pump
Exhaust
Compressor
Vacuum Pump
Figure 4-14. Vacuum Leak Test

Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
Low Side High Side

Service Hose
Robert Bosch GmbH

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
ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge

Identifier
Tank Liquid
Liquid Solenoid
Robert Bosch GmbH

AIR PURGE PROCESS

ID Solenoid
Solenoid Pressure
ID Orifice
Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve

System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge Oil Drain
95
Solenoid
Pump Exhaust
Check Valve
Vacuum Pump
Figure 4-15. Air Purge

Exhaust
Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Check Valve
will occur when the machine is on and idle for 5 minutes, and prior to background fill.
Oil 1 Inject
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
SP00D00609
Bottle
Low Side High Side

Service Hose
The air purge solenoid is activated to release excess pressure from the internal storage vessel (ISV). The air purge
2018-03-26
ISV Pressure
Air Transducer
Diffuser
RI Filter
SP00D00609
Air Purge
Identifier
Tank Liquid
Liquid Solenoid
oil PAG inject bottle.

ID Solenoid
2018-03-26
Solenoid Pressure
ID Orifice
Sensor
HS Charge Recycle
Solenoid Solenoid
OIL INJECT 1 (PAG) PROCESS

HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
96
Oil Drain
Check Valve
Vacuum Pump
Exhaust
Compressor
Vacuum Pump
Figure 4-16. Oil Inject 1 (PAG)

Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
Low Side High Side

Service Hose
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
Robert Bosch GmbH

ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge

Identifier
Tank Liquid
Robert Bosch GmbH

Liquid Solenoid
oil POE inject bottle.

ID Solenoid
Solenoid Pressure
ID Orifice
Sensor
HS Charge Recycle
Solenoid Solenoid
OIL INJECT 2 (POE) PROCESS

HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
97
Gauge
Oil Drain
Check Valve
Vacuum Pump
Exhaust
Compressor
Vacuum Pump
Figure 4-17. Oil Inject 2 (POE)

Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
SP00D00609
Bottle
Low Side High Side

Service Hose
and the machine injects the oil automatically. The system being serviced must have a vacuum to pull oil from the
The oil injection is an automatic process. During the charge setup, the operator must enter the amount of oil wanted
2018-03-26
ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge
SP00D00609
Identifier
Tank Liquid
Liquid Solenoid

ID Solenoid
2018-03-26
Solenoid Pressure
ID Orifice
Sensor
UV DYE INJECT PROCESS

HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
98
Oil Drain
Check Valve
Vacuum Pump
Exhaust
Figure 4-18. UV Dye Inject

Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
Low Side High Side

Service Hose
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.
Robert Bosch GmbH

ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge

Identifier
Tank Liquid
Robert Bosch GmbH

Liquid Solenoid

ID Solenoid
Solenoid Pressure
ID Orifice
Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
PRE-CHARGE PROCESS (R1234yf only if enabled)

Vacuum
Solenoid
HS Filter/Drier
Gauge
99
Oil Drain
A/C system and perform a pressure test to check any leaks.

Check Valve
Vacuum Pump
Figure 4-19. Pre-Charge

Exhaust
Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
SP00D00609
Low Side High Side
Service Hose

During the pre-charge process (before to perform the charge), the unit charge a little amount of refrigerant in the
2018-03-26
ISV Pressure
Air Transducer
Diffuser
RI Filter
SP00D00609
Air Purge
Identifier
Tank Liquid
Liquid Solenoid
CHARGE PROCESS
ID Solenoid
2018-03-26
Solenoid Pressure
ID Orifice
Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
100
Oil Drain
Check Valve
Figure 4-20. Charge

Vacuum Pump
Exhaust
Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
Low Side High Side

Service Hose
will prompt the user in completing the charge. When the charge process is complete, user must equalize hoses.
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
Robert Bosch GmbH

ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge

Identifier
tank pressure.
Tank Liquid
Robert Bosch GmbH

Liquid Solenoid

ID Solenoid
Solenoid Pressure
ID Orifice
Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
RECYCLE/POWER CHARGE PROCESS

Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
101
Oil Drain
Check Valve
Vacuum Pump
Exhaust
Compressor
Vacuum Pump
Oil Drain
Figure 4-21. Recycle/Power Charge

Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
SP00D00609
Bottle
Low Side High Side

Service Hose
If the unit does not complete a full charge, the compressor and recycle solenoid are activated, then stop to build
2018-03-26
ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge
SP00D00609
Identifier
Tank Liquid
Liquid Solenoid

ID Solenoid
Solenoid
2018-03-26
Pressure
HOSE FLUSH PROCESS

ID Orifice
Sensor
to flush hoses or residual oils.

HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
Oil Drain
102
Check Valve
Vacuum Pump
Figure 4-22. Hose Flush

Exhaust
Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
Low Side High Side

Service Hose
previous vehicle serviced. During the Hose Flush Process, the compressor is activated. The high side and low side
Robert Bosch GmbH

charge, high side and low side inlet and recover solenoids are intermittently activated in a charge/recover 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
ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge

Identifier
Tank Liquid
Robert Bosch GmbH

Liquid Solenoid

ID Solenoid
Solenoid Pressure
ID Orifice
Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
PERIODIC LEAK TEST (R1234yf only)

Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
103
Oil Drain
Check Valve
Vacuum Pump
Exhaust
Vacuum Pump
Compressor
Figure 4-23. Periodic Leak Test

Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
SP00D00609
Bottle
charge, high side inlet, low side inlet, recycle, oil return, recover solenoids to check any pressure decay.
Low Side High Side
Service Hose
During the periodic leak test process the circuit is pressurized. The unit activates the high side charge, low side
2018-03-26
ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge
SP00D00609
Identifier
Tank Liquid
Liquid Solenoid

ID Solenoid
2018-03-26
Solenoid Pressure
ID Orifice
Sensor
N2H2 INJECTION PROCESS

HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
Oil Drain
104
Check Valve
Vacuum Pump
Exhaust
Figure 4-24. N2H2 Injection

Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
system thru the ACS service hoses. Pressure is monitored by the Low Side Tranducer.
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
Bottle
Low Side High Side

Service Hose
During the N2H2/N2 injection process, the N2H2 Inlet Solenoid opens to allow the gas flooding the vehicle A/C
Robert Bosch GmbH

ISV Pressure
Air Transducer
Diffuser
RI Filter Air Purge

Identifier
Tank Liquid
Robert Bosch GmbH

Liquid Solenoid

ID Solenoid
Solenoid Pressure
ID Orifice
N2H2 VENTING PROCESS

Sensor
HS Charge Recycle
Solenoid Solenoid
HS Charge
Cutout Swtich
Accumulator
Transducer
Low Side
That prevents refrigerant contamination.

Solenoid Solenoid
Service Port
Internal
Recover Check
Tank
Valve
System Oil
Separator
Oil Return
Solenoid
Vacuum
Solenoid
HS Filter/Drier
Gauge
105
Oil Drain
Check Valve
Vacuum Pump
Exhaust
Figure 4-25. N2H2 Venting

Compressor
Vacuum Pump
Oil Drain
Bottle
Injection
Solenoid
N2H2 Port
Oil Inject 1
Oil Inject 2 Bottle
Solenoid
Contamination
Port
Oil 2 Inject Relief
Dye Inject Bottle
Solenoid
N2H2 Inlet
N2H2 Vent Solenoid
Solenoid
N2H2
Dye Inject
Check Valve
Diffuser
Dye Inject
SP00D00609
Bottle
Low Side High Side

Service Hose
2018-03-26
N2 trapped into the ACS inlet. Vacuum is then performed to remove any possible remained N2H2/N2 after venting.
During the N2H2/N2 injection process (when injection is completed), the N2H2 Vent Solenoid opens to purge N2H2/
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. GAUGE, LOW-SIDE— Monitors low-side
BOTTLE, OIL DRAIN — Recovers the used oil pressure of the vehicle being serviced.
during the oil drain process. HIGH-PRESSURE CUTOUT SWITCH— Switch
BOTTLE, UV DYE INJECT — Stores UV dye opens at 22.5 ± 0.7 bar (326 ± 10 psi) and resets
for injection into the A/C system. at 17 ± 0.7 bar (250 ± 10 psi). If pressure in
BOTTLE, OIL INJECT 1 (PAG) — Stores PAG the high side of the system exceeds 22.5 bar
oil for injection into the A/C system. (326 psi), the switch opens stopping all functions.
BOTTLE, OIL INJECT 2 (POE) — Stores POE INTERNAL STORAGE VESSEL (ISV)—
oil for injection into the A/C system. Storage tank where the recovered and recycled
refrigerant is stored. Vapor, liquid, and air purge
BREAKER, CIRCUIT— Protects the unit from access is on-top of tank.
drawing too much current. If tripped, unit is
completely inoperative. KEYPAD— Touch-pad providing the user
interface for controlling, entering date, or
CALIBRATION WEIGHT— Calibration standard navigating through the operation of the unit.
that attaches to magnet under scale assembly.
Used to verify scale calibration. MAIN MANIFOLD ASSEMBLY— Internal
manifold assembly that contains solenoids,
CHECK VALVE— Allows refrigerant, air, or oil check valves and switches. Refrigerant will
flow in one direction only. flow through the manifold assembly for proper
COMPRESSOR— Moves refrigerant from the distribution.
A/C system being serviced into the ISV on the MUFFLER, AIR EXHAUST— Disperses
unit. excessive air from the ISV. Provides effective
COMPRESSOR CAPACITOR— Used for reduction of objectionable air exhaust noise.
starting the compressor, helping reduce the OIL DRAIN ASSEMBLY— Provides a means
initial high current demand required by the for attaching the oil drain bottle to the unit.
compressor on start-up.
INJECTION MANIFOLD ASSEMBLY — Allows
COMPRESSOR OIL SEPARATOR — Removes oil/dye to be injected into the vehicle A/C system
the compressor oil from the refrigerant leaving during the charge mode.
the compressor. New oil is returned to the
compressor when the oil return solenoid FLUSH + N2H2 MANIFOLD ASSEMBLY—
receives power. Internal manifold assembly that contains
solenoids and check valve. N2H2 will flow
CONTROL PANEL— User interface panel, through the manifold assembly for proper
display, and keypad for controlling refrigerant distribution.
recovery, recycling and recharging.
MUFFLER, N2H2 EXHAUST— Disperses
DISPLAY/CONTROL BOARD— Front display excessive N2H2 from the A/C system. Provides
panel and main control of the unit. effective reduction of objectionable N2H2
FAN— Keeps the compressor from exceeding exhaust noise.
its normal operating temperature. The fan runs ORIFICE, UNION— Fitting used to reduce the
whenever the power switch is turned on. flow rate.
FILTER DRYER, SPIN-ON— Used to remove
moisture and particles from refrigerant. Must be
changed every time 150 kg (R1234yf) - 68 kg
(R134a) of refrigerant is recovered.

ACS 753, ACS 763, ACS 863 Service Manual Parts and Components
POWER CORD— Supplies main power to the SOLENOID (S11), RECOVER— When
unit. energized, provides the primary pathway of
PRESSURE RELIEF VALVE — Spring-loaded removing refrigerant from the system being
safety valve to release pressure from internal serviced. This solenoid is also powered during
storage vessel if pressure exceeds 25 bar the Flush process.
(362 psi). SOLENOID (S12), DEEP RECOVER— When
POWER BOARD— Controls power to all energized, uses vacuum pump to perform deep
electrical components. recovery of refrigerant from the system being
serviced.
SCALE ASSEMBLY— Measures the amount
of refrigerant in the ISV being charged into or SOLENOID (S13), OIL RETURN— When
recovered from the vehicle A/C system. energized, it returns compressor oil from the
compressor oil separator to the compressor
SIGHTGLASS— Used to view vacuum pump and equalizes the pressure on the high and low
oil level. side of the compressor.
SOLENOID (S1), AIR PURGE— Energized SOLENOID (S14), OIL INJECT 2 (POE) —
to allow excessive air to escape from the ISV. Energized during the POE Oil Inject process to
SOLENOID (S2), OIL INJECT 1 (PAG) — allow A/C system oil to be replenished.
Energized during the PAG Oil Inject process to SOLENOID (S15), UV DYE— Energized during
allow A/C system oil to be replenished. the UV dye Inject process to allow the UV dye
SOLENOID (S3), OIL DRAIN— Energized at to enter in the A/C system.
the end of the Recover process to drain oil. SOLENOID (S17), IDENTIFIER—Energized
SOLENOID (S4), LOW-SIDE INLET— Allows during the refrigerant identifier process, allows
an open pathway for refrigerant flow and vacuum to analyse the A/C system refrigerant.
between the A/C system low side and the unit. SOLENOID (S18), N2H2 INLET—When
This solenoid is powered during the Recover, energized, allows to inlet the N2H2 or N2 in
Vacuum and Flush process. the A/C system.
SOLENOID (S5), HIGH-SIDE INLET— Allows SOLENOID (S20), N2H2 VENTING—When
an open pathway for refrigerant flow and vacuum energized, allows to venting the N2H2 or N2
between the A/C system high side and the unit. from the A/C system.
This solenoid is powered during the Recover,
Vacuum, and Leak Check process. SOLENOID (S22), TANK LIQUID—When
energized, allows refrigerant from ISV to enter
SOLENOID (S6), HIGH-SIDE CHARGE— of system being serviced.
When energized, allows refrigerant from ISV
to enter high side of system being serviced. SWITCH ON/OFF — Allows the unit to be turned
ON and OFF.
SOLENOID (S7), LOW-SIDE CHARGE— When
energized, allows refrigerant from ISV to enter S Y S T E M O I L S E PA R AT O R / H E AT
low side of system being serviced. EXCHANGER— Heat exchanger with high-side
coils that provide internal heat to the canister
SOLENOID (S8), RECYCLE— When energized, causing saturated vapor and accumulated liquid
increases tank pressure to assist the charging refrigerants to evaporate. This process prevents
function. liquid refrigerant from entering the compressor
SOLENOID (S9), VACUUM — When energized, and separates the refrigerant oil.
allows a vacuum or deep recovery to be pulled
on the A/C system being serviced.

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.
TRANSDUCER, LOW-SIDE— Measures the
pressure of incoming refrigerant from the A/C
system. Pressure readings are then relayed to
the control board.
VACUUM PUMP— Pump designed to removed
moisture and air from an A/C system. Also aids
in the recovery process by performing a deep
recovery of A/C system.

ACS 753, ACS 763, ACS 863 Service Manual Notes
Notes

Robert Bosch GmbH
Franz-Oechsle-Straße 4
73207
DEUTSCHLAND
www.bosch.com
bosch.prueftechnik@bosch.com
SP00D00609 | 2018-03-26

ACS 753 - ACS 763 - ACS 863: A/C Service Unit

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© Robert Bosch GmbH

SP00D00609 2018-03-26 2 Robert Bosch GmbH

Robert Bosch GmbH 3 SP00D00609 2018-03-26

Safety signal words designate the degree, or level, of hazard seriousness.

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 protection goggles.

Electrical shock hazard.

SP00D00609 2018-03-26 4 Robert Bosch GmbH

WARNING: To prevent personal injury,

ALLOW ONLY QUALIFIED PERSONNEL TO OPERATE THE MACHINE. Before operating

PRESSURIZED TANK CONTAINS LIQUID REFRIGERANT. Do not overfill the internal

HOSES MAY CONTAIN LIQUID REFRIGERANT UNDER PRESSURE. Contact with

DO NOT BREATHE REFRIGERANT AND LUBRICANT VAPOR OR MIST. Refrigerant

DO NOT DISPERSE THE REFRIGERANT INTO THE ENVIRONMENT. Such a precaution

Robert Bosch GmbH 5 SP00D00609 2018-03-26

HIGH VOLTAGE ELECTRICITY INSIDE THE MACHINE HAS A RISK OF ELECTRICAL

NEVER LEAVE THE MACHINE LIVE IF AN IMMEDIATE USE IS NOT SCHEDULED.

CAUTION : To prevent equipment damage,

DO NOT USE THIS MACHINE IN AREAS WHERE THERE IS A RISK OF EXPLOSION.

Refrigerant Tank Test

Robert Bosch GmbH 7 SP00D00609 2018-03-26

SP00D00609 2018-03-26 8 Robert Bosch GmbH

Robert Bosch GmbH 9 SP00D00609 2018-03-26

Control Panel Functions Main Menu

menu item to the previous item. PAG POE Dye

ARROW DOWN moves selection of

VACUUM activates the sequence PAUSE to pause a process.

HELP displays information related to WIFI indicates that the WiFi

MENU accesses additional functions BLUETOOTH indicates that the

SP00D00609 2018-03-26 10 Robert Bosch GmbH

kg oz lb to set the unit of measurement Carry out the following setup:

Robert Bosch GmbH 11 SP00D00609 2018-03-26

Periodic Leak Test Oil Load Cells

SP00D00609 2018-03-26 12 Robert Bosch GmbH

Model Replacement filter at: 68 kg

This menu item displays the filter capacity re-

Robert Bosch GmbH 13 SP00D00609 2018-03-26

General Maintenance 8. Select OK icon to start the tank fill process.

Robert Bosch GmbH 15 SP00D00609 2018-03-26

Internal Refrigerent Identifier Vacuum Pump Maintenance

NOTE: In case it is necessary to add more oil,

SP00D00609 2018-03-26 16 Robert Bosch GmbH

Figure 1-8. Replace Print Paper

Robert Bosch GmbH 17 SP00D00609 2018-03-26

Calibration Check Scales Reset

Figure 1-9. Magnet Location

SP00D00609 2018-03-26 18 Robert Bosch GmbH

Pressure Decay Leak Test Lockout

software-controlled self-test in regular intervals Lockout as shown in Figure 1-10.

NOTE: Leak Check may also be selected at

Robert Bosch GmbH 19 SP00D00609 2018-03-26

SP00D00609 2018-03-26 20 Robert Bosch GmbH

ACS 763 ACS 863 ACS 753