Bosch ACS 561 Repair Instructions
  1. Manuals
  2. Brands
  3. Bosch Manuals
  4. Other
  5. ACS 561
  6. Repair instructions

Bosch ACS 561 Repair Instructions

A/c service unit
Hide thumbs
Table of Contents

Quick Links

ACS 561
en Repair instruction
A/C Service Unit
Table of Contents
loading

Related Manuals for Bosch ACS 561

Summary of Contents for Bosch ACS 561

  • Page 1 ACS 561 en Repair instruction A/C Service Unit...
  • Page 2 ACS 561 Service Manual BOSCH Robert Bosch GmbH, Postfach 1119D-73201 Plochingen Direct any discrepancies or corrections to the address above. © Robert Bosch GmbH SP00D00517 2018-07-11 Robert Bosch GmbH...

  • Page 3: Table Of Contents

    ACS 561 Service Manual able of onTenTs Safety Warnings ....................4 Introduction ......................7 Introduction ........................8 Unit Specifications ......................16 Maintenance Schedule ....................17 Diagnostics and Testing ..................18 Updating System Software ..................... 19 Service Center Menu Options ..................20 Troubleshooting ......................

  • Page 4: Safety Warnings

    CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. These safety messages cover situations Bosch is aware of. Bosch cannot know, evaluate, and advise you as to all possible hazards. You must verify that conditions and procedures do not jeopardize your personal safety.
  • Page 5 ACS 561 Service Manual WARNINGS: To prevent personal injury, ALLOW ONLY QUALIFIED PERSONNEL TO OPERATE THE MACHINE. Before operating the machine, read and follow the instructions and warnings in this manual. The operator must be familiar with air conditioning and refrigeration systems, refrigerants, and the dangers of pressurized components.
  • Page 6 ACS 561 Service Manual 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.

  • Page 7: Introduction

    Introduction ACS 561 Service Manual n TroduCT I o n Introduction ......................8 Control Panel Functions ....................9 Glossary ..........................9 Setup Menu Functions ....................10 General Maintenance ..................... 12 Unit Specifications ....................16 Maintenance Schedule ..................17 Robert Bosch GmbH SP00D00517 2018-07-11...

  • Page 8: Introduction

    ACS 561 Service Manual Introduction Model ACS 561 is designed to be compatible with existing service equipment and standard service procedures. This machine is a single-pass system that meets specifications for recycled refrigerant. Follow recommended service procedures for the containment of refrigerant.

  • Page 9: Control Panel Functions

    RECOVER activates the sequence for this machine; 8.9 kg capacity. to recover refrigerant from the vehicle A/C system. Machine: Model No. ACS 561. VACUUM activates the sequence Recovery/Recycling: Refrigerant is recovered that pulls a deep vacuum on the from an A/C system, filtered, and stored in the vehicle A/C system to remove air ISV.

  • Page 10: Setup Menu Functions

    Service Menu Pump Maintenance For Bosch service center use only. Displays how long the vacuum pump has oper- Select Units ated since the last oil change, and the amount...
  • Page 11 ACS 561 Service Manual Unit Activation Initial Setup procedure Failure to register and activate the machine The ACS 561 launches into the initial Setup within 30 days of initial startup will cause the mode. machine to lock out and no longer function.

  • Page 12: General Maintenance

    Introduction ACS 561 Service Manual General Maintenance Tank Fill Wipe off the machine often using a clean cloth This menu item is used to transfer refrigerant to remove grease and dirt. from a source tank to the ISV. 1. Connect the low-side (blue) hose to the Electrical Protection liquid connector on a full source tank.
  • Page 13 Introduction ACS 561 Service Manual Filter Change Caution: Use only authentic filters in this machine. All performance tests and claims The filter is designed to trap acid and particu- are based on using this specific filter. lates, and to remove water from refrigerant. Only the SP00101192 filter includes the code To meet the mandate for adequate moisture...
  • Page 14 Introduction ACS 561 Service Manual Change Vacuum Pump Oil 7. Install the cap on the oil fill port, and press Vacuum pump oil must be changed with every filter change, or more often as necessary. 1. Select CHANGE VACUUM PUMP OIL from the Setup menu or when prompted.
  • Page 15 Introduction ACS 561 Service Manual Edit Print Header Calibration Check If the optional printer is installed, changes to This function is used to ensure the machine’s the printed text can be made. To make changes internal scale is always calibrated. During this...

  • Page 16: Unit Specifications

    Diagnostics and Testing ACS 561 Service Manual UNIT SPECIFICATIONS GENERAL INFORMATION Voltage: 220 – 240VAC (230VAC Nominal) Frequency: 50 – 60 Hz Amperage: 6.0 Amps @ 230VAC Refrigerant: R1234yf (SAE J-2099) Storage Temperature Range: -20°C to 70°C (0°F to 140°F) Operating Temperature Range: 10°C to 50°C (50°F to 120°F)

  • Page 17: Maintenance Schedule

    Introduction ACS 561 Service Manual MAINTENANCE SCHEDULE MAINTENANCE TASK RECOMMENDED INTERVAL After 150 kg (331 lbs.) of refrigerant has Change filter been filtered. Refer to Filter Change in the Maintenance section of this manual. When the filter is replaced. Refer to Change...

  • Page 18: Diagnostics And Testing

    Diagnostics and Testing ACS 561 Service Manual I a g n o s T I C s and esTIng Updating System Software ...................19 Service Center Menu Options ................20 Service Menu ........................20 Diagnostics and Troubleshooting ..................20 Calibrate Load Cells ......................20 Calibrate Air Flow .......................

  • Page 19: Updating System Software

    Diagnostics and Testing ACS 561 Service Manual UPDATING SYSTEM SOFTWARE Download Current Software Install Current Software Equipment Requirements: The following instructions outline the basic (1) SD Card Reader/Programmer steps to complete this procedure. (1) SD Card 1. Connect the unit to its power source. Verify These items may be purchased from an office the power switch is OFF.

  • Page 20: Service Center Menu Options

    Calibrate Load Cells Perform the following: Diagnostics and Troubleshooting The ISV scale is the only load cell in the ACS 561. After selecting Calibrate Load Cells, 1. Turn unit on and allow it to run through the the following displays: boot sequence.
  • Page 21 Diagnostics and Testing ACS 561 Service Manual 4. Enter the second weight (10-20 kg reco- mended) using the keypad. When finished press Continue (F1) to save the entered weight value. The following is displayed: 2. Press Start (F1). 5. If the calibration is accepted, the offset and slope will be calculated.

  • Page 22: Calibrate Air Flow

    Diagnostics and Testing ACS 561 Service Manual Accepted: 6. If Continue (F1) is pressed, the following displays: Calibrate Air Flow The air flow inside the unit must be present at the correct volume to make sure enough air is present to prevent the buildup of refrigerant and to keep the compressor temperature below its upper limit.

  • Page 23: Set Tank Tare

    Diagnostics and Testing ACS 561 Service Manual Set Tank Tare Tank tare is the empty weight of the ISV tank. The tare is subtracted from the total weight of refrigerant plus the tank to arrive at the amount of refrigerant present in the ISV.
  • Page 24 Diagnostics and Testing ACS 561 Service Manual The inlet pressure should stay below 0.35 bar throughout the Service Vacuum. The outputs (Vacuum , Charge, Liquid, Oil Re- turn, and Recover solenoids) will turn ON. 4. When the vacuum Time Remaining falls to 00.00, the outputs will turn OFF and the...

  • Page 25: Service Leak Check

    Diagnostics and Testing ACS 561 Service Manual During pressurization, the Accumulator and If the Inlet pressure stays above 0.35 bar, Inlet pressures will build to greater than 3.5 bar. the only alternative is to press Cancel (F2). As long as the pressures are below 3.5 bar, the The following displays: tank liquid solenoid will be energized.
  • Page 26 Diagnostics and Testing ACS 561 Service Manual 4. To reset an amount, press Menu then enter 28712 in the space provided. Press Enter. 5. If the password is valid, the following dis- plays: 1. Scroll to Maintenance Counters and press Select (F1).

  • Page 27: Output Test

    Diagnostics and Testing ACS 561 Service Manual Output Test OUTPUT TEST The Output Test checks the electrical outputs from the power board and wiring harnesses to PUMP Vacuum Pump the various solenoids, fan, vacuum pump, and COMP Compressor compressor. This test is useful as a trouble-...

  • Page 28: Keypad Test

    Diagnostics and Testing ACS 561 Service Manual INPUT TEST The “X” represents the key to be tested. The first key is Menu. After each key check, the next Parameter Value Format Property key will scroll up automatically. ISV Wt XX.XXXYY...

  • Page 29: Configuration

    Diagnostics and Testing ACS 561 Service Manual The items, selectable options, and default settings are listed in the table. ITEM OPTIONS DEFAULT Refrigerant R1234yf / R134a R1234yf Inject Enabled Yes /No Inject Load Cell Yes /No Drain Load Cell Yes /No...

  • Page 30: Select Model

    Diagnostics and Testing ACS 561 Service Manual Select Model Reset All Unless absolutely necessary, resetting the 1. From Production Test or Service menu scroll board is not recommended. Resetting the con- trol board with “Reset All”: will completely erase to Select Model.

  • Page 31: Troubleshooting

    Diagnostics and Testing ACS 561 Service Manual TROUBLESHOOTING Grounding, Noise, and Power Power Issues The power applied to the unit must be from a Issues stable, low impedance source. Long term stabil- ity must be within +5% or –10% of the nominal To provide proper protection and maximize voltage.

  • Page 32: Will Not Power-Up, No Display

    Diagnostics and Testing ACS 561 Service Manual Will Not Power-Up, No Display 5. Connect the unit to a proper AC power source and place the unit power switch on. a. Disconnect the cable from power board 1. Verify the unit is connected to a known good PBP4.

  • Page 33: Will Not Fill Tank

    Diagnostics and Testing ACS 561 Service Manual Will Not Fill Tank Will Not Perform Clearing The compressor should be running The compressor should be running during this test. If it does not run, refer during this test. If it does not run, refer...

  • Page 34: Will Not Recover

    Diagnostics and Testing ACS 561 Service Manual 5. Verify the low-side (gauge), tank, and accu- 3. Remove both the normal discharge and mulator transducer pressures are providing clearing discharge check valves. logical readings. A transducer reading of 4. Inspect them for debris and cut o-rings.

  • Page 35: Will Not Drain Oil

    Diagnostics and Testing ACS 561 Service Manual 7. Verify that the accumulator transducer is Determine the reason the oil separator functioning properly by attaching a calibrated isn’t draining properly. Improper draining gauge to the service port and compare could be caused by a faulty component readings to those on the transducer ID plate.

  • Page 36: Fails Leak Test

    Diagnostics and Testing ACS 561 Service Manual Fails Leak Test 6. Check the oil inject solenoid for bleed- through and proper operation. This can be done by checking for suction at the oil inject To ensure an accurate leak test, it is tube in the oil inject bottle.

  • Page 37: Will Not Inject Oil

    Diagnostics and Testing ACS 561 Service Manual Will Not Charge Pressure Decay Leak Test 1. Check the oil drain (S6) and oil return (S7) There is no component that pumps solenoids for bleed-through. refrigerant into a system during the 2. Verify Vapor check valve on the tank work charge process.

  • Page 38: Will Not Hose Flush

    Diagnostics and Testing ACS 561 Service Manual Will Not Print Slow Charge When there is a slow charge error, “Try again?” will be displayed if the charge slows and fails 1. Does the printer have power? after three (3) attempts.

  • Page 39: Error Messages

    Diagnostics and Testing ACS 561 Service Manual Error Messages LS Pressure Error L The low-side pressure transducer is reading Refer to the list of error messages: low-side pressure less than 77.5 cm-Hg (30.54 in-Hg) of vacuum. Increase vacuum. ACC Pressure Error H...

  • Page 40: Power Board Troubleshooting

    Diagnostics and Testing ACS 561 Service Manual Power Board Troubleshooting Control Board Troubleshooting 1. Possible reasons to replace the power 1. Possible reasons to replace controller: board: • Repeated read errors. • No power to any components. • Repeated Communication errors.

  • Page 41: Compressor

    Diagnostics and Testing ACS 561 Service Manual Compressor Compressor Troubleshooting 1. Check for proper power source, circuit breaker, and electrical connectors for dam- age or corrosion. 2. Connect the unit directly to a known good power source. Do not use an extension cord.

  • Page 42: Vacuum Pump

    Diagnostics and Testing ACS 561 Service Manual Vacuum Pump Vacuum Pump Troubleshooting Vacuum Pump Does Not Run 1. Check gauges for vacuum. 1. Check for proper power source, circuit 2. If pressure is over 0.7 kgf/cm (10 psi), re- breaker, and electrical connectors for dam- cover hoses.

  • Page 43: Error Messages

    Diagnostics and Testing ACS 561 Service Manual ERROR/WARNING PROCEDURE DESCRIPTION OF ERROR/ WARNING Air Flow Calibration failed! Calibrate Air Flow Air flow sensor is not reading air flow correctly. Press Retry (F1) or Exit (F2). Calibration failed! Offset is Calibrate Load Cells...
  • Page 44 Diagnostics and Testing ACS 561 Service Manual ERROR/WARNING PROCEDURE DESCRIPTION OF ERROR/ WARNING Serial number has already Filter Change Filter serial number must be different been used. from any other filter serial number previously installed. Press Re-Enter (F1) or Exit (F2).
  • Page 45 Diagnostics and Testing ACS 561 Service Manual ERROR/WARNING PROCEDURE DESCRIPTION OF ERROR/ WARNING Oil life remaining: XX:XXX Oil Change The display shows how long the Change oil now? vacuum pump has operated since the last oil change. IOE Communication failed!

  • Page 46: Electrical Operation And Troubleshooting

    Electrical ACS 561 Service Manual leCTrICal peraTIon and roubleshooTIng Electrical System Operation .................47 Power Board and Power Supply Operation ..............47 Power Board Connector Assignments ................47 Control Board Operation ....................48 Control Board Connector Assignments ................48 Control Board Functions ....................48 Sensors and Transducers ....................

  • Page 47: Electrical System Operation

    Electrical ACS 561 Service Manual Electrical System Operation breaker to PBP3 pins: • Pin 1 – Unit ground (on center divider) The electrical system provides the various volt- • Pin 2 – AC low age levels required for the machine to operate •...

  • Page 48: Control Board Operation

    Electrical ACS 561 Service Manual Control Board Functions Control Board Operation 1. Reads Keypad The Control Board, Figure 3-3, is mounted in • If a key does not respond, it’s most likely the control panel and provides the control for...

  • Page 49: Sensors And Transducers

    Electrical ACS 561 Service Manual Sensors and Transducers Memory Expansion The sensors and transducers provide the input Two types of memory expansion are available: and feedback data needed to control the opera- 1. SDIO: An SD expansion card port for up tion of unit.
  • Page 50 Electrical ACS 561 Service Manual 230VAC POWER Input Power SUPPLY ADJ. GND1 GRN/YEL POWER BOARD POWER SWITCH CIRCUIT BREAKER GND1 GRN/YEL CONTROL BOARD JTAG Figure 3-4. Electrical Connections (Sheet 1 of 3) SP00D00517 2018-07-11 Robert Bosch GmbH...
  • Page 51 Electrical ACS 561 Service Manual PRINTER ASSEMBLY AIRFLOW SENSOR (AF) ACCUMULATOR PRESSURE CONTROL TRANSDUCER BOARD (AT) JTAG LOW-SIDE PRESSURE TRANSDUCER (LST) SCALE GND2 ASSEMBLY Wire Braid Component Lead Figure 3-4. Electrical Connections (Sheet 2 of 3) Robert Bosch GmbH SP00D00517...
  • Page 52 Electrical ACS 561 Service Manual PANEL MANIFOLD ASSEMBLY S1 Recover S2 Vacuum S3 Charge S4 ISV Liquid POWER BOARD OIL INJECT BULKHEAD BLOCK S5 Oil Inject SEPARATOR ASSEMBLY S6 System Oil BLUE Separator S7 Compressor Oil Separator High Pressure Switch...

  • Page 53: Replacement Power Board

    Electrical ACS 561 Service Manual Replacement Power Board Remove the Existing Power Board 1. Disconnect unit from the power source. 2. Remove shroud. Disconnect the unit from the power 3. Disconnect all wires from power board. source before beginning service 4.

  • Page 54: Replacement Control Board

    Electrical ACS 561 Service Manual Replacement Control Board 4. Disconnect all wires from control board in- cluding keypad and display ribbon cables. 5. Remove screws securing control board in Disconnect the unit from the power place, and remove control board.

  • Page 55: Replacement High Pressure Cut-Out Switch

    Electrical ACS 561 Service Manual 14. Set Unit Serial Number (check unit data 3. Remove the shroud to access the manifold plate for number). block. 15. Set Manufacturing Date (set board replace- 4. Disconnect the wires from the faulty high ment date).

  • Page 56: Replacement Scale Assembly/Magnet

    Electrical ACS 561 Service Manual Replacement Scale Assembly/Mag- 4. Depressurize the unit. 5. Disconnect the liquid hose and vapor hose from the tank. 6. Disconnect the wires from the air purge Disconnect the unit from the power solenoid, liquid solenoid, tank temperature source before beginning service sensor, and pressure transducer.

  • Page 57: Wire Connector Designations

    Wire Connector Designations The following several illustrations depict the designated names and locations for the con- nection points throughout the ACS 561. See figure 3-9 (sheets 1 through 4). ASSEMBLY WIRING GROUNDS Note: Take note of the wire harness positions before disturbing a harness location and routing to the components in this unit.
  • Page 58 Electrical ACS 561 Service Manual CAPACITOR LEADS SCREW OIL I NJECT MANIFOLD ASSEMBLY GRN/YEL GND2 CBP8 COMPRESSOR ASSEMBLY SCALE ASSEMBLY ISV ASSEMBLY (TOP VIEW) VACUUM CHARGE RECOVER SOLENOID SOLENOID SOLENOID (RED CABLE) (WHITE CABLE) (BROWN CABLE) PANEL MANIFOLD OIL SEPARATOR ASSEMBLY ASSEMBLY Figure 3-9.
  • Page 59 Electrical ACS 561 Service Manual POWER SWITCH PSJ2 CIRCUIT BREAKER PSJ1 POWER SUPPLY AIRFLOW SENSOR GNDF PRINTER PRNTR Figure 3-9. Component Connections (Sheet 3 of 4) Robert Bosch GmbH SP00D00517 2018-07-11...
  • Page 60 Electrical ACS 561 Service Manual PBP4 PBP8 PBJ1 PBP3 PBP1 PBP6 PBP7 PBP5 PBP2 POWER BOARD CONTROL BOARD CBP15 CBP19 CBP5 CBP6 CBP18 CBP1 CBP8 CBJ1 Figure 3-9. Component Connections (Sheet 4 of 4) SP00D00517 2018-07-11 Robert Bosch GmbH...

  • Page 61: Plumbing And Mechanical

    Plumbing and Mechanical ACS 561 Service Manual lumbIng and eChanICal Plumbing and Mechanical System Operation ............62 Compressor ........................62 Vacuum Pump ........................62 Manifold Assembly ......................62 Internal Storage Vessel (ISV) ..................... 62 Cooling Fan ......................... 62 Bulhead Oil Inject Block Assembly ................... 62 Oil Drain Bottle ........................

  • Page 62: Plumbing And Mechanical System Operation

    Plumbing and Mechanical ACS 561 Service Manual Plumbing and Mechanical System Manifold Assembly The “top” or “panel” manifold assemblly consists Operation of the high- and low-side pressure gauges, high- and low-side manually operated ball The plumbing and mechanical system is con- valves, and three solenoids (S1, Recover;...

  • Page 63: Oil Drain Bottle

    Plumbing and Mechanical ACS 561 Service Manual Oil Drain Bottle: This bottle provides a reser- voir for used oil and must be drained when the user is instructed to do so by the control panel. Operators could drain this bottle prior to each use of the unit to make sure unit operation is not interrupted.

  • Page 64: Replacement Compressor

    Plumbing and Mechanical ACS 561 Service Manual Replacement Compressor 4. Disconnect the three (3) copper lines from the compressor. There may be pressure in the copper Disconnect the unit from the power line. source before beginning service work. Incorrect use or connections 5.
  • Page 65 Plumbing and Mechanical ACS 561 Service Manual PANEL MANIFOLD ASSEMBLY OIL SEPARATOR / (SEE NOTE 3, 6, 7) DRYER FILTER ASSEMBLY VACUUM PUMP (SEE NOTE 3, 6, 7) (SEE NOTE 3, 7) (SEE NOTE 3, 7) FLUSH BLOCK SEPARATOR 1010mm ±3mm...

  • Page 66: Replacement Vacuum Pump

    Plumbing and Mechanical ACS 561 Service Manual Replacement Vacuum Pump 5. Loosen the four screws of the pump as- sembly (pump plus anti-vibration plates) on the unit base. Disconnect the unit from the power 6. Remove the vacuum pump assembly from source before beginning service the unit by sliding and pulling it upwards.

  • Page 67: Replacement Manifold Block

    Plumbing and Mechanical ACS 561 Service Manual Replacement Manifold Block Removing the Manifold Block 1. Disconnect the unit from the power source. 2. Remove the shroud. Disconnect the unit from the power 3. Close the tank valve. source before beginning service 4.
  • Page 68 Plumbing and Mechanical ACS 561 Service Manual NOTE: All wires must be clear of moving parts, pinch points, and sharp edges. VACUUM SOLENOID HIGH-SIDE (RED CABLE) GAUGE LOW-SIDE SCHRADER GAUGE OIL INJECT CORE VALVE SOLENOID CHARGE (RED CABLE) RECOVER SOLENOID...

  • Page 69: Bulkhead/Oil Inject Block Repair

    Plumbing and Mechanical ACS 561 Service Manual Bulkhead/Oil Inject Block Repair 4. Depressurize the unit. 5. Remove the red and blue service hoses from the left side of the unit. Disconnect the unit from the power 6. Remove two (2) upper screws from the...

  • Page 70: Replacement Manifold Solenoid

    Plumbing and Mechanical ACS 561 Service Manual Replacement Manifold Solenoid 5. Remove the fastener holding the coil on the solenoid, and remove the coil. 6. Remove the solenoid assembly from the Disconnect the unit from the power manifold block. source before beginning service 7.

  • Page 71: Replacement Manifold Check Valve

    Plumbing and Mechanical ACS 561 Service Manual Replacement Check Valve Removing the Check Valve 1. Disconnect the unit from the power source. 2. Remove the shroud. Disconnect the unit from the power 3. Close the tank valve. source before performing service 4.

  • Page 72: Component Application Chart

    Plumbing and Mechanical ACS 561 Service Manual COMPONENT APPLICATION CHART Manifold Component Application Chart, ACS 561 S1 Recovery Solenoid S2 Vacuum Solenoid S3 Charge Solenoid S4 Tank Liquid Solenoid S5 Oil Inject Solenoid S6 Oil Drain Solenoid S7 Oil Return Solenoid...

  • Page 73: Flow Diagrams

    Plumbing and Mechanical ACS 561 Service Manual FLOW DIAGRAMS Pressure Relief TANK FILL Air Purge Pressure Relief Vapor High Pressure Accumulator Check Switch Transducer Valve Filter/Dryer Compressor Liquid Oil Separator Ball Heat Exchanger/ Compressor Valve System Oil (COMP) Separator Oil Return...

  • Page 74: Clear

    Plumbing and Mechanical ACS 561 Service Manual CLEARING Pressure Relief Air Purge Pressure Relief High Pressure Vapor Accumulator Check Switch Transducer Valve Filter/Dryer Compressor Liquid Oil Separator Ball Heat Exchanger/ Compressor Valve System Oil (COMP) Separator Oil Return Internal Solenoid...

  • Page 75: Recover

    Plumbing and Mechanical ACS 561 Service Manual RECOVERY Pressure Relief Air Purge Pressure Relief Vapor High Pressure Accumulator Check Switch Transducer Valve Filter/Dryer Compressor Liquid Oil Separator Ball Heat Exchanger/ Compressor Valve System Oil (COMP) Separator Oil Return Internal Solenoid...

  • Page 76: Vacuum

    Plumbing and Mechanical ACS 561 Service Manual VACUUM Pressure Relief Air Purge Pressure Relief High Pressure Vapor Accumulator Check Switch Transducer Valve Filter/Dryer Compressor Liquid Oil Separator Ball Heat Exchanger/ Compressor Valve System Oil (COMP) Separator Oil Return Internal Solenoid...

  • Page 77: Oil Inject

    Plumbing and Mechanical ACS 561 Service Manual Pressure Relief OIL INJECT Air Purge Pressure Relief High Pressure Vapor Accumulator Check Switch Transducer Valve Filter/Dryer Compressor Liquid Ball Oil Separator Heat Exchanger/ Valve Compressor System Oil (COMP) Separator Oil Return Internal...

  • Page 78: Charge

    Plumbing and Mechanical ACS 561 Service Manual CHARGE Pressure Relief Air Purge Pressure Relief Vapor High Pressure Accumulator Check Switch Transducer Valve Filter/Dryer Compressor Liquid Oil Separator Ball Heat Exchanger/ Compressor Valve System Oil (COMP) Separator Oil Return Internal Solenoid...

  • Page 79: Leak Test

    Plumbing and Mechanical ACS 561 Service Manual LEAK TEST Pressure Relief Air Purge Pressure Relief Vapor High Pressure Accumulator Check Switch Transducer Valve Filter/Dryer Compressor Liquid Oil Separator Ball Heat Exchanger/ Compressor Valve System Oil (COMP) Separator Oil Return Internal...

  • Page 80: Hose Flush

    Plumbing and Mechanical ACS 561 Service Manual Pressure Relief HOSE FLUSH Air Purge Pressure Relief Vapor High Pressure Accumulator Check Switch Transducer Valve Filter/Dryer Compressor Liquid Oil Separator Ball Heat Exchanger/ Compressor Valve System Oil (COMP) Separator Oil Return Internal...

  • Page 81: Oil Drain

    Plumbing and Mechanical ACS 561 Service Manual OIL DRAIN Pressure Relief Air Purge Pressure Relief Vapor High Pressure Accumulator Check Switch Transducer Valve Filter/Dryer Compressor Liquid Ball Oil Separator Heat Exchanger/ Compressor Valve System Oil (COMP) Separator Oil Return Internal...

  • Page 82: Service Bulletins

    Service Bulletins ACS 561 Service Manual e r v I C e u l l e T I n s Place all service bulletins for the ACS 561 in this section SP00D00517 2018-07-11 Robert Bosch GmbH...

  • Page 83: Appendix

    Appendix ACS 561 Service Manual ppendIx Main Power Cable ....................84 Power Board AC Input Harness ................85 Board to Board Harness ..................86 12VDC Power Harness ..................87 Printer Power and Communication Harness ............88 AT and LST Transducer Harness .................89 Compressor, Fan, Vacuum Pump, and Air Flow Sensor Harness (Sheet 1) ..90 Compressor, Fan, Vacuum Pump, and Air Flow Sensor Harness (Sheet 2) ..

  • Page 84: Main Power Cable

    Appendix ACS 561 Service Manual Main Power Harness MAIN POWER HARNESS CONNECTOR NO. CONNECTS TO Power Switch ES2 Power Switch ES3 GND1 Lower Ground Stud on Center Divider View from “A” GND1 “A” YEL/GRN Figure A-1. Main Power Cable SP00D00517...

  • Page 85: Power Board Ac Input Harness

    Appendix ACS 561 Service Manual AC Power Input Harness AC POWER INPUT HARNESS CONNECTOR NO. CONNECTS TO Power Board (PBP3) PBP3 P1 (Pin 1) Ground Stud on center divider (GND1) P1 (Pin 2) Power Switch (ES1) P1 (Pin 3) Circuit Breaker (CB2)

  • Page 86: Board To Board Harness

    Appendix ACS 561 Service Manual Board to Board Cable BO ARD T O BO ARD CABL E C O N N E C TO R N O . C O N N E C TS TO J1 C o n tro l B o a rd...

  • Page 87: 12Vdc Power Harness

    Appendix ACS 561 Service Manual 12 VDC Power Harness Pin 1 12 V O L T P O W ER HARNES S C O N N E C TO R N O . C O N N E C TS TO...

  • Page 88: Printer Power And Communication Harness

    Appendix ACS 561 Service Manual Printer Power/Communication Harness P RINT ER P O W ER/CO M M UNICAT IO N HARNES S C O N N E C TO R N O . C O N N E C TS TO...

  • Page 89: At And Lst Transducer Harness

    Appendix ACS 561 Service Manual Accumulator and Low Side Pressure Transducer Harness LST and AT TRANSDUCER HARNESS CONNECTOR NO. CONNECTS TO Control Board (CBP5) Low Side Pressure Transducer (LST) Control Board (CBP6) Accumulator Pressure Transducer (AT) CABLE TIE (7X) CBP5...

  • Page 90: Compressor, Fan, Vacuum Pump, And Air Flow Sensor Harness (Sheet 1)

    Appendix ACS 561 Service Manual Compressor, Fan, Vacuum Pump, and Air Flow Harness (Sheet 1) CO M P RES S O R, F AN, a n d V ACUUM P UM P HARNES S C O N N E C TO R N O .

  • Page 91: Compressor, Fan, Vacuum Pump, And Air Flow Sensor Harness (Sheet 2)

    Appendix ACS 561 Service Manual Compressor, Fan, Vacuum Pump, and Air Flow Harness (Sheet 2) GND1 CBP1 CABLE TIE (23X) PBP5 Noise and Surge Suppresor LT BLU PBP6 (To “A” on sheet 1.) Figure A-7. Compressor, Fan, Vacuum Pump, and Air Flow Sensor Harness (Sheet 2)

  • Page 92: Solenoid Control Harness

    Appendix ACS 561 Service Manual Solenoid Control Harness SOLENOID CONTROL HARNESS CONNECTOR NO. CONNECTS TO Power Board (PBP8) P1 (Pins 1, 13) Recover Solenoid (S1) P1 (Pins 2, 14) Vacuum Solenoid (S2) P1 (Pins 3, 15) Charge Solenoid (S3) P1 (Pins 4, 16)

  • Page 93: High Pressure Switch Harness

    Appendix ACS 561 Service Manual High Pressure Switch Harness HIGH PRESSURE SWITCH HARNESS CONNECTOR NO. CONNECTS TO PBP7 HPS (2X) High Pressure Switch Power Board (PBP7) Figure A-9. High Pressure Switch Harness Robert Bosch GmbH SP00D00517 2018-07-11...

  • Page 94: Compressor Pigtail Harness

    Appendix ACS 561 Service Manual Compressor Pigtail Harness COMPRESSOR PIGTAIL HARNESS CONNECTOR NO. CONNECTS TO COMP on Compressor, Fan, and Vacuum Pump Harness Compressor Start Relay Compressor Thermal Switch Compressor Ground Noise Suppressor COMP YEL/GRN Figure A-10. Compressor Pigtail Harness...
  • Page 96 Robert Bosch GmbH Franz-Oechsle-Straße 4 73207 DEUTSCHLAND www.bosch.com [email protected] S P00 D00 517 | 2018-07-11...

Table of Contents