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Bosch ACS 511 User Manual

Bosch ACS 511
40 pages
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ACS 511
en
Repair instruction
A/C Service Unit

Table of Contents

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Bosch ACS 511 Specifications

General IconGeneral
BrandBosch
ModelACS 511
CategoryService Equipment
LanguageEnglish

Summary

Symbols Used

1.1 Documentation Symbols

Explains warning notices and symbols used in the documentation.

1.2 Product Symbols

Emphasizes observing warning notices on the product itself.

Important Information

Test Equipment and Auxiliary Materials

Safety Regulations

4.1 Refrigerant Handling

Guidelines for safe handling of refrigerant R134a, including skin and inhalation risks.

4.2 UV Dye Handling

Instructions for safe handling and use of UV dye, including eye and skin contact.

4.3 Vehicle Work Safety

Safety precautions when working on vehicles, especially high-voltage systems.

4.4 Operation Notes

Operational guidelines and environmental considerations for the ACS 511.

4.5 Maintenance Work

Recommendations for maintenance and contacting customer service for parts.

4.6 Safety Devices

Information on required safety devices like residual current circuit breakers.

4.7 PED Directive Compliance

Details on parts subject to the Pressure Equipment Directive (PED).

Product Description

5.1 Unit Description

Overview of the unit's components and different views.

5.1.1 Front View

Identifies components visible from the front of the unit.

5.1.2 Rear View

Identifies components visible from the rear of the unit.

5.1.3 Display and Control Panel

Description of the operating unit's display and control panel interface.

5.1.4 Selection and Function Keys

Explains the function and operation of various keys on the control panel.

5.1.5 Input Keys

Details the use of input keys for entering letters, numbers, and special characters.

Program Structure

6.1 Calibration and Tare

Procedures for calibrating and setting tare values for the unit's scales.

6.2 Settings

Options for configuring various settings like language, date/time, and measurement units.

6.3 Repair Functions

Instructions for performing repair-related functions like filter or oil changes.

6.4 Vehicle and Customer Data

Management of vehicle and customer specific data, including databases.

6.5 Menu Navigation

Overview of the main menu structure and how to navigate through options.

6.6 Manual Mode

Details on operating the unit in manual mode for specific tasks.

6.7 Automatic Mode

Information on performing service operations automatically based on parameters.

6.8 Optional Flush Function

Instructions for using the optional flushing function.

6.9 Enter Function

Explanation of the 'Enter' function and its uses for confirming inputs.

Hydraulics Diagram

Service Phases

8.1 Recovery Phase

Step-by-step guide for the refrigerant recovery process from the vehicle.

8.2 Used Oil Draining

Procedure for draining used oil into the designated bottle and saving the value.

8.3 Vacuum Phase and Recycling

Details on performing vacuum and recycling operations simultaneously.

8.3.1 Vacuum Phase

Explains the vacuum generation process and its purpose for preparing refrigerant.

8.3.2 Refrigerant Recycling

Describes the refrigerant recycling process that occurs during the vacuum stage.

8.4 Leak Test

Procedure for performing a leak test on the system after the vacuum phase.

8.5 Refrigerant Preparation

Steps for preparing the refrigerant, which is similar to the recovery phase.

8.6 Fresh Oil Filling

Instructions for filling fresh oil into the vehicle's AC system compressor.

8.7 UV Contrast Medium Filling

Procedure for filling UV contrast medium to detect leaks in the AC system.

8.8 Filling Refrigerant

Detailed steps for filling the vehicle's AC system with refrigerant.

8.9 Separating Compressor Oil

Process for separating compressor oil from refrigerant and returning it.

8.10 Non-Condensing Gases

Management of non-condensing gases via drain and safety valves.

Troubleshooting

9.1 Service Messages

Explanation of service messages like 'CHANGE OIL' and 'REPLACE FILTER'.

9.2 Fault Messages

List and explanations of various fault indications and their causes.

Emptying the ACS 511

10.1 Automatic Emptying

Procedure for automatic extraction of refrigerant from internal hoses.

10.2 External Extraction Method

Method for extracting refrigerant using a second A/C service unit.

Troubleshooting and Analysis

11.1 Recovery Faults

Common faults encountered during the refrigerant recovery process.

11.1.1 Compressor Starts

Troubleshooting compressor start issues during recovery.

11.1.2 Compressor Does Not Start

Diagnosing and resolving issues when the compressor fails to start.

11.1.3 Recovery Fault Messages

Specific fault messages like "CYLINDER FULL" during recovery.

11.1.4 Other Fault Messages

References to other fault messages described in chapter 9.2.

11.2 Vacuum Phase Faults

Identifying and fixing problems during the vacuum process.

11.2.1 Vacuum Pump Starts

Troubleshooting lack of vacuum generation despite pump operation.

11.2.2 Vacuum Pump Does Not Start

Steps to take when the vacuum pump fails to start.

11.2.3 Vacuum Phase Fault Messages

Handling "A/C SYSTEM FULL" message during vacuum phase.

11.3 Refrigerant Preparation Faults

Troubleshooting issues encountered during refrigerant preparation.

11.4 Non-Condensing Gases Not Drained

Diagnosing issues with non-condensing gas drainage, testing valve V6.

11.5 Filling Refrigerant Faults

Problems encountered during the refrigerant filling process.

11.5.1 System Cannot Be Filled

Resolving issues where the AC system cannot be filled with refrigerant.

11.5.2 Other Fault Messages

References to other fault messages described in chapter 9.2.

Component Test and Maintenance

12.1 Vacuum Pump Maintenance

Maintenance and operational checks for the vacuum pump, including oil changes.

12.2 Pressure Sensor P1 Test

Testing and checking the P1 pressure sensor for voltage and output signals.

12.3 Pressure Switch P2 Test

Testing and checking the P2 pressure switch for proper operation.

12.4 Expansion Valve Test

Testing the function and settings of the expansion valve.

12.5 Combo Filter

Procedures for maintaining the combo filter, including replacement.

12.5.1 Combo Filter Replacement

Step-by-step guide for safely replacing the combo filter.

12.5.2 Filter Reset

Procedure to reset the filter change interval after replacement.

12.6 Vacuum Pump Oil

Maintenance tasks related to the vacuum pump oil.

12.6.1 Changing Vacuum Pump Oil

Instructions for changing the vacuum pump oil, including safety.

12.6.2 Reset Oil Change Interval

How to reset the vacuum pump oil change interval after service.

Calibration

13.1 Internal Refrigerant Cylinder Scales

Steps for calibrating the internal refrigerant cylinder scales.

13.2 Fresh Oil Bottle Scales

Procedure for calibrating the fresh oil bottle scales.

13.3 Used Oil Bottle Scales

How to calibrate the used oil bottle scales.

13.4 Tara Values

Information on factory-set Tara values for refrigerant and oil bottles.

13.5 Pressure Sensor Calibration

Procedures for checking and adjusting the pressure sensor.

13.5.1 Checking Pressure Sensor Adjustment

How to check the current adjustment of the pressure sensor.

13.5.2 Adjusting Pressure Sensor

Detailed steps for adjusting the pressure sensor using a simulator or simplified method.

Component Test

14.1 LCD Test

Testing the functionality of the LCD display and LED indicators.

14.2 Outputs Test

Testing the outputs of various system components for proper function.

14.3 Control PCB Input Signal Test

Checking the input signals received by the control PCB.

14.4 Printer Test

Performing a test print to check printer functionality.

14.5 Counter Display

Displays operational data like refrigerant quantity and operating hours.

14.6 Service Printout

Function to print a service report with key operational data.

14.7 Draining Oil for Maintenance

Procedure to drain oil for maintenance purposes, enabling EV7 service.

Changing Basic Settings

Software Management

16.1 Vehicle Database Updates

Information on updating the vehicle database using a PS2 stick.

16.2 Data Backup Procedure

How to save configuration data before software updates to avoid recalibration.

16.3 Software Update Process

Procedure for updating the unit's software using a PS2 stick.

16.4 Loading Data Backup

Steps to restore configuration data from a backup after software updates.

Circuit Diagram

17.1 Control PCB Schematic

Schematic diagram of the control printed circuit board and its connections.

17.2 Computer Printed Circuit Board

Schematic diagram of the computer printed circuit board and its connections.

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