ACS 653, ACS 663 Service Manual
SP00D00624 2021-04-08Robert Bosch GmbH
91
Plumbing and Mechanical
These instructions outline the steps to replace
the existing main manifold. See Figure 4-4.
In most cases, the main manifold 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 5 in Removing Main Manifold.
The remaining steps (6-8) outline the procedure
for removing the entire main manifold.
See Figure 4-4.
If the injection manifold is being repaired,
refer to the Repairing or Replacing a Solenoid
or Replacing Check Valve as needed.
When installing hoses, solenoids, and check
valves, replace the O-rings and use thread
sealant where necessary.
1. Clear service hoses and remove them.
2. Disconnect unit from the power source.
3. Remove the front plastic cover.
4. Open the service rear door.
5. Remove the rear cover (above the service
door) by pushing it up and extract it by
pulling it out.
6. Disconnect all hoses from the main manifold.
7. Disconnect all wires from the block
components.
8. Remove the main manifold.
See Figure 4-4 while performing the following
procedures.
1. Connect the hoses and lines to the main
manifold. Refer to Figures 4-1, 4-3, and 4-4
for the proper location of the hoses.
2. Reconnect all wiring as shown in Figure 4-4.
3. Insert the rear cover so that the 4 holes on
the sides the cover t into the 4 clips on the
machine. Push down to hook the rear cover.
4. Close the service rear door.
5. Reinstall the plastic frontal cover.
6. Attach the outside high- (red) and low-side
(blue) service hoses. Tighten at 7.9 Nm
torque.
7. Connect the unit to the power source,
perform a function test, and check for leaks.
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