Bosch RG8.0 Einrichtungshandbuch

RG8.0 / RG4.0

Repair instructions

Refrigerant recovery unit

F 002 DG9 H10 2018-08-21|Bosch Automotive Service Solutions GmbH

| RG8.0 / RG4.0 | 3 en

Contents English

1. Symbols used 4

1.1 In the documentation 4

1.1.2 Symbols in this documentation 4

1.2 On the product 4

2. Safety instructions 5

3. Requirements for repair 6

3.1 Preparations for repair 6

3.2 Purging residual refrigerant 6

3.3 Instructions for replacement of red, blue

and black knobs 6

4. Overview of parts 7

4.1 Parts list - RG8.0 7

4.2 Parts list - RG4.0 8

4.4 Additional parts / kits 9

4.4.1 For RG8.0 9

4.4.2 For RG4.0 9

5. Troubleshooting 9

5.1 Basic operational test 9

5.2 Diagnosing component failure 10

5.2.1 Of circuit breaker 10

5.2.2 Of HP / LP switch 10

5.2.3 Of start relay (for RG8.0) 10

5.2.4 Of capacitors 11

5.2.5 Of motor 11

5.2.6 Of power switch 11

5.3 Internal leak test 12

6. Repair 12

6.1 Replacing the LH enclosure 12

6.2 Replacing the RH enclosure 12

6.3 Replacing the HMI cover 12

6.4 Replacing the manifold assembly 13

6.5 Replacing the HP gauge 13

6.6 Replacing the LP gauge 13

6.7 Replacing the HP switch 14

6.8 Replacing the LP switch 14

6.9 Replacing the condenser 14

6.10 Replacing the fan 15

6.10.1 For RG8.0 15

6.10.2 For RG4.0 15

6.11 Replacing the power switch 15

6.12 Replacing the capacitors 15

6.13 Replacing the motor 15

6.14 Replacing the compressor 16

6.15 Repairs to compressor 16

6.16 Replacing the copper tube between

manifold and compressor outlet / inlet 16

6.17 Replacing the IEC connector 16

6.18 Replacing the start relay (only for RG8.0) 16

6.19 Cleaning the particle ﬁlter 17

7. Electrical terminal diagram 18

7.1 For RG8.0, 230 V, 50 Hz variant 18

7.2 For RG8.0, 110 V, 60 Hz variant 19

7.3 For RG4.0, 230 V, 50 Hz variant 20

7.4 For RG4.0, 110 V, 60 Hz variant 21

8. Hydraulic connection diagram 22

8.1 For RG8.0 22

8.2 For RG4.0 23

9. Appendix 24

9.1 Compressor repair kits - Instructions for

compressor repair 24

9.1.1 Piston seal replacement kit

RGB400230 24

9.1.2 Valve replacement kit RGB400240 25

9.1.3 Compressor repair kit RGB400250 26

9.1.4 Shaft seal replacement kit

RGB400260 28

9.1.5 Shaft replacement kit RGB400270 29

9.1.6 Piston repair kit RGB800250 30

9.1.7 Valve repair kit RGB800230 31

F 002 DG9 H10 2018-08-21| Bosch Automotive Service Solutions GmbH

4 | RG8.0 / RG4.0 | Symbols useden

1. Symbols used

1.1 In the documentation

1.1.1 Warning notices - Structure and meaning

Warning notices warn of dangers to the user or people

in the vicinity. Warning notices also indicate the con-

sequences of the hazard as well as preventive action.

Warning notices have the following structure:

Warning

symbol

KEY WORD – Nature and source of hazard!

Consequences of hazard in the event of fail-

ure to observe action and information given.

¶Hazard prevention action and information.

The key word indicates the likelihood of occurrence and

the severity of the hazard in the event of non-observance:

Key word Probability of

occurrence

Severity of danger if in-

structions not observed

DANGER Immediate

impending danger

Death or severe injury

WARN-

ING

Possible impending

danger

Death or severe injury

CAUTION Possible dangerous

situation

Minor injury

1.1.2 Symbols in this documentation

Symbol Designation Explanation

!Attention Warns about possible property damage.

iInformation Practical hints and other

useful information.

Multi-step

operation

Instruction consisting of several steps.

eOne-step

operation

Instruction consisting of one step.

 Intermedi-

ate result

An instruction produces a vis-

ible intermediate result.

"Final result There is a visible final result on

completion of the instruction.

1.2 On the product

!Observe all warning notices on products and ensure

they remain legible.

Read the original

instructions before operation.

Wear protective goggles.

Wear a safety mask.

Wear protective gloves.

Risk of electric shock

Do not open the enclosures while operat-

ing the RG8.0 / RG4.0. Touching live parts

results in electric shock.

Risk of fire

Do not use this equipment in the vicinity

of hazardous and flammable substances.

F 002 DG9 H10 2018-08-21|Bosch Automotive Service Solutions GmbH

Safety instructions | RG8.0 / RG4.0 | 5 en

2. Safety instructions

iRepair may only be carried out by

customer service staff trained and instructed

by Bosch Automotive Service Solutions GmbH

or organizations authorized by

Bosch Automotive Service Solutions GmbH. Opening

or modification of the units by unauthorized persons

will invalidate all warranty entitlements.

Read and observe all safety instructions thoroughly be-

fore servicing the RG8.0 / RG4.0.

RWear proper Personal Protective Equipment (PPE)

when servicing the RG8.0 / RG4.0.

RAvoid refrigerant coming into contact with skin. The

low boiling point of some refrigerants can cause

frostbite. In case of contact with skin, remove

affected clothing immediately and rinse the affected

area of skin with plenty of water.

RDisconnect power supply before moving or servicing

the RG8.0 / RG4.0.

RDo not exceed the torque values during repair.

RIf moisture enters the refrigerant system, it is likely

to cause damage. Cover the ports of RG8.0 / RG4.0

with caps after service.

Do not breathe in refrigerant or oil vapors. The

vapors can irritate the eyes and the breathing

passage of the nose. If liquid refrigerant/oil

gets into the eyes, rinse the eyes thoroughly

with water for 15 minutes. Then, seek medical

attention, even if the eyes do not hurt.

Do not mix air with refrigerant.

Some mixtures of air and refrigerant are highly

flammable at high pressure. These mixtures

are potentially hazardous and can cause fires

or explosions resulting in damage to property

and injury to people.

Danger: Risk of fire or explosion

Flammable refrigerants used.

¶Repair should be performed by customer

service staff trained and instructed by

Bosch.

¶Do not puncture refrigerant tubing.

¶Dispose of flammable refrigerants in

accordance with federal or local regula-

tions.

When the RG8.0 / RG4.0 is functioning, do

not open or unplug connectors, receptacles or

components in the hydraulic path.

Danger: Risk of electric shock

Improper electrical connections during

repair causes fatal electric shock. Conse-

quently, the RG8.0 / RG4.0 might also be

damaged.

¶Wear appropriate PPE during repair.

¶Refer to the electrical connection

diagram for completing the electrical

connections.

Danger: Risk of injury due to high pres-

sure

Pressurized refrigerant in the RG8.0 / RG4.0

will escape and cause injury.

¶Observe the pressure gauges. Ensure

that the reading is 0 before proceeding

with repair. Else purge the refrigerant till

the pressure drops to 0 (refer

chapter 3.2).

¶Wear appropriate PPE during repair.

Danger: Risk of electric shock

Touching live parts in the RG8.0 / RG4.0

causes fatal electric shock.

¶Switch off the mains supply and discon-

nect the power cable from the mains

supply before proceeding with repair.

¶Wear appropriate PPE during repair.

Danger: Risk of burns

Touching hot parts in the RG8.0 / RG4.0

causes burns.

¶Wait till the surface of heated parts cool

down before repair.

¶Wear appropriate PPE during repair.

F 002 DG9 H10 2018-08-21| Bosch Automotive Service Solutions GmbH

6 | RG8.0 / RG4.0 | Requirements for repairen

3. Requirements for repair

RPersonal Protective Equipment (PPE)

RHeat gun for unfastening joints secured by Loctite

RGeneral tools for electricians and A/C mechanics

RLoctite 577 for fastening hydraulic joints

RCleaning medium for hydraulic joints

RDry powder for dousing fire or CO2fire extinguisher,

if the RG8.0 / RG4.0 is used to recover flammable

refrigerants.

3.1 Preparations for repair

!Do not perform repair without executing the steps

listed in this chapter.

1. Ensure that the knob positions are set as follows:

$Black knob to RECOVER position

$Red and blue knobs to CLOSED position

2. Observe the pressure gauges. Ensure that the read-

ing is 0. Else purge the residual refrigerant in the

RG8.0 / RG4.0 (refer chapter 3.2).

If the purging is successful, the reading on the

pressure gauges should be 0. Else, replace the

pressure gauges (refer chapter 6.5).

3. Switch off the mains supply to the RG8.0 / RG4.0.

4. Disconnect the power cable from the mains supply.

5. Disconnect the other end of the power cable from

the power socket of the RG8.0 / RG4.0.

3.2 Purging residual refrigerant

OUT

LIQUID

VAPOUR

OPEN

RECOVER

PURGE

CLOSED CLOSED

Fig. 1: Valve positions for purging residual refrigerant

1. Ensure that the inlet control valve of the

RG8.0 / RG4.0 is in the CLOSED position.

2. Ensure that the outlet control valve is open and con-

nected to a recovery tank with the same refrigerant

as in the unit.

3. Ensure that the RG8.0 / RG4.0 is powered off.

4. Turn the recovery / purge (Black) knob of

RG8.0 / RG4.0 to PURGE position (pointed down-

wards) as shown in Fig. 1

5. Start the RG8.0 / RG4.0 and slowly turn the inlet

(Blue) control valve of the RG8.0 / RG4.0 to PURGE

position as shown in Fig. 1.

The RG8.0 / RG4.0 starts purging automatically.

6. Run until desired vacuum is achieved or until low

pressure switch shuts off the RG8.0 / RG4.0.

7. Close the valve on the recovery tank, then the outlet

control valve of the RG8.0 / RG4.0.

8. Power off the RG8.0 / RG4.0.

9. Turn the inlet control valve to the closed position.

10. Close all hose shut-off valves, then disconnect and

store the hoses.

3.3 Instructions for replacement of red,

blue and black knobs

Follow these instructions when you remove the red,

blue and black knobs during repair. Only one of the

knobs and the corresponding valve is depicted in the

following illustration. The instructions are applicable for

all the knobs.

H00_35Nkv

Fig. 2: Overview of knob and ball valve

1 Direction indicator

2 Indent on ball valve

1. Before fixing the knob to the ball valve, notice the

indent on the ball valve (Fig. 2, Pos. 2).

2. Fix the knob such that the direction indicator

(Fig. 2, Pos. 1) of the knob is latitudinally opposite

to the indent.

F 002 DG9 H10 2018-08-21|Bosch Automotive Service Solutions GmbH

Overview of parts | RG8.0 / RG4.0 | 7 en

4. Overview of parts

4.1 Parts list - RG8.0

14 15 16

18 3

19 20 21

Fig. 3: Exploded view of RG8.0

Position

number

Part number Part description

1 RGB800100 Compressor

2 RGB800120

RGB800110

Motor 230 V

Motor 115 V

3 RGB800130 Fan blade

4 RGB480130 Pump bracket

5 RGB800140 Tube - Manifold to compressor outlet

6 RGB800270 LH enclosure

7 RGB800150 Fan blade housing

8 RGB480120 Knob - Main power switch

9 RGB480140 Main power switch

10 RGB480250 Condenser

11 RGB480150 Manifold assembly

A RGB480160 Gauge - High Pressure

B RGB480170 Gauge - Low Pressure

C RGB480180 Switch - High Pressure

D RGB480190 Switch - Low Pressure

12 RGB800160 Grill - Black

13 RGB480200 Knob - Ball valve (Red)

14 RGB480210 Knob - Ball valve (Blue)

15 RGB480220 Knob - Ball valve (Black)

Position

number

Part number Part description

16 RGB480230 HMI cover

17 RGB480240 Front panel

18 RGB480260 RH enclosure

19 RGB800170 Run capacitor

20 RGB800280

RGB800290

Motor bracket assembly 230 V

Motor bracket assembly 115 V

21 RGB800180 Start capacitor (only for 230 V)

22 RGB800190 Interface - Motor and compressor

23 RGB800200 Tube- Manifold to compressor inlet

24 RGB800220 Coupler (Counterweight)

25 RGB480310

RGB800320

Circuit breaker 8 A, 230 V

Circuit breaker 15 A, 115 V

26 RGB800300

RGB800310

Start relay 230 V

Start relay 115 V

27 RGB480320 Power receptacle, 230 V / 115 V

28 RGB480330 Power cord, 230 V

F 002 DG9 H10 2018-08-21| Bosch Automotive Service Solutions GmbH

8 | RG8.0 / RG4.0 | Overview of partsen

4.2 Parts list - RG4.0

14 15

Fig. 4: Exploded view of RG4.0

Position

number

Part number Part description

1 RGB400100 Tube - Manifold to compressor inlet

2 RGB400120 Compressor

3 RGB400130 Start capacitor (only for 115 V)

4 RGB400150

RGB400140

Motor 230 V

Motor 115 V

5 RGB400290

RGB400160

Motor bracket 230 V

Motor bracket 115 V

6 RGB400280 LH enclosure

7 RGB480120 Knob - Main power switch

8 RGB480130 Pump bracket

9 RGB480140 Main power switch

10 RGB400180

RGB400170

Electrical fan 230 V

Electrical fan 115 V

11 RGB480150 Manifold assembly

A RGB480160 Gauge - High pressure

B RGB480170 Gauge - Low pressure

C RGB480180 Switch - High pressure

D RGB480190 Switch - Low pressure

12 RGB400190 Grill - gray

13 RGB480200 Knob - Ball valve (Red)

14 RGB480210 Knob - Ball valve (Blue)

15 RGB480220 Knob - Ball valve (Black)

16 RGB480230 HMI cover

Position

number

Part number Part description

17 RGB480240 Front Panel

18 RGB480250 Condenser

19 RGB480260 RH Enclosure

20 RGB400200 Tube- Manifold to compressor

outlet

21 RGB400210 Interface - Motor and compressor

22 RGB400220 Coupler

23 RGB480310

RGB400300

Circuit breaker 8 A, 230 V

Circuit breaker 12 A, 115 V

24 RGB480320 Power receptacle, 230 V / 115 V

25 RGB480330 Power cord, 230 V

F 002 DG9 H10 2018-08-21|Bosch Automotive Service Solutions GmbH

Overview of parts | RG8.0 / RG4.0 | 9 en

4.4 Additional parts / kits

4.4.1 For RG8.0

Part number Part Description

RGB800230 Valve repair kit

RGB800240 Compressor repair kit

RGB800250 Piston replacement kit

RGB480270 Filter drier

RGB480280 Filter hose

RGB480290 Filter / Hose kit

RGB480300 Inlet fitting with filter screen

4.4.2 For RG4.0

Part number Part Description

RGB400230 Piston repair kit

RGB400240 Valve repair kit

RGB400250 Compressor repair kit

RGB400260 Shaft seal repair kit

RGB400270 Shaft replacement kit

RGB480270 Filter drier

RGB480280 Filter hose

RGB480290 Filter / hose kit

RGB480300 Inlet fitting with filter screen

5. Troubleshooting

5.1 Basic operational test

iBy performing the basic operational test, you can

validate normal and correct operation of all features.

Refer to the table following this procedure if you

encounter any problems.

1. Ensure that there is no residual refrigerant left in the

RG8.0 / RG4.0. If there is residual refrigerant, refer

to chapter 3.2 for purging residual refrigerant.

2. With nothing connected to the RG8.0 / RG4.0 and

recovery / purge valve (black) in the RECOVER posi-

tion, open the inlet control valve (blue) and outlet

control valve (red) valves.

3. Start the RG8.0 / RG4.0 and close the inlet valve.

The RG8.0 / RG4.0 should shut-off due to Low

Pressure (LP) cut-out. Upon opening the inlet

valve, the RG8.0 / RG4.0 should restart.

4. Upon closing the outlet valve, the RG8.0 / RG4.0

should begin to pump up pressure on the High Side

(red) gauge.

When the pressure reaches approximately

38.5 bar, the RG8.0 / RG4.0 should shut off due

to High Pressure (HP) safety switch.

5. Slowly open the outlet valve and the RG8.0 / RG4.0

should restart when pressure drops below 28 bar.

F 002 DG9 H10 2018-08-21| Bosch Automotive Service Solutions GmbH

10 | RG8.0 / RG4.0 | Troubleshootingen

Symptom /

Problem

Checklist Cause/Action

RG8.0 / RG4.0

does not start

/ run when the

main switch is

in turned on.

Is the RG8.0 / RG4.0

plugged into the cor-

rect voltage and fre-

quency source?

Verify power to

RG8.0 / RG4.0

Is there power at the

outlet / mains source?

Verify power to

RG8.0 / RG4.0

Has the circuit

breaker tripped?

RReset the

circuit breaker.

RIf the circuit break-

er cannot be re-

set, replace the

circuit breaker.

Does the blue

gauge read 0 or

less pressure?

LP cut-out triggered.

RClean or replace

the particle fil-

ter in inlet port of

RG8.0 / RG4.0 (re-

fer chapter 6.19).

RRaise inlet pres-

sure by opening

the inlet valve.

Does the red gauge

show a value great-

er than 38.5 bar?

HP cut-out trig-

gered. Release the

pressure carefully.

The RG8.0 / RG4.0

should restart after

relieving pressure.

Check for physical

damage or loose con-

tacts in

internal wiring.

Refer to the electrical

diagrams in chapter 7.

Open the LH and RH

enclosure. Rectify the

loose connections.

Replace the wir-

ing harness.

Perform test to locate

defective component

Refer chapter 5.2.

Replace the defec-

tive component.

The

RG8.0 / RG4.0

does not

pull down in-

to vacuum.

Perform internal leak

test as described

in chapter 5.3.

If the leak test

fails, rectify the

leak or replace the

faulty tubing.

Replace the seals

in the manifold.

Replace the

manifold assembly.

Symptom /

Problem

Checklist Cause/Action

Poor

recovery rate

The

RG8.0 / RG4.0

does not pump

up to 38.5 bar.

Check if the parti-

cle filter in inlet port

of the RG8.0 / RG4.0

is clogged.

Clean or replace the

clogged particle filter.

Refer chapter 6.19.

Perform internal leak

test as described

in chapter 5.3.

If leak test fails, recti-

fy the leak or replace

the faulty tubing.

Replace the seals

in the manifold.

Replace the man-

ifold assembly.

Compressor seals

worn out: In-

stall a new com-

pressor kit or re-

place compressor.

5.2 Diagnosing component failure

5.2.1 Of circuit breaker

1. Execute the steps listed in chapter 3.1.

2. Unfasten the screws of the LH and RH enclosures

(Fig. 3, Pos. 6, 18) / (Fig. 4, Pos. 6, 19).

3. Disconnect the electrical connections to the circuit

breaker.

4. Using a multimeter, check the continuity between

the terminals of the circuit breaker.

5. If continuity exists, the circuit breaker is functional.

Else, replace the circuit breaker.

5.2.2 Of HP / LP switch

1. Execute the steps listed in chapter 3.1.

2. Unfasten the screws of the LH and RH enclosures

(Fig. 3, Pos. 6, 18) / (Fig. 4, Pos. 6, 19).

3. Disconnect the electrical connections to the HP / LP

switch.

4. Using a multimeter, check the continuity between

the terminals of the HP / LP switch.

5. If continuity exists, the HP / LP switch is functional.

5.2.3 Of start relay (for RG8.0)

1. Execute the steps listed in chapter 3.1.

2. Unfasten the screws of the LH and RH enclosures

(Fig. 3, Pos. 6, 18) / (Fig. 4, Pos. 6, 19).

3. Disconnect the electrical connections to the relay.

4. Check the continuity and execute action as listed in

the following table:

Continuity

between

terminals...

Result Action

4 and 3 No continuity

Replace relay4 and 2 Continuity observed

3 and 2 Continuity observed

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