Retrofit test kits for diesel systems of the latest generation. Prüftechnik

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1 Retrofit test kits for diesel systems of the latest generation Prüftechnik

2 Fit for the future diesel test equipment for passenger cars and commercial vehicles Special accessory kits CP1 CP2 CP3 CRIN CRI 846 Retrofit kits VPM 844 CRS 845 Basic test bench EPS 815 with KMA

3 Diesel systems conquer the market 3.1 CRS VPM 844 Bosch the leader in diesel technology and workshop test equipment Since its production of the first diesel truck in 1924 and the first diesel automobile in 1936, Bosch has been the world leader in the supply of diesel technology. Based on close and continuous co-operation with engine designers and a high degree of innovative power in development and production, recent years have seen the emergence of modern high-pressure systems which, with their high performance and economy, have boosted the market share held by diesel engines. Our expertise as an original equipment manufacturer also enabled us to develop innovative test equipment, including the ESI[tronic] software product. The test equipment enables us to diagnose our electronically controlled diesel systems on the vehicle itself in order to identify and replace faulty components. In this way Bosch offers service centres everything they need to master state-of-the-art diesel systems and open up new selling potentials. The basis for component testing from Bosch is the EPS 815 component test bench plus KMA test instrument technology. Expanding this system to include the CRS 845 test kit (3.1) for testing common rail high pressure pumps CP1, CP2, CP3 and the VPM 844 test kit (3.2) for testing solenoid valve controlled distributor pumps of type VP29/30/44 will safeguard the future of your testing operations. The test equipment and programs simulate all necessary operating states as in normal running of the vehicle. During testing, all process steps are displayed continuously on the monitor. The information required for this is derived from the test data CD. Why Bosch? Component testing in accordance with manufacturer's specifications is only possible with the use of CRS 845, CRI 846 and VPM 844 retrofit kits. This ensures that: Statutory emissions regulations are complied with Precise and repeatable measured values are determined A warranty evaluation in accordance with manufacturers' specifications is possible

4 Automatic programming with VPM Precision voltage stabiliser 4.4 Processor unit 4.2 Piston stroke measuring device Delta Phi Test data CD All data for programming pump control units and testing components The VPM 844 retrofit kit for testing solenoid valve controlled distributor pumps This test concept, too, is largely an automated process. There are no more adjuster screws. All adjustment operations are effected by programming the control unit. This test, defined on the basis of strict factory specifications, incorporates all parameters such as engine speed, pressure, temperature, setting, waiting and measuring times. 4.3 Test nozzle holder combination type X By means of the precision voltage stabiliser (required for VPM 844 and CRI 846) (4.1) the components are supplied with exactly the right voltage. The processor unit (4.4) is used for calibration and programming. Data communication with the pump control unit is by way of specially developed measurement and evaluation boards. Measurement of the piston stroke Delta Phi (4.2) requires a special device.

5 The high pressure route to success CRS High pressure rail 5.2 Distributor WiNDOWS 2000 CD-ROM: RobertBosch GmbH Bosch Automotive Aftermarket D Plochingen CD- TestData 2005/1 2004/1 EPS V EPS V FD 2003/11 Starten mit Setup.exe Bilder von Pumpen Bosch Diagnostics Software CD-TestData The retrofit kit for testing common rail pumps. The main externally visible feature is the splash guard (3.1), which is essential at a continuous pressure of 1600 bar. The high pressure rail (5.1), including pressure sensors, serves as a pressure accumulator with an integral regulator. 5.3 Heat exchanger The distributor (5.2) splits the volumetric flow upstream of the cooling and quantity measurement stages. The control unit controls the sensors and valves of the test specimen and of the rail. The control valve regulates the back pressure of the pump under test and thereby simulates the vehicle situation. The adapters for mounting of the various pumps are available as accessories. The heat exchanger (5.3) is required to cool the test oil prior to measurement in both systems.

6 Test equipment for common rail high pressure pumps CP1 CP3 Diesel Service opens up new opportunities for the workshop High performance modern common rail systems are becoming increasingly accepted in the market place. Initially, the required high pressures were produced by the CP1 high pressure pump. Today, the latest generations of high pressure pumps are used in the vehicles, such as the quantity-regulated CP3 system which is designed for pressures of 1600 bar or higher and the CP2 system which is used in the commercial vehicle sector. Bosch test technology allows workshops to carry out professional diagnosis and repairs of state-of-the-art diesel systems. Bosch's know-how is also available to the diesel specialist for complex component repairs. CP2 Special accessory sets The special accessory sets CP1, CP2 and CP3 supplement retrofit kit CRS 845 with regards to pump testing. For testing common rail pumps Bosch offers diesel workshops the complete equipment package for inspecting high pressure pumps: After connecting the removed diesel injection pump on the test bench and to the retrofit kit, the individual test steps are carried out almost entirely automatically. All steps of the test procedure are visualised on the monitor (6.1) The CD test data provides all the information for inspecting the pumps 6.1 equality test

7 Common rail injector test 7.1 CRI CRI 846 on EPS 815 Retrofit kit CRI 846 including passenger car and commercial vehicle accessory sets Powerful performance development and attractive engine characteristics of state-of-the-art diesel engines mean that the number of vehicles with diesel drive technology is rising. The common rail technology thereby provides the basis. In addition to the high pressure pump, the injector is a key component of a modern common rail injection system. With the common rail injector retrofit kit CRI 846 (7.1) including special accessory set for passenger cars, up to 6 passenger car injectors (1st and 2nd generation) can be set up for a test procedure (7.2).The tight manufacturing tolerances and the associated high measuring accuracy will allow the diesel specialist in future to readjust the injectors after repair, as well as inspect injectors with IMA* technology. Special accessory set CRIN (7.3) allows the inspection of commercial vehicle injectors (1st and 2nd generation). The prerequisite for special accessory set CRIN is retrofit kit CRI CRIN *) Injektor-Mengen-Abgleich `= injector quantity adjustment

8 Repairs made easy Tools CATalogue 2005/1 2004/1 Service Werkzeuge/ Service Tools/ Diagnostic Equipment Bosch / Zexel Deutsch, English Français, Español Italiano, Português, Svenska WINDOWS 95/98/NT/ME/2000/XP CD-ROM: / RobertBoschGmbHBoschAutomotiveAftermarketD-73207Plochingen Bosch Diagnostics Software ToolsCATalogue ESI[tronic]-W "Diesel test values" For testing and setting inline and distributor fuel injection pumps for diesel units. 8.2 Well equipped for component replacement and repair for diesel and electric thanks to easily understood repair manuals and quick location of spare parts. This special software (DVD with quarterly updates as subscription) helps you save time and increase profit per order ( ). ESI[tronic]-K "Component repair instructions" Repair and test manuals, service information and service telegrams for diesel and electrical system components assist in fault analysis. ESI[tronic]-D "Diesel spares" Comprehensive overview of diesel products, unique with detailed exploded views. ESI[tronic]-K/W "Archive" Each new customer receives one free copy of the archive data of ESI[tronic]K and W with the ESI[tronic] subscription. The ToolsCATalogue CD provides information about all customer service tools and special accessories (8.3). It contains around 2200 Bosch and Zexel tools for repairing starters, alternators, and also diesel fuel injection systems, including information on how to use them. It also contains a special accessories catalogue for test benches. This CD is available free of charge from your local Bosch distributor. The test data CD Test data for Bosch common rail high pressure pumps, common rail injectors and VP29/29/30/44 distributor-type injection pumps (available as a subscription, available through the ESI[tronic] service line).

9 Training for success 9.1 The training courses teach basic knowledge 9.2 KTS 650, the top-end device for control unit diagnosis Training at one of our training centres is essential before successful diagnosis and servicing can be carried out. The essential basic knowledge is taught in theory and practise. These training courses are offered among others: EP 4 Common rail system Course content: Design, function and mode of operation of common rail high pressure pumps. Special features to be observed when servicing pumps. Testing on the EPS 815 component test bench with KMA test instrument technology. EP 3.2 New generation distributor pumps Course content: Design, function and mode of operation of solenoid valve controlled distributor pumps, types VE- M and VR (VP 29, VP 30, VP 44). Servicing and testing with service tools, test equipment and the EPS 815 pump test bench with KMA test instrument technology. EP vehicles, commercial vehicle EDC Course content: Design and function of the various commercial vehicle EDC systems with H pump MS 5 system and MS 6.1 with PDE MS 6.2 with CRS MS 6.3 in commercial vehicle and the older M7 system with pump Onboard testing of components on commercial vehicles with engine testers. Fault finding with ESI[tronic] and state-of-the-art diagnosis technology (9.2). Input and output testing on a dynamometer. EP vehicles, passenger car EDC Course content: Distr. type EDC injection pumps, inline EDC pumps, VR EDC injection pumps, common rail, UIS, UPS. Function, design and mode of operation of individual components. Interaction of components in overall system, possible faults, testing components in situ using the engine tester. Fault finding with ESI[tronic] and state-of-the-art diagnosis technology (9.2).

10 Data and facts Retrofit kit VPM 844 Designation Order no.vp 29/30 VP 44 Retrofit kit VPM 844 for solenoid valve controlled distributor-type injection pumps 29/30/ X X Caution: Max. permissible coolant temperature during tests (VP 29/30/44) is 17 C. If temperature is exceeded, this may make additional on-site measures necessary Win2000 VP 44 multilingual processor unit without keyboard X X Note: If WIN 2000 PC available, order only VP-M upgrade kit Retrofit kit VP-M X X Transformer conversion kit V for EPS 815* (only necessary for VP 29/30/44) X X Transformer conversion kit V for EPS 815* (only necessary for VP 29/30/44) X X Reducing fitting L= 350 mm (Ford/Rover) X Reducing fitting L= 450 mm (Audi/BMW/Ford/Nissan/Opel) X Test pressure line L= 845 mm (Cummins/John Deere/MAN/Nissan/VM Motori/Volvo) X Test pressure line L= 450 mm (Opel VP 29/SISU, Perkins VP 30) X Adapter cable PSG2 (pump control unit type 2) X Test nozzle holder combination type IX car/comm.veh. (d= 0.5) 6 units recommended X X Test nozzle holder combination type X car (d= 0.4) 6 units recommended X Perforated plate for type X test nozzle/holder combination (d=0.5) 6 units required (X) Test nozzle holder combination type X comm.veh. (d= 0.5) 66 units recommended X Clamping stand, Audi, 2 units required X Heat exchanger Important! Required for CRS 845 and VPM X X Specifications test data CD for CR injectors (passenger car/commercial vehicle) X X and CR/VP-M pumps. Note: Update subscription from ESI[tronic] service line Tools CATalogue Retrofit kit CRS 845 Designation Order no.cp1 CP2 CP3 Retrofit kit CRS 845 for common rail high pressure pumps X X X Win2000 multilingual processor unit without keyboard X X X inc. standard (inline/dist. pumps) and common rail software Alternatively: upgrade kit if EPS processor unit already has (X) (X) (X) Win Me Riser retrofit kit (12-channel for old KMA up to approx. 3/2001) (X) (X) (X) Special accessory set CP1 (clamping sets for CP1 pumps) X Special accessory set CP2 (clamping sets for CP2 pumps) X Special accessory set CP3 (clamping sets for CP3 pumps) X A drive flange is also required if accessory set CP1 is not available X Heat exchanger Important! Required for CRS 845 and VPM X X X Upgrade kit for heat exchanger. Measurement set split from 6 to 12 channels (X) (X) (X) Note: required for testing of pumps with delivery rate >160 l/h Specifications test data CD for CR injectors (passenger car/commercial vehicle) X X X and CR/VP-M pumps. Note: Update subscription from ESI[tronic] service line Tools CATalogue Retrofit kit CRI 846 Designation Order no. Retrofit kit CRI 846 incl. special accessory set for passenger car common rail injectors (CRS 845 required) Note: Before commissioning the test unit for the first time, it is necessary to calibrate the rail pressure sensor on the EPS 815 Precision voltage stabiliser Note: Only required if no test unit VPM 844 is available Voltage stabiliser kit (only for new stabiliser purchase) Transformer conversion kit V for EPS 815 (only necessary for VP 29/30/44) Transformer conversion kit V for EPS 815 (only necessary for VP 29/30/44) Special accessory set CRIN for commercial vehicle common rail injectors (CRI 846 required) Specifications test data CD for CR injectors (passenger car/commercial vehicle) and CR/VP-M pumps Note: Update subscription from ESI[tronic] service line Tools CATalogue X = required (X) = if required * Transformer conversion kit required by production date 07/05 (estimated) Subject to modifications and program changes.

11 Our knowledge, your success. Bosch Diagnostics Diagnostics the key to the automotive workshop of the future Motor vehicle systems are becoming increasingly complex; the demands placed on qualified diagnosis in workshops are rising. For professional service on modern vehicles, Bosch provides everything at one stop, perfectly coordinated: testing technology, software, technical training and hotline, supplemented by parts in initial equipment quality. ESI[tronic] Software for Test technology matched Service training Technical hotline diagnostics and service to each workshop type knowledge as a factor for support from the system Simple operation Optimized combination of success developer Rapid access hardware and software for Comprehensive training Support in difficult Modular structure rapid troubleshooting, program for automotive technical situations Comprehensive market qualified repair and high workshops Skills covering all brands coverage time savings Practical training courses and manufacturers Continually updated PC-based, testing techno- Highly qualified trainers Universal operation re- logy of the latest generation with a great deal of gardless of manufacturer with extendable modules practical experience

12 Bosch skilled partner for workshop business ECU Diagnostics KTS AA/PDT2 WAW 3220 GB The right to make changes of a technical nature and to alter the range on offer is reserved Developments from Bosch stand for innovative progress in automobile manufacturing Geared to the growing proportion of electronics in the vehicle, Bosch offers workshops the suitable testing technology for all sizes of company and service concepts. Sturdy, innovative, state-of-the-art automobile technology: Computer-assisted diagnosis systems help in finding any fault more quickly and more reliably. The modular layout - using future-oriented technologies enables broad networking and efficient use of comprehensive information from the ESI[tronic] software. Mobility and user-friendly user guidance support the workshop in reliable and timesaving diagnosis. Engine System Testing FSA Emissions Analysis BEA Diesel System Testing EPS Battery Service BAT Brake Testing BSA Where to find Original Bosch Quality: Wheel Alignment FWA Air Conditioning Service ACS Robert Bosch GmbH Automotive Aftermarket D Karlsruhe I