ESI[tronic] 2.0 Trainer

Service Training Center Robert Bosch GmbH Automotive Aftermarket Diagnostics www.bosch-diagnostics.de

ESI[tronic] User training Course documentation Name :... Date : from... to... Location :... This training document is intended to provide information for training purposes. It must not be used for carrying out repairs on vehicles. Repair work must be carried out in accordance with valid workshop documentation. All values listed here are application-dependant and are therefore not generally applicable.

ESI[tronic] 2.0 Trainer Operation 1. Print menu/main menu - Print menu.... 4 - Main menu.... 5 - Multimeter.... 6 - Oscilloscope.... 8 - Protocols... 9 2. Vehicle identification - Vehicle identification... 11 - By description... 12 - Last 30 vehicles....... 14 - VIN Identification. 15 - Asanetwork.. 18 - CoRe. 19 3. Vehicle diagnosis - Vehicle info... 20 - Diagnosis (KTS 5xx / KTS 6xx).... 21 - System group and System selection 22 - Pin selection.... 23 - System search/search result... 25 - Function selection... 27 - Diagnosis (KTS Truck) 30 - System group and System selection 31 - Diagnostic socket.... 32 - Diagnostic function.. 33 - Trouble-shooting. 36 - SIS/CAS 37 - Known faults.. 39 - Maintenance 40 - Maintenance schedules. 42 - Circuit diagrams.. 43 - Equipment....... 44

Print menu The current screen display, certain parts of the current screen display (e. g. lists, diagrams), the current protocol or the maintenance schedules for the vehicle selected are printed. Print menu Select. The layout of the print-outs (header, margins, scaling) can be altered under: " Main menu >> User settings >> Print settings". We recommend that the scaling (100 %) is changed only if the printer distorts the print out or crops the content. Under: "Main menu >> User settings >> Company data" it is possible to select a company logo which will be displayed in the "Company header". Select print options Select Current display, e.g. screen shot, list or Selected vehicle, e.g. current protocol, maintenance schedules. Select Print preview or Print. The document is displayed or printed. Depending on the current window, not all options may be active and can therefore not be selected. 4

Main menu Main menu Main menu. Multimeter The purpose of the integrated multimeter is to measure voltage, current, resistance, diode voltage, continuity and open circuit. Oscilloscope The integrated 2-channel oscilloscope can be used to display voltages and currents in the form of a time profile. Hardware settings Diagnostic units can be configured and activated. Protocol/maintenance schedule management The stored protocols/maintenance schedules can be displayed, saved, printed or deleted. Alter user settings - Language settings - Company data - Messages - Proxy settings - Print settings - Protocol - Maintenance - Units - Truck units - Vehicle identification - User Interface - Asanetwork - Product enhancement Show system information - About ESI[tronic] - Software information - System information ESI[tronic] 2.0 licensing Licensing is performed by way of a license file or online. Execute online update For installation of ESI[tronic] 2.0 software updates available on the Bosch download server. Create ESI Ticket ESI Ticket is your direct link to Bosch (ESI[tronic] Hotline). - Show instructors - Show ESI[tronic] News - Show vehicle list - End ESI[tronic] 5

Main menu Multimeter Only with activated KTS 5xx / KTS 6xx Notes on multimeters: DANGER Risk of electric shocks from high voltage! Charges produce potentially fatal voltages if measurements are taken without a ground cable. Contact with live parts leads to electric shocks and heart failure and may be fatal. Multimeter Main menu >> Multimeter. The purpose of the integrated multimeter is to measure voltage, current, resistance, diode voltage, continuity and open circuit. 6

Select Select measurement mode (U, I or R). measuring range (e. g. Auto, 2 V, 100 ohms). The measuring range is specified automatically if the menu item "Auto" has been selected. The last measuring range selected is adopted for the time profile display Time prof. Select current (DC, RMS or AC). Select measurement mode Diode test, Open circuit or Short circ. Time prof. provides graphical representation of the measured values set in the time profile display. Heed "Notes on multimeter" in Online Help. 7

Main menu Oscilloscope Only with activated KTS 590. Oscilloscope Main menu >> Oscilloscope. The integrated 2-channel oscilloscope can be used to display voltages and currents in the form of a time profile. 8

Main menu Protocols The stored protocols/maintenance schedules can be displayed, saved, printed or deleted Protocols Main menu >> Protocols. Select Protocols/maintenance schedules with. Select Print preview, Save, Print or Delete. Protocols/maintenance schedules are displayed, saved, printed or deleted. 9

For protocol/maintenance schedule selection, there must be a tick in front of the protocol/maintenance schedule concerned. Marking (protocol/maintenance schedule on blue background) is not sufficient. All protocols are selected if the tick in the table header is selected. Use Edit to add customer data to the marked protocol/maintenance schedule. Customer data are displayed on the protocol/maintenance schedule. Select records using. Select <Open> or <Delete>. The recording is displayed or deleted. 10

Vehicle identification The vehicle identification procedure permits quick and easy vehicle selection. Vehicle identification By Description Vehicle identification by way of selection of vehicle data, e. g. type of vehicle, type of drive. Asanetwork" Asanetwork jobs can be selected and accepted. The job status is displayed. Vehicle identification via entry of country-specific key numbers. VIN identification The vehicle identification number (VIN) is the internationally standardized 17-character number that unequivocally identifies a motor vehicle. Last 30 vehicles Vehicle identification by way of selection of one of the last 30 identified vehicles. RB key Vehicle identification via entry of Bosch key. 11

By description Vehicle identification by way of selection of vehicle data, e. g. type of vehicle, type of drive. Vehicle identification "By description" By Description. Specify the vehicle identification as fully as possible (select all menus). Country, Vehicle type, Drive type and Make must be selected. The last makes selected (favorite makes) are displayed in the open "Make" menu, followed by all makes in alphabetical order for quick and easy selection. Select Search. Search for vehicles. 12

Selected the desired vehicle. Show vehicle information with "Vehicle info", execute diagnosis with "Diagnosis", perform trouble-shooting with "Trouble-shooting", perform maintenance with "Maintenance", show circuit diagrams with "Circuit diagrams" or show equipment with "Equipment". 13

Last 30 vehicles Vehicle identification by way of selection of one of the last 30 identified vehicles. Vehicle identification by "Last 30 vehicles" Last 30 Vehicles. Selected the desired vehicle. Show vehicle information with "Vehicle info", execute diagnosis with "Diagnosis", perform trouble-shooting with "Trouble-shooting", perform maintenance with "Maintenance", show circuit diagrams with "Circuit diagrams" or show equipment with "Equipment". The stored logs can be displayed, saved, printed or deleted. 14

Vehicle identification by "VIN identification" The vehicle identification number (VIN) is the internationally standardized 17-character number that unequivocally identifies a motor vehicle. The VIN can be read out automatically, the vehicle can be identified by entering the VIN or rapid diagnosis can be performed. Automatic VIN readout Select VIN identification. Select VIN readout. Link with control unit is established. Vehicle is identified by VIN readout. Not all these functions are available for certain vehicles and can therefore not be selected. Rapid diagnosis 15

Select Rapid diagnosis. Link with control unit is established. Vehicle is identified by VIN readout. "Diagnosis" is displayed. Show system overview with <System search>. A system search takes place and the search results are displayed. Select system, e. g. Engine management. Select <Direct selection>. Function selection is displayed, e.g. fault memory, actual values. 16

Manual VIN entry Select VIN identification. Enter VIN. Select Search. Vehicle is identified by entering the VIN. If several vehicles are displayed: Selected the desired vehicle. The VIN is usually to be found in the engine compartment, on the door sill next to the front passenger's seat or in the luggage compartment. 17

Vehicle identification by "Asanetwork" Asanetwork can be used to link various systems (e.g. office systems with order management, measurement and testing devices, time recording systems, data storage and data communications). Asanetwork provides a standard method of data exchange irrespective of the type of information being transmitted. Asanetwork jobs can be selected and accepted. The job status is displayed. Asanetwork Select Asanetwork wählen. Menu option is only displayed if this function has been activated in: "Main menu >> User settings >> Asanetwork". Mark asanetwork job. Press <F5> to refresh the view of asanetwork jobs. Sort selection list entries alphabetically: Click table header, e.g. License plate. Press <F12> to accept asanetwork job. Asanetwork job is accepted. Vehicle data are inserted in the KBA-Schlüssel (D) or By Description tab (if the asanetwork job contains an incorrect or no KBA-Schlüssel). 18

CoRe The CoRe" software (Connected Repair) makes it possible to exchange customer and vehicle information as well as reports at the workshop. The testers (CoRe clients) are connected to a central computer (CoRe server) via the computer network. CoRe Further information can be obtained from your Customer Service agent. 19

Vehicle info Information on details of vehicle, equipment systems possibly fitted in the vehicle and the fitting location of the diagnosis socket. Vehicle info Vehicle info. Vehicle details Information on vehicle selected, e.g. engine code, capacity. Equipment systems Overview of equipment systems possibly fitted in the vehicle. Diagnosis socket Vehicle-specific information on the fitting location and pin assignment of the diagnostic connector as well as connection options. Important Important information for control unit diagnosis. Important make info Make-specific information on function in the vehicle. Abbreviations Alphabetical list of abbreviations used and explanatory notes. Return to Vehicle Identification with. 20

Diagnosis (KTS 5xx / KTS 6xx) Identifying and providing precise and clear diagnoses for systems installed in the vehicle. Diagnosis procedure Diagnosis. ESI[tronic] 2.0 and KTS permit control unit diagnosis, e.g.: - Read error memory - Erase error memory - Show actual values System overview System selection by way of "System overview" permits quick and easy searching for all the control units fitted in the vehicle. Repair System selection by way of "Repair" permits quick and easy searching for the control units fitted in the vehicle. The control units are arranged according to system groups e. g. ABS, engine management. Service tasks The selection of service activities by way of "Service tasks" permits the display and rapid implementation of work relating to servicing. Components Components (e.g. alternators) can be diagnosed and repaired with the aid of repair instructions, without performing vehicle identification. ESI[tronic] type of information "K" (repair instructions) must be activated. Return to Vehicle Identification with. 21

Diagnosis System group and System selection System group and system selection permits quick and easy searching for the control units fitted in the vehicle. Select system group and system Diagnosis >> Repair or Service tasks. All available system groups are displayed on the left. Select system, e. g., z. B. Diesel EDC. We recommend Direct selection if only one system is displayed. If several systems are shown in a group, we recommend System search. Entries are sorted in alphabetic order ("A" to "Z"). Entries are sorted in reverse alphabetical order ("Z" to "A"). Entries are sorted by system. By entering a search term into the search input box, entries can be filtered. By searching / filtering for a system, it is possible to perform a diagnosis of a system without knowing the corresponding system group. In case of a search for a system, the search is conducted not only within the selected system group but in all system groups. The system group selection is therefore canceled, and all systems are shown in the list. In that case, a <Direct selection> of a system found can be carried out but no <System search>. If a system is highlighted, the corresponding system group is highlighted in light blue. To carry out a system search in that system group, the corresponding system group must be selected. 22

Diagnosis Pin selection Pin selection permits manual alteration of the assignment to the K-wire, L-wire and CAN wire. Pin selection If no system was found on account of the assignment of the pins differing from the specified pin assignment of the diagnosis socket, e. g. for country versions. Diagnosis >> Repair >> Pin selection. Select pin setting, e. g., z. B. "ISO K=6 L=1". Continue with Select. Pin selection has been altered. 23

Activating/deactivating adapter detection The connected vehicle adapter is automatically detected and displayed at the bottom of the field if adapter detection is switched on. The vehicle adapter is not checked if adapter detection is switched off (e.g. if a control unit is detected as vehicle adapter). Only the actuated pins are displayed at the bottom of the field. 24

Diagnosis System search/search result The search result indicates the systems found per group and the number of faults. Systems can be selected and function selection started. Diagnosis >> Repair >> System search. The systems found are displayed for each system group. The number of faults is displayed for each system found. If no faults were read, the column remains blank. "0" is displayed if no fault was found. If a system found was an unknown control unit version, this is displayed as substitute system. Only a restricted scope of diagnostic functions is then available. If no system was found in a group, the non-searchable systems of the group or "No system found" are/is displayed in the search result. 25

Select system within system group. Select Start. Function selection is displayed, e. g. fault memory, actual values. 26

Diagnosis Function selection "Function selection" permits analysis and/or alteration of the control unit selected. Function selection Select function (e. g. "Actual values"). Select Continue. The function is displayed. Reading, erasing fault memory In menu point Fault memory, faults are read out of the control unit. Function key Continue, displays further information. 27

Displayed data are stored with Save and can thus be shown in the protocol. It is recommended to give the customer the faults found in printed form. All faults should therefore be saved, printed out and discussed with the customer. Clearing the fault memory In menu point Clear fault memory, the fault memory can only be cleared after it has been read out. Actual values Actual values permit plausibility checking of system parameters, e. g. load signal or ignition angle. The measured values determined for the actual values selected can be displayed as a numerical value or time characteristic. Select Continue. The measured values for the selected actual values (e. g. load signal, ignition angle) are displayed. Up to four or eight actual values can be selected depending on the control unit chosen. The actual values are output by the corresponding vehicle control unit. The time characteristic display of the actual values provides a graphical representation of the actual values (e. g. load signal, ignition angle). 28

Actuators Actuators: For activation of system-specific actuators (e. g. valves, motors) to check operation. 29

Diagnosis (KTS Truck) Identifying and providing precise and clear diagnoses for systems installed in the vehicle. Diagnosis procedure Select Diagnosis. ESI[tronic] 2.0 software permits control unit diagnosis, e. g.: - Read error memory - Erase error memory - Show actual values is used for return to Vehicle identification. 30

Diagnosis System group and System selection System group and system selection permits quick and easy searching for the control units fitted in the vehicle. The system group and system selection enables rapid and simple selection of non vehiclespecific control units without having to go through the vehicle identification procedure. Additionally a system can be searched for via an input box.(only if KTS Truck is active). System group and System selection Select Diagnosis. All available system groups are displayed on the left. "OBD" shows all the emission-specific systems of all system groups for the selected vehicle (EOBD/OBD = On-board diagnostics as per EU standard, HD-OBD = On-board diagnostics as per CARB standard for USA). ALL shows all systems of all system groups of the vehicle selected. Switch on the ignition. Select system group, e.g. Engine. management. System selection, e. g. Engine For certain system groups/systems, further Functions are available: Systeminfo Display of system information, e. g. circuit diagrams, test specifications. Modellinfo Maintenance schedules and test specifications are displayed. System overviewshow vehicle-specific System overview. DTC Lookup Fault information is displayed after entering fault codes (DTC = Diagnostic Trouble Code). Select Continue. Information on connection of KTS Truck to vehicle is displayed. 31

Diagnosis Diagnostic socket Information on fitting location and pin assignment of diagnostic socket is displayed as well as connection options. Connection of KTS Truck to vehicle Determine installation location of diagnostic socket from illustration. The Adapter lead and UNI Adapter buttons display further Information, e.g. the order number of the OBD diagnostic lead or pin allocation and information on the Universal adapter lead power supply. The message Use this diagnostic connector? is displayed on vehicles fitted with several diagnostic sockets. If the diagnostic socket displayed is not to be used, a different connection option can be displayed with <No>. Connect KTS Truck to vehicle as specified. Select Continue. Link with control unit is established. Diagnostic functions are displayed. 32

Diagnosis Diagnostic function Identifying and providing precise and clear diagnoses for systems installed in the vehicle. Diagnostic function The function selection of the control unit search is displayed. With function key Continue the possibilities that depend on the system are selected, for example Error memory or Identification. 33

Reading, erasing fault memory In menu point Fault memory, faults are read out of the control unit. Function key Continue, displays further information. Displayed data are stored with Save and can thus be shown in the protocol. It is recommended to give the customer the faults found in printed form. All faults should therefore be saved, printed out and discussed with the customer. Clearing the fault memory In menu point Clear fault memory, the fault memory can only be cleared after it has been read out. 34

Actual value Actual values permit plausibility checking of system parameters, e. g. load signal or ignition angle. Actuators Actuators activates system-specific actuators (e.g. valves and motors) to check operation. 35

Trouble-shooting Information on trouble-shooting with SIS/CAS and on make, as well as general information on vehicle diagnosis. Trouble-shooting Trouble-shooting. SIS/CAS Information on trouble-shooting with SIS/CAS. SIS = Service information system. CAS = Computer Aided Service forms the link between the SIS trouble-shooting instructions and diagnosis. Make information Make-specific information, e. g. Service information can be displayed. General information General information, e. g. on Alarm, Brakes or Lights. Known faults "Known faults" provides rapid and easy access to known vehicle problems. Known issues online Experience gained from the Bosch diagnosis hotline and internet forums indicates that certain issues with automotive technology occur again an again with specific vehicle models. Experienced Bosch authors will review every case and approve it. That way, they continually create new descriptions of known repair scenarios based on actual practice and provide new solutions in ESI[tronic] 2.0. 36

Trouble-shooting SIS/CAS Information on trouble-shooting with SIS/CAS. SIS/CAS Trouble-shooting >> SIS/CAS >> <System group/system> >> <Continue>. The manual validity indicates the designation of the system to be tested and on which vehicle model the manual was compiled. Notes on system identification and diagnosis are filed here. The system description contains filed detailed functional descriptions on the individual systems. Actual values and set values are clearly arranged in tabular form in the new layout. The system test contains precise descriptions on individual components and parts and how to test them. The new instruction manual layout contains an accurate description of the installation position, as well as providing detailed information on assembly and disassembly features. The layout of the instruction manual as shown on the example below has been completely revised and optimized to match the requirements placed on a modern workshop and repair process. All new instructions have been structured according to this pattern. They are slightly different according to the system to be tested, e.g. gasoline injection, ABS and are adapted to suit system requirements. 37

Example of an electrical terminal diagram. 38

Trouble-shooting Known faults Find known problems in vehicles and remedy in accordance with specifications. Known faults Trouble-shooting >> Known faults >> <Area/Problem> >> <Display solution>. Known faults provides rapid and easy access to known vehicle problems. - Symptomatic assignment to areas, e. g. ride comfort, electrical system, body - Clear description of causes - Repair advice Known issues online Experience gained from the Bosch diagnosis hotline and internet forums indicates that certain issues with automotive technology occur again an again with specific vehicle models. Experienced Bosch authors will review every case and approve it. That way, they continually create new descriptions of known repair scenarios based on actual practice and provide new solutions in ESI[tronic] 2.0. 39

Maintenance Clear-cut, systematic representation of mechanical system information, e. g. maintenance schedules including resetting of maintenance interval display, notes on toothed belt replacement, wheel setting data and notes on key programming. Maintenance Maintenance. Maintenance schedules The maintenance schedules specified by the manufacturer and the maintenance work to be performed. Work units per maintenance schedule. Notes on individual maintenance operations. Spare parts Information on spare parts required, e. g. engine oil, toothed belt is displayed. Maintenance illustrations Vehicle-specific maintenance illustrations, e. g. "Oil inlet and drainage openings" are displayed together with additional information, e. g. tightening torques, and can be enlarged for greater clarity. Maintenance interval display Information on the fitting location of the maintenance interval display in the vehicle and instructions on resetting the maintenance interval display. Show Diesel exhaust gas aftertreatment For vehicles with exhaust gas aftertreatment, the following information, for example, is displayed: General, Safety precautions, Special tool, Mode of operation: Initiate a DPF regeneration cycle 40

VIN plate location Information on the position of the vehicle identification plate and engine rating plate in pictorial form. Tire sizes and pressures Information on vehicle-specific inflation pressures for all rim and tire sizes. Test specifications Vehicle-specific Test specifications are displayed in various categories. Toothed belt Information and instructions on toothed belt. Replacement intervals for toothed belt, job times, special tools, removal and installation instructions. Illustrations on toothed belt removal and installation Replace additional timing belt IInformation and instructions on additional timing belt. Wheel setting data Information on the running gear of the vehicle is displayed in various categories: Dimensions for wheelbase, toe, Tightening torques, Wheel test specifications, Wheel settings. Key programming Information and instructions on function, operation, synchronization and re-programming of remote control units for anti-theft alarms and central locking systems with illustrations showing procedures, e. g. battery replacement. Show current maintenance data online Current vehicle-specific information is displayed in the standard browser (e.g. Windows Internet Explorer or Mozilla Firefox). 41

Maintenance Maintenance schedules The maintenance schedules specified by the manufacturer and the maintenance work to be performed. Work units per maintenance schedule. Notes on individual maintenance operations. Maintenance schedules Maintenance >> Maintenance schedules >> Maintenance interval >> Display operations. Further information can be displayed by clicking for information with. Additional text can be entered in the "Remarks / Test specifications" column. The maintenance operations for the maintenance interval (in the example 90000 km or 72 months) are displayed in the List of operations and can be performed/ticked off. 42

Circuit diagrams Display of vehicle-specific circuit diagrams and information on their individual components. Circuit diagrams Circuit diagrams >> <System group/system> >> <Continue>. Circuit diagrams are displayed for the system selected. Select component in component overview. The item number of the component selected is marked in the circuit diagram or Move the cursor to the item number of the component in the circuit diagram. The component selected is marked in the component overview. 43

Equipment Vehicle-related equipment/search for parts. Show equipment Select Equipment. Switch from ESI[tronic] for Truck to ESI[tronic], which provides access to the full range of Bosch motor vehicle equipment. The Bosch replacement part catalogs, including the catalog data of the Bosch associate ZF Services, also containing service information and fitting instructions for Sachs, Lemförder, Boge and ZF Parts products, are then available. Information on ESI[tronic] can be found in the ESI[tronic] Online Help. 44