KTS 650 System Tester

KTS 650

System Tester for

Control-Unit Diagnosis

Robert Bosch GmbHCopyright © 2004

Manual P/N 08002754

Printed in USA 7/04

Table of Contents

1. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DANGER OF INJURY/CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DANGER OF ASPHYXIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DANGER OF BURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DANGER OF FIRE, EXPLOSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

HIGH VOLTAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DANGER OF IMPLOSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DANGER OF ACID BURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

AGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

USER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CONNECTING TO THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4. SCOPE OF DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5. DESCRIPTION OF UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

KTS 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DVD/CD DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

PS/2 KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

MOUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

EXTERNAL MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6. PUTTING THE KTS 650 INTO OPERATION. . . . . . . . . . . . . . . . . . 13

BEFORE SWITCHING ON FOR THE FIRST TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

INSTALLING THE OPERATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

KTS 650 System Tester for Control-Unit Diagnosis TOC-1

NOTES ON THE WINDOWS CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SWITCHING THE KTS 650 ON AND OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

ADJUSTING THE BRIGHTNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SOFTWARE UPDATE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CONNECTING THE PS/2 KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

CONNECTING AN EXTERNAL MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

TOUCHSCREEN WITH STYLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

VIRTUAL KEYBOARD WITH STYLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

PS/2 KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

8. MEASURING MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

9. SPECIAL INFORMATION FOR OPERATION VIA THE VEHICLE BATTERY 23

MULTIMETER, OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

CONTROL-UNIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

10. PRINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

PRINTING (CONTROL-UNIT DIAGNOSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

CHANGING THE DEFAULT PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

11. WHAT TO DO IF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

THE UNIT CANNOT BE SWITCHED ON AND THE DISPLAY STAYS DARK OR FLICKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

THE UNIT DOES NOT REACT WHEN THE KEYS ARE PRESSED . . . . . . . . . . . . . 25

MALFUNCTIONS ARE DISPLAYED IN THE INFO BAR DURING OPERATION 25

THE MOUSE POINTER IS DISPLAYED IN A DIFFERENT PLACE AFTER CLICKING THE TOUCHSCREEN WITH THE STYLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

THE KTS 650 CAN NO LONGER BE OPERATED USING THE STYLUS AND TOUCHSCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

12. CHANGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

13. OPTIONAL EXTRAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

TOC-2 KTS 650 System Tester for Control-Unit Diagnosis

14. SERVICE PARTS AND PARTS SUBJECT TO WEAR . . . . . . . . . . . . 28

15. MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

16. DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

DISPOSAL OF ELECTRONIC WASTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

DISPOSAL OF THE LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

DISPOSAL OF RECHARGEABLE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

17. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

KTS 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

POWER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

WEIGHTS AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

TEMPERATURE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

ELECTROMAGNETIC COMPATIBILITY (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

KTS 650 System Tester for Control-Unit Diagnosis TOC-3

TOC-4 KTS 650 System Tester for Control-Unit Diagnosis

Danger of Injury/Crushing Safety Instructions

1. SAFETY INSTRUCTIONS

DANGER OF INJURY/CRUSHINGIf the vehicle is not prevented from rolling away, there is a danger of people being crushed against a workbench, for example. Both running and stationary engines have rotating and moving parts (e.g., belt drives) which may cause injuries to fingers and arms. A special hazard is presented by electrically driven fans, in that they may be switched on without warning while the engine is stationary and the ignition is switched off.

SAFETY PRECAUTIONS:• Take steps to prevent the vehicle from rolling away while it is being tested.

• Select the park position if the vehicle has an automatic transmission and apply the handbrake or lock the wheels with chocks (wedges).

• Wear work clothes without loose bands and loops.

• Keep well away from rotating/moving parts while the engine is running.

• When working on or in the vicinity of electrically driven fans, allow the engine to cool down first, then disconnect the plug of the fan motor.

• Keep the tester connecting cables well away from all rotating parts.

• Lay the connecting cables in such a way that no one can trip over them.

• Lock the brakes on the test system trolley so that it cannot roll away.

• Do not place heavy objects on or lean on the sensor holder.

DANGER OF ASPHYXIATIONCar exhaust fumes contain carbon monoxide (CO) - a colorless, odorless gas. If inhaled, carbon monoxide causes an oxygen deficiency in the body. Extreme caution is therefore essential when working in a pit, as some of the components of the exhaust gas are heavier than air and settle at the bottom of the pit. Caution is also necessary when working on LPG-driven vehicles.

SAFETY PRECAUTIONS:• Always ensure effective ventilation and suction (especially when working in a pit).

• Always switch on and connect the exhaust hose.

KTS 650 System Tester for Control-Unit Diagnosis Page 1

Safety Instructions Danger of Burning

DANGER OF BURNINGWhen working on a hot engine, there is a risk of injury from burning if such components as the exhaust gas manifold, the turbocharger, the Lambda sensor, etc. are touched or if parts of the body come too close to them. These components may be heated to temperatures of several hundred degrees Celsius. Depending on the duration of the exhaust gas measurements, the sampling probe of the exhaust gas measuring instrument may also become extremely hot.

SAFETY PRECAUTIONS:• Always wear protective clothing, e.g., gloves.

• Allow the engine to cool down first (this also applies to auxiliary heating systems).

• Keep the tester connecting cables well away from all hot parts.

• Do not leave the engine running any longer than necessary for the test or setting.

DANGER OF FIRE, EXPLOSIONThere is a risk of fire and explosion from fuels and fuel vapors when work is performed on the fuel system or on the mixture control system.

SAFETY PRECAUTIONS:• Switch off the ignition.

• Allow the engine to cool down first.

• Avoid naked flames and potential sources of sparks.

• Do not smoke.

• Collect any leaked fuel.

• Always ensure effective ventilation and suction when working in closed areas.

NOISENoise levels in excess of 70 dB(A) can occur when measurements are carried out on a vehicle, especially at high engine speeds. Damage to hearing may result if human beings are exposed to noise at such levels over an extended period of time.

SAFETY PRECAUTIONS:• If necessary, noise protection facilities must be provided by the owner at all workplaces in the vicinity of

the testing area.

• If necessary, suitable personal noise protection facilities must be used by the operator.

Page 2 KTS 650 System Tester for Control-Unit Diagnosis

High Voltages Safety Instructions

HIGH VOLTAGESHazardous voltages occur in both the lighting system and the electrical system of a motor vehicle. If contact is made with live parts (e.g., ignition coil), there is a risk of electric shock from flashover voltages caused by damaged insulation (e.g., ignition cables which have been attacked by rats). This applies to both the primary side and the secondary side of the ignition system, to the cable harness and the plug connections, to the lighting systems (Litronic), and to the tester connections.

SAFETY PRECAUTIONS:• All testers must be connected to properly grounded, shockproof sockets (in accordance with VDE 01 00

or the corresponding country-specific regulations).

• Testers must always be connected using the power cables supplied with them.

• All extension cables must be fitted with shockproof contacts.

• Any cables with damaged insulation must be replaced (e.g., power or ignition cables).

• Connect testers to the lighting system and switch them on before connecting them to the vehicle.

• Connect testers to the engine ground or to the battery (B-) before switching on the ignition.

• Always switch off the ignition before performing any work on the electrical system of the vehicle. The term “work” includes connecting testers, replacing parts of the ignition system, removing assemblies (e.g., generators), connecting assemblies to a test bench, etc.

• Wherever possible, tests and settings should always be carried out with the ignition switched off and the engine stationary.

• If tests or settings are carried out with the ignition switched on or the engine running, care must be taken not to touch any live parts. This applies to all the connecting cables of the testers as well as to the connections of any assemblies at the test bench.

• Test connections must always be made using suitable connectors (e.g., Bosch testing cable set or vehicle-specific adapter cables).

• Make sure that all test connections are properly plugged in and secure.

• Switch off the ignition before disconnecting the tester from the engine ground or the battery (B-).

• Never open the casing of the screen.

• Never open the housing of the tester.

DANGER OF IMPLOSIONThere is a danger of the screen tube imploding if the screen is improperly handled (e.g., the tube is subjected to some form of impact, sudden temperature change, the glass is damaged).

SAFETY PRECAUTIONS:• Make sure that the screen is well vented so that heat can properly dissipate.

• Never cover the vents (e.g., with a towel) while the screen is in.


Safety Instructions Danger of Acid Burning

DANGER OF ACID BURNINGWhen exhaust gas measurements are taken, the sampling hoses which are used release a highly caustic gas (hydrogen fluoride) that can cause acid burning in the respiratory system when heated to temperatures in excess of 250 °C (482 °F) or in the event of fire.

RULES OF CONDUCT:• Consult a doctor immediately after inhaling!

• Always wear gloves made of neoprene or PVC when removing residues left after a fire.

• Neutralize any residues left after a fire with a calcium hydroxide solution. This produces non-toxic calcium fluoride, which can be washed away.

Acids and alkalis can cause severe burning on unprotected skin. Hydrogen fluoride in combination with moisture (water) forms hydrofluoric acid.

The condensate which accumulates in the sampling hose and in the condensate container likewise contains acid.

When replacing the O2 measuring sensor, bear in mind that it contains alkali.

When replacing the NO measuring sensor, bear in mind that it contains acid.

RULES OF CONDUCT:• Rinse any affected parts of the skin immediately in water, then consult a doctor!

• NO and O2 measuring sensors are hazardous waste and must be disposed of separately. Your Bosch specialist supplier can dispose of sensors in the proper manner.

If liquid crystal escapes from a damaged liquid crystal display, it is imperative to avoid direct skin contact, inhalation, and swallowing.

RULES OF CONDUCT:• Wash the skin and clothing thoroughly with soap and water if it has come into contact with liquid crystal.

• If you have inhaled or swallowed liquid crystal, consult a doctor immediately!

If fluid (electrolyte) escapes from batteries and rechargeable batteries, avoid getting it on your skin or in your eyes.

RULES OF CONDUCT:• If contact with skin or eyes happens nevertheless, wash the affected parts immediately with clean water

and then consult a doctor.


Agreement Important Information

2. IMPORTANT INFORMATION

AGREEMENTYour use of the product means that you accept the following conditions:

COPYRIGHT

Software and data are the property of Robert Bosch GmbH or its suppliers and are protected against unauthorized reproduction under copyright laws, international contracts, and other national legal provisions. The reproduction or sale of data and software or any part thereof is prohibited and punishable by law; in the event of violations, Robert Bosch GmbH reserves the right to prosecute and to assert claims for damages.

LIABILITY

As far as possible, all the data in this program are based on information from the manufacturer and importers. Robert Bosch GmbH furnishes no guarantee for the correctness and completeness of software or data; we assume no liability for damage caused by faulty software and data. At any event, the liability of Robert Bosch GmbH is limited to the amount which the customer has actually paid for this product. This exemption from liability does not apply to damages caused intentionally or by gross negligence on the part of Robert Bosch GmbH.

WARRANTY

Any use of hardware and/or software that has not been approved by Bosch constitutes a modification of our products, and hence exclusion of all liability and warranty claims, even if the hardware has been subsequently removed, or the software erased in the interim.

Our products must not be modified in any way. Furthermore, our products may only be used with original accessories/original spare parts. Disregard for the above will render all warranty claims invalid.

The present Bosch tester may only be used with operating systems approved by Bosch. Using the Bosch tester with different operating systems than those which we have approved will render our warranty obligation null and void, in accordance with our terms of delivery. In addition, we cannot assume liability for damages and consequential damages which are the result of the use of a non-approved operating system.

NOTEBefore connecting, starting up, and operating test units, always read the Operating Instructions of the tester thoroughly in order to rule out any uncertainty and associated risks with regard to safety when working with testers. All operations and workings as well as the connecting of testers close to the engine and to the ignition system must be executed only when the engine does not turn and the ignition circuit is switched off.


General Information User Group

USER GROUPThis product may only be used in the automotive sector by skilled personnel who are trained and instructed in it, such as motor-vehicle mechanics, electricians, foremen, technicians, and engineers.

3. GENERAL INFORMATION

APPLICATION The KTS 650 is a tester for mobile testing equipment in automotive repair shops. The KTS 650 enables you to:

• Perform control-unit diagnosis of electronic control units in the vehicle to:

• read the fault log

• display actual values

• trigger actuators

• provide a graphic display of actual values over time (time curves)

• make use of other control-unit specific features, e.g., interval reset

• Employ Bosch ESI[tronic] software (component testing, electrical wiring diagrams, installation locations of components, required test conditions, assembly instructions, service information, etc.)

• Use the multimeter for:

• voltage measurements

• resistance measurements

• current measurements (only with optional extras amps clamp 1 687 224 864/06500966 or current measuring shunt 1 684 503 103/06500965)

• Employ a 2-channel oscilloscope to record measured values

The KTS 650 is a high-precision instrument and must not be exposed to heat sources (e.g., direct sunlight), jolts or vibrations, magnetic fields, or excessive dirt.

TRANSPORT The connecting cables on the rear of the tester must be disconnected for transport. Moreover, the KTS 650 should only be transported and stored in the supplied case.


Connecting to the Vehicle General Information

CONNECTING TO THE VEHICLE The KTS 650 is designed to operate with a supply voltage of 12 V (cars) and 24 V (commercial vehicles).

CAUTION

CAUTION! Make sure that the diagnostic cable on the KTS 650 is plugged in correctly. If incorrectly plugged in, the pins on the male connector may be broken off.

FIGURE 1. Connection Diagram of KTS 650


Scope of Delivery Connecting to the Vehicle

4. SCOPE OF DELIVERY

The KTS 650 System Tester comes with the following items:

• KTS 650

• Universal power pack

• Power cord for power pack

• OBD-Multiplexer

• USB cable, 2 m

• Universal cable, 6-way

• Measuring lead, red

• Measuring lead, blue

• Measuring lead, yellow

• Ground cable, black

• Test prods, red (2)

• Terminal, black

• Y-connection cable for power supply

• Touchscreen stylus (2)

• Case

• Operating instructions (CD)

• External DVD/CD drive

5. DESCRIPTION OF UNIT

The KTS 650 is a modular, portable, fully mobile diagnostic, information, and measuring system.

The device contains a computer unit, a hard disk with pre-installed software, touch-screen display (TFT), rechargeable lithium-ion battery and the measuring module with multimeter and oscilloscope.

The latest ESI[tronic] A, C and P and Bosch Applications Menu software is pre-installed on the hard disk at the factory.

For operating the unit, a virtual keyboard is available as well as the stylus for the touchscreen. A PS/2 keyboard specific to the country of use can also be connected.

Data and measured values can be printed out via the USB interface using an external printer.

A liquid crystal display is used, but you can also connect to an external monitor.


Connecting to the Vehicle Description of Unit

The KTS 650 and accessories are housed in a protective case.

FIGURE 2. KTS 650 and Accessories Arranged in Their Case

1 KTS 650

2 Case

3 OBD-Multiplexer cable

4 Touchscreen stylus

5 Y-connector for connecting the KTS 650 and DVD/CD drive to the power pack

6 Ground cable with terminal

7 Measuring leads for multimeter

8 Universal power pack with power cord


Description of Unit KTS 650

KTS 650

OPERATOR AND DISPLAY UNIT

CAUTION

CAUTION! When the KTS 650 is placed in the engine compartment, there is a risk that the metallic floor of the tester may short the vehicle battery. When the KTS 650 is hooked onto the steering wheel, there is a risk of triggering the airbag.

FIGURE 3. KTS 650 Operator/Display Unit

1 Carrying handle

2 LCD with touchscreen

3 On/Off button

4 Windows Start Menu key

5 LED for unit On

6 LED for external power supply

7 LED for battery charge

8 LED for access to hard disk


KTS 650 Description of Unit

TERMINAL STRIP

NOTEThere is a key to the terminal strip on the back of the KTS 650.

FIGURE 4. KTS 650 Terminal Strip

1 Socket for oscilloscope and U/I-measurements (CH2)

2 Ground socket

3 Socket for oscilloscope and U/R/I-measurements (CH1)

4 Socket for diagnostic cable

5 PCMCIA slot, e.g., for DVD drive

6 Socket (RJ45) for network (LAN)

7 USB interface

8 Socket for microphone

9 Socket for headphones

10 Socket for external monitor (video outlet)

11 Socket for power pack

12 Socket for country-specific PS/2 keyboard (no plug socket for a PS/2 mouse)


Description of Unit DVD/CD Drive

DVD/CD DRIVEThe DVD/CD drive is an optional extra for updating the ESI[tronic] software. Please see Software Update Installation on page 18 for a description of how to connect the DVD/CD drive and install the ESI[tronic] software.

FIGURE 5. DVD/CD Drive, Front View

1 DVD/CD drawer

2 Access display (lights up when data are being read from the DVD/CD-ROM)

3 CD Eject

4 Emergency Eject

FIGURE 6. DVD/CD Terminal Strip

1 DC input, power pack socket

2 Socket for interconnecting cable to KTS 650

3 Audio sockets


PS/2 Keyboard Putting the KTS 650 into Operation

PS/2 KEYBOARD The KTS 650 can also be operated using an external PS/2 keyboard. The PS/2 keyboard is available as an optional extra in various country-specific versions.

MOUSE A USB mouse is the only kind of mouse that can be connected to the KTS 650.

EXTERNAL MONITOR When an external monitor is connected, the same user interface appears as on the LCD of the KTS 650. Both displays are active.

6. PUTTING THE KTS 650 INTO OPERATION

BEFORE SWITCHING ON FOR THE FIRST TIME Before using the KTS 650 for the first time, make sure that the voltage matches the voltage stated on the power pack (use the supplied power cord).

BATTERY CHARGING The battery of the KTS 650 is always charged automatically when external voltage is supplied. When the battery is nearly empty, it takes approximately 3 hours to re-charge it until it is ready for operation and can operate the KTS 650. The LED that indicates the battery charge flashes when the charge is < 80%. If the battery is charged to < 20%, a warning signal (beep) is sounded. In this case, re-charge the battery immediately. You can read the battery charge at any time on the energy indicator. You can view the energy indicator on the display by double-clicking with the stylus on the relevant icon in the taskbar.

NOTE The American power cord forms part of the standard scope of delivery. Other country-specific power cords are not included in the scope of delivery.


Putting the KTS 650 into Operation Installing the Operating System

INSTALLING THE OPERATING SYSTEM The Windows XP operating system is pre-installed in the KTS 650 in several languages. When using the KTS 650 for the first time, you must select a language, which will then be permanently installed.

1. Before commencing installation, check that the power pack is connected.

2. Switch on the KTS 650 with the button.

3a. Use the stylus to select the appropriate language for Windows XP.

After switching the device on the first time, select a language for the Windows operating system in a menu.

3b. Click with the light stylus on the language you want and follow the on-screen instructions.

After the system has started, the KTS 650 remains in the Bosch Applications Menu start screen. This start screen now always appears after switch-on (see Switching On on page 16).

The Bosch Applications Menu start screen and all applications are displayed in the chosen language version of the operating system.

NOTEThe battery energy indicator only provides accurate information about the battery capacity after several charging and discharging cycles.

NOTE All other Windows language versions will be deleted. You cannot change this language at a later date. However, if this is necessary, contact your authorized Bosch dealer.

NOTE Until the Windows installation is complete, the KTS 650 can only be shut down by simultaneously pressing and holding down the and # keys for about 3 seconds.

NOTE You must enable the software before you can work with ESI[tronic]. Please observe the ESI[tronic]-Setup and Installation instructions included with the ESI[tronic] starter kit.


Notes on the Windows Control Panel Putting the KTS 650 into Operation

NOTES ON THE WINDOWS CONTROL PANEL In the Windows XP operating system, the Control Panel menu is normally opened via Settings in the Windows Start Menu. However, with the KTS 650, the Control Panel is reached via Programs in the Windows Start Menu. When you open the Control Panel, a warning will appear informing you that under certain circumstances the unit will no longer function perfectly if you alter certain parameters.

POWER SUPPLY The KTS 650 can be operated with the following voltage supplies:

• Power pack (only use the power pack included in the scope of delivery!).

• Vehicle battery [supply via the OBD cable connected to the diagnostic socket in the vehicle. The vehicle battery voltage (UBatt) should equal at least 12V].

• Internal rechargeable battery (see Charging the Battery on page 15).

BATTERY OPERATION OF THE KTS 650

The fully charged battery integrated in the KTS 650 takes the form of a back-up battery, guaranteeing approximately 1 hour of autonomous operation. It is therefore important to ensure that a permanent external voltage supply is always available (vehicle battery or power pack) when operating the KTS 650 for longer periods.

CHARGING THE BATTERY

The battery of the KTS 650 is charged automatically. The battery is re-charged whenever the KTS 650 is connected to the power pack or the vehicle battery (via the diagnostic cable/adapter cable connected to the diagnostic socket in the vehicle).

NOTEIf the unit no longer functions perfectly due to a change you have made in the Control Panel, any necessary repairs will be subject to a fee.

NOTEDo not operate the KTS 650 without the rechargeable battery.

NOTEIf the KTS 650 is operated only with the rechargeable battery, the charge LED of the tester lights up (Figure 3, item 7).


Putting the KTS 650 into Operation Switching the KTS 650 On and Off

Whenever the battery capacity is less than 80%,

• the state of charge LED (Figure 3, Item 7) flashes while charging when the KTS 650 is switched off.

• the LED for the external supply voltage (Figure 3, Item 8) flashes when the KTS 650 is switched on.

Once maximum battery capacity has been achieved, the KTS 650 switches from high-rate charging to float charging.

SWITCHING THE KTS 650 ON AND OFF

SWITCHING ON

Switch on the KTS 650 using the key (Figure 3, item 3).

After the system has started, the KTS 650 remains in the Bosch Applications Menu start screen. This start screen is always displayed when the tester is switched on.

The start screen displays the various applications that can be selected.

Using the stylus, touch the application with which you wish to work. If you are using a PS/2 keyboard, select the required application using the Cursor keys ↑↓. Start the application with the hardkey.

NOTE The Software Installation application is only available if the ESI[tronic] DVD is inserted in the external DVD/CD drive, and the drive is connected to the KTS 650. The application is required for the software update (also see Software Update Installation on page 18).

FIGURE 7. Start Screen


Switching the KTS 650 On and Off Putting the KTS 650 into Operation

SWITCHING OFF MANUALLY

There are several ways you can switch off the KTS 650.

• You can stop the KTS 650 by pressing the On/Off key.

• You can open the Windows Start Menu with the # key and bring the KTS 650 to a stop with Shut Down.

• You can also select Exit Windows in the Bosch Applications Menu. All active applications are closed and the KTS 650 switches itself off.

AUTOMATIC SWITCH-OFF

Via Programs / Control Panel / Power Management, you can set parameters which enable you to bring the KTS 650 to standby mode either in mains or vehicle battery operation and to switch off the monitor or the hard disk. Open the Power Schemes pull-down menu and set the required parameters.

The diagram below shows you the factory default settings.

NOTE If the KTS 650 can no longer be operated due to a computer error, you can switch it off by simultaneously pressing the On/Off key (Figure 3, item 3) and the # Windows Start Menu key (Figure 3, item 4) for at least 3 seconds.

CAUTION

CAUTION!Do not alter the settings in the menu tabs Warning or Extended.

FIGURE 8. Power Option Properties Default Settings


Putting the KTS 650 into Operation Adjusting the Brightness

ADJUSTING THE BRIGHTNESS You can open the brightness adjustment menu on screen by clicking with the stylus on the Light icon in the task bar.

Click the + button to make the display brighter; click on the - button to make it dimmer.

Different brightness values have been stored for battery operation and for an external supply voltage.

SOFTWARE UPDATE INSTALLATION Software installation takes place via the external DVD/CD drive.

CONNECTING THE DVD/CD DRIVE 1. Switch off the KTS 650.

2. Use the supplied Y-connector to connect the power pack to the KTS 650 and the DVD/CD drive.

The appropriate socket is located on the terminal strip of the KTS 650 (Figure 4, item 11).

The CD drive socket is located on the back of the unit.

3. Connect the KTS 650 to the DVD/CD drive. Use the interconnecting USB cable.

CAUTION

CAUTION!Do not use the DVD/CD drive in a dusty environment.

CAUTION

CAUTION!The DVD/CD drive has no On/Off switch. The voltage is supplied to the plugged-in power pack via the Y-cable.

NOTEDo not yet connect the power pack to the mains!

FIGURE 9. Brightness Adjustment Menu

Light icon


Software Update Installation Putting the KTS 650 into Operation

4. Insert the interconnecting USB cable in the socket on the back of the DVD/CD drive.

5. Connect the power pack to the mains.

6. Switch on the KTS 650.

7. After you have successfully connected the external DVD/CD drive, please read Proper handling of a DVD, Inserting the DVD in the DVD drive, and Removing the DVD from the DVD drive before installing the software.

8. Open Software Installation in the Bosch Applications Menu and follow the instructions. Software update installation takes approximately 30 minutes.

NOTEManufacturing tolerances may result in it being very difficult to insert the PCMCIA card in the upper slot. In this case, please use the lower slot.

FIGURE 10. DVD/CD Drive Connected to the KTS 650

1 KTS 650

2 DVD drive

3 Power pack

4 Y-connector

5 Interconnecting USB cable

6 Country-specific power cord


Putting the KTS 650 into Operation Connecting the PS/2 Keyboard

PROPER HANDLING OF A DVD • Ensure that your hands are clean and free from grease when inserting the DVD in the DVD/CD drive.

• Do not touch the blank side of the DVD.

• Do not mark, write on, or stick labels on the DVD.

• Never use solvents such as benzine, paint thinner, record cleaner, or antistatic agent to clean a dirty DVD.

• Simply wipe off fingerprints or dust from the center outwards with a soft cloth.

• Keep the DVD away from high temperatures and direct sunlight.

INSERTING THE DVD IN THE DVD DRIVE 1. Open the drawer by pressing the CD Eject button on the DVD drive.

2. Carefully lay the DVD in the drawer with the writing uppermost.

3. Close the drawer by pressing the CD Eject button again.

REMOVING THE DVD FROM THE DVD DRIVE 1. Press the CD Eject button to open the drawer. The drawer opens completely.

2. Take the DVD out of the drawer, holding the outer edge with your thumb and forefinger.

3. Place the DVD in its transport case.

CONNECTING THE PS/2 KEYBOARDInsert the connector of the PS/2 keyboard into the appropriate socket in the terminal strip of the KTS 650 (Figure 4, item 12).

CONNECTING AN EXTERNAL MONITOR Insert the monitor/VGA cable into the appropriate socket in the terminal strip of the KTS 650 (Figure 4, item 10). Plug the other end of this cable into the monitor.

CAUTION

CAUTION!Never use force to push the drawer into the CD drive!

NOTE If you wish to use a PS/2 keyboard, when using the KTS 650 for the first time you must select the appropriate country-specific keyboard in the Bosch Applications Menu start screen via Control Panel / Configuration / Set.


Touchscreen with Stylus Operation

7. OPERATION

The KTS 650 is operated by means of:

• the touchscreen with stylus, or

• the virtual keyboard with stylus, or

• the external PS/2 keyboard (optional extra)

TOUCHSCREEN WITH STYLUS The touchscreen of the KTS 650 is operated using the stylus. The stylus basically has the same functions as a mouse.

Touching an icon once with the stylus, for example, is the same as clicking once with the left-hand mouse button or positioning the cursor in an entry field.

Touching the touchscreen twice with the stylus is the same as double-clicking with the left-hand mouse button. This starts an application program, for example.

Touching the touchscreen for more than 2 seconds with the stylus is the same as clicking with the right-hand mouse button to open any available Help menus.

NOTEThe monitor has to be plugged in before you switch on the KTS 650.


Operation Virtual Keyboard with Stylus

VIRTUAL KEYBOARD WITH STYLUS

The KTS 650 features a virtual keyboard. To open the virtual keyboard, click on the icon in the taskbar.

The chosen character will be shown in an entry field when you touch the key twice with the stylus.

To switch the keyboard over to capital letters and symbols, click on the Shift key. Click on the Shift key again to change the characters back to small letters and numbers.

To change the character set of the virtual keyboard to the language you require, click on the appropriate icon in the taskbar. The icon will then display a different abbreviation (e.g., En, Fr, It, etc.).

PS/2 KEYBOARDIf you use the PS/2 keyboard to operate the KTS 650, make sure that the Num. LED is lit; otherwise you will not be able to enter numbers using the number keys. The table below explains the keyboard’s most important functions.

Function Key

Go to a different button, register, or entry field (TAB key)

Move within a button, register, or list (Cursor keys)

Activate or deactivate menus SPACE bar

Select Start button CTRL + ESC

Confirm entries or Next (ENTER)

Cancel ESC

Activate a pull-down menu ALT + letter

Switch between active applications ALT + TAB

Exit active applications ALT + F4

Open Bosch Applications Menu F10

FIGURE 11. Virtual Keyboard


Multimeter, Oscilloscope Measuring Module

8. MEASURING MODULE

With the KTS 650, you have a 2-channel multimeter and 2-channel oscilloscope at your disposal.

Only use the supplied measuring leads with electric shock protection. Always plug the measuring leads into the KTS 650 first, then into the vehicle.

Do not route the unscreened measuring leads close to strong interference sources such as ignition cables. For high-resistance low-level encoder signals, use screened measuring lead 1 684 465 490/06500964 (special accessory).

9. SPECIAL INFORMATION FOR OPERATION VIA THE VEHICLE BATTERY

MULTIMETER, OSCILLOSCOPE If you use channel 2 of the KTS 650 for voltage measurements using a multimeter or oscilloscope, the voltage supply from the vehicle battery will be shut off, for measuring channel 2 is not floating, and incorrect measurements could therefore result.

CONTROL-UNIT DIAGNOSIS The voltage supply from the vehicle is cut off automatically before communication with the control unit commences in order to ensure reliable communication. The LED for external supply goes out to inform you of this status.

WARNING!

Only use the KTS 550/650 for vehicles, and not for measuring alternating/direct voltages of > 60 V. If no diagnostic cable is connected, you must produce a connection to vehicle ground from the KTS 650 using the supplied ground cable prior to any measurements of U, R,or I. Measuring without a ground cable may result in voltages which are dangerous to life due to static charge. Connect the ground cable as close as possible to the object of measurement.

NOTE When reading vehicle data in Control-Unit Diagnosis mode, the 1-channel oscilloscope offers restricted functionality (sampling rate 50 kHz instead of 100 kHz) and the 2-channel oscilloscope cannot be used.


Printing Printing (Control-Unit Diagnosis)

10. PRINTING

A printer can be connected via the USB interface of the KTS 650.

PRINTING (CONTROL-UNIT DIAGNOSIS) Using the stylus click twice on the psc (print screen) button on the virtual keyboard. The control unit diagnostic program’s print menu is opened.

Two types of print-out are possible:

• Hardcopy

• Work log (this contains the repair shop address and all previously saved measured values)

A Page Preview function is also available (on-screen display of the work log).

You can print out all displayed screens by selecting Hardcopy.

NOTE If you wish to print out fault log details, actual values, etc. later in the work log, you must first save these values in the displayed screen by means of

the softkey.

FIGURE 12. Printout Menu


Changing the Default Printer What To Do If

CHANGING THE DEFAULT PRINTER Change the default printer PDR 218 by way of the Bosch Applications Menu. Open the Control Panel. Under Configuration, open the Set / Printer menu. Select the required printer driver and confirm with the » softkey.

11. WHAT TO DO IF

THE UNIT CANNOT BE SWITCHED ON AND THE DISPLAY STAYS DARK OR FLICKERSThe internal battery has insufficient capacity to start the unit. Connect the external power pack or the diagnostic cable to the vehicle (ignition on), so that the unit will be ready for operation and the battery will be charged.

THE UNIT DOES NOT REACT WHEN THE KEYS ARE PRESSED

The unit must be set to a defined status. To do so, press the and # hardkeys for approximately 3 seconds.

MALFUNCTIONS ARE DISPLAYED IN THE INFO BAR DURING OPERATIONFollow the instructions on the LCD.

NOTE Only switch the unit off in this manner if it no longer reacts when any keys are pressed. Switching the unit off in this way during regular operation may, in certain circumstances, result in the loss of data from the hard disk. Data which have been entered during this diagnostic application may have to be re-entered.


Changing the Battery The Mouse Pointer Is Displayed In A Different Place After

THE MOUSE POINTER IS DISPLAYED IN A DIFFERENT PLACE AFTER CLICKING THE TOUCHSCREEN WITH THE STYLUSYou must re-calibrate the touchscreen. Open the RBsystem menu via Programs/Control Panel in the Start Menu. Open the TouchScreen Adjustment program. First click Run. You can now adjust the touchscreen. Take care not to alter any other parameters of this program.

The touchscreen calibration menu offers a total of 20 calibration points, which you must click one after the other. This will enable very precise calibration.

On completion, you can then check the calibration. Use the stylus to click on different places on the LCD and compare these with the mouse.

THE KTS 650 CAN NO LONGER BE OPERATED USING THE STYLUS AND TOUCHSCREENIt is possible that the touchscreen has been adjusted incorrectly. Connect a USB mouse to the KTS 650 and complete the touch-creen adjustment procedure. The adjustment procedure is described in the above section.

12. CHANGING THE BATTERY

Only use the Original Bosch battery pack for the KTS 650!

The battery is installed in the rear of the unit. Proceed as follows:

1. Switch off the KTS 650.

2. Undo the screws (Figure 13, item 1) and open the cover panel (Figure 13, item 3).

3. Disconnect the fan connector (Figure 13, item 2), if present.

4. Undo the screws (Figure 13, item 4) and remove the battery cover (Figure 13, item 5).

5. Disconnect the battery connector (Figure 13, item 6).

6. Replace the battery pack (Figure 13, item 7).

NOTE In order to avoid parallax errors, your eyes must be directly vertical above the calibration points. Click on the calibration points as accurately as possible.


The KTS 650 Can No Longer Be Operated Using The Stylus and TouchScreen Changing the Battery

WARNING!Do not heat, burn, short-circuit, or mechanically damage the battery; do not charge with excessive currents or with reverse polarity.

Improper treatment of the battery results in a risk of explosion, bursting, or fire.

Suitable extinguishing agents: Water, CO2, sand.

CAUTION

CAUTION!Dispose of used battery packs in accordance with the appropriate guidelines or regulations.

FIGURE 13. Changing the Battery of the KTS 650


Optional Extras The KTS 650 Can No Longer Be Operated Using The Stylus

13. OPTIONAL EXTRAS

14. SERVICE PARTS AND PARTS SUBJECT TO WEAR

Designation Part Number

CARB adapter box 1 684 462 346 / 06500969

OBD-extension lead (26-pin; 2 m) 1 684 465 489 / 06500962

OBD-Multiplexer 1 684 465 506 / 06500950

NOTEFor vehicle-specific connecting cables and other measuring leads, refer to the Program Description 1 689 979 858.

Designation Part Number

Y-connectora

a. Parts subject to wear.

1 684 448 309 / 06500978

Case 1 685 438 144 / 06500979

OBD-Multiplexer cablea 1 684 465 520 / 06500950

Universal cable 1 684 465 488 / 06500953

Measuring lead, reda 1 684 430 065 / 06500956

Measuring lead, bluea 1 684 430 066 / 06500957

Measuring lead, yellowa 1 684 430 067 / 06500958

Ground cable, blacka 1 684 431 068 / 06500961

OBD-extension lead a 1 684 465 489 / 06500962


Disposal of Electronic Waste Maintenance

15. MAINTENANCE

The housing and display of the KTS 650 should only be cleaned with a soft cloth and neutral cleaning agents. Do not use abrasive cleaning agents or rough workshop cloths.

16. DISPOSAL

DISPOSAL OF ELECTRONIC WASTEPlease dispose of electronic waste by returning components for recycling.

DISPOSAL OF THE LCD Please dispose of the LCD in accordance with local regulations governing the disposal of hazardous waste.

DISPOSAL OF RECHARGEABLE BATTERIES Dispose of the rechargeable battery in accordance with the local regulations concerning disposal of hazardous waste.


Technical Data KTS 650

17. TECHNICAL DATA

KTS 650 • PC board

• Celeron, 650 MHz

• 512 MB RAM (main memory)

• 40 GB hard disk

• TFT 12" color display, 800 x 600 pixels

• Lithium-ion battery; 7.2 V; 6 Ah

Control-unit diagnosis via interface protocols ISO9141-2, SAE J1850VPW, SAE J1850PWM and CAN ISO 11898 ISO 15765-4 (OBD), OBD diagnosis to ISO 15031.

MULTIMETER Channel 1 (CH1) floating

Channel 2 (CH2) non-floating

Operating voltage via vehicle battery or power pack

10 V ... 30 V DC

Wattage approx. 40 W

Accuracy of DC measurement (CH1 and CH2):

Measuring ranges 0 to 200 V, auto ranging

Accuracy ± 0.75 % of measured value, plus ± 0.25 % of measuring range

Resolution 100 µV - 100 mV (depending on measuring range)


Multimeter Technical Data

Accuracy of AC and r.m.s. measurements (CH1 and CH2):

AC frequency range 5 Hz - 400 Hz

Measuring ranges 0 to 200 V, auto ranging

Accuracy ± 3 % of measured value, plus ± 0.25 % of measuring range

Resolution 100 µV - 100 mV (depending on measuring range)

Accuracy of resistance measurement (CH1):

Measuring ranges 0.1 Ω to 1 MΩ, auto ranging

Accuracy ± 0.75 % of measured value, plus ± 0.25 % of measuring range

Resolution 0.1 Ω ... 1000 Ω (depending on measuring range)

Current measurement range (CH1 and CH2):

100 A clamp 0 to +/- 100 A

600 A clamp 0 to +/- 600 A

Shunt (CH1 only) 0 to 600 mA

General input resistance 1.5 MΩ

Diode test Test voltage max. 2 VTest current < 2 mA


Technical Data Oscilloscope

OSCILLOSCOPE

POWER PACK

WEIGHTS AND DIMENSIONS

Measuring ranges 0 to 200 V

Coupling DC, AC

Signal source U, I-clamp, I-shunt

Trigger mode Standard, auto, auto threshold

Trigger source CH1, CH2

x-deflection 5 ms to 100 s

From a time-base sweep of 1 s, the oscilloscope is run in scrolling mode.

y-deflection for U 200 mV to 200 V

y-deflection with 600A amps clamp (1 mV/A)

200 A, 500 A, 600 A

y-deflection with 100A amps clamp (1 mV/A)

20 A, 50 A, 100 A

y-deflection with 600 mA shunt 200 mA, 500 mA, 600 mA

Input voltage 90 - 264 VAC

Input frequency 47 - 63 Hz

Output voltage 15 V

Operating temperature 0 °C to 40 °C

Dimensions (L x W x H) 300 x 400 x 125 mm

Weight (without connecting cables) 4200 g


Temperature Limits Technical Data

TEMPERATURE LIMITS

ELECTROMAGNETIC COMPATIBILITY (EMC) This is a Class A product in accordance with EN 55 022.

Operating temperature 0 °C to 40 °C


KTS 650 System Tester

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