Retrofit test kits for diesel systems of the latest … test kitsfor diesel systems of the latest...

Retrofit test kits for diesel systemsof the latest generation

Prüftechnik

3624 Prüfsätze 12S_E 27.04.2005 12:52 Uhr Seite 1

Fit for the future – diesel test equipmentfor passenger cars and commercial vehicles

Basic test bench

Retrofit kits

Special accessory kits

EPS 815 with KMA

VPM 844 CRS 845

CRI 846

CRINCP1 CP2 CP3


Bosch – the leader in diesel technology and workshoptest equipmentSince 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 pro-

duction, 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 manufac-

turer also enabled us to develop innovative test equipment,

including the ESI[tronic] software product. The test equip-

ment 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 isthe EPS 815 component test bench plus KMA testinstrument 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 oper-

ating 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

Diesel systems conquer the market

3.1 CRS 845 3.2 VPM 844


4.1 Precision voltage stabiliser

4.2 Piston stroke measuring device Delta Phi

Automatic programming with VPM 844

Test data CD

All data for programming

pump control units and

testing components

4.4 Processor unit

The VPM 844 retrofit kit for testing solenoid valvecontrolled distributor pumps This test concept, too, is largely an automated process.

There are no more adjuster screws. All adjustment oper-

ations are effected by programming the control unit. This

test, defined on the basis of strict factory specifications,

incorporates all parameters such as engine speed, press-

ure, temperature, setting, waiting and measuring times.

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.

4.3 Test nozzle holder combination type X


The retrofit kit for testing common railpumps.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.

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.

The high pressure route to success – CRS 845

5.1 High pressure rail 5.2 Distributor

5.3 Heat exchanger

Bosch Diagnostics Software

CD-TestData

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Special accessory setsThe special accessory sets CP1, CP2 and CP3 supplement

retrofit kit CRS 845 with regards to pump testing.

For testing common rail pumpsBosch 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

Diesel Service opens up new opportunitiesfor the workshopHigh 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 genera-

tions 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.

CP3

Test equipment for common railhigh pressure pumps

CP2

6.1 equality test

CP1


Common rail injector test

7.2 CRI 846 on EPS 815

7.3 CRIN

7.1 CRI 846

Retrofit kit CRI 846 including passenger car andcommercial vehicle accessory setsPowerful 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 injec-

tors 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 846.

*) „Injektor-Mengen-Abgleich” `= injector quantity adjustment


Repairs made easy

8.3

8.1

8.2

Bosch Diagnostics Software

ToolsCATalogue

2004/1

Service Werkzeuge/Service Tools/

Diagnostic Equipment Bosch / Zexel

Deutsch, EnglishFrançais, Español

Italiano, Português,Svenska

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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 (8.1 – 8.2).

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]-W "Diesel test values"For testing and setting inline and distributor fuel injection

pumps for diesel units.

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 allcustomer 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 CDTest 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).


Training for success

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 systemCourse 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 techno-

logy.

EP 3.2 New generation distributor pumpsCourse 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 EDCCourse 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 EDCCourse 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).

9.1 The training coursesteach basic knowledge

9.2 KTS 650, the top-end devicefor control unit diagnosis


Designation Order no. VP 29/30 VP 44

Retrofit kit VPM 844 for solenoid valve controlled distributor-type injection pumps 29/30/44 1 687 001 844 X XCaution: Max. permissible coolant temperature during tests (VP 29/30/44) is 17 °C. If temperature is exceeded, this may make additional on-site measures necessaryWin2000 VP 44 multilingual processor unit without keyboard 1 687 022 959 X XNote: If WIN 2000 PC 1 687 022 958 available, order only VP-M upgrade kitRetrofit kit VP-M 1 687 001 556 X XTransformer conversion kit 400–500V for EPS 815* (only necessary for VP 29/30/44) 1 687 001 800 X XTransformer conversion kit 200–240V for EPS 815* (only necessary for VP 29/30/44) 1 687 001 801 X XReducing fitting L= 350 mm (Ford/Rover) 1 680 750 100 XReducing fitting L= 450 mm (Audi/BMW/Ford/Nissan/Opel) 1 680 750 101 XTest pressure line L= 845 mm (Cummins/John Deere/MAN/Nissan/VM Motori/Volvo) 1 680 750 102 XTest pressure line L= 450 mm (Opel VP 29/SISU, Perkins VP 30) 1 680 750 103 XAdapter cable PSG2 (pump control unit type 2) 1 684 465 498 XTest nozzle holder combination type IX car/comm.veh. (d= 0.5) 6 units recommended 1 688 901 116 X XTest nozzle holder combination type X car (d= 0.4) 6 units recommended 1 680 901 032 XPerforated plate for type X test nozzle/holder combination (d=0.5) 6 units required 1 680 103 110 (X)Test nozzle holder combination type X comm.veh. (d= 0.5) 66 units recommended 1 688 901 035 XClamping stand, Audi, 2 units required 1 688 030 186 XHeat exchanger Important! Required for CRS 845 and VPM 844 1 687 010 030 X XSpecifications test data CD for CR injectors (passenger car/commercial vehicle) 1 687 370 270 X Xand CR/VP-M pumps. Note: Update subscription from ESI[tronic] service lineTools CATalogue 1 987 729 257

Retrofit kit CRS 845

X = required (X) = if required* Transformer conversion kit required by production date 07/05 (estimated)Subject to modifications and program changes.

Data and facts

Retrofit kit VPM 844

Designation Order no. CP1 CP2 CP3

Retrofit kit CRS 845 for common rail high pressure pumps 1 687 001 845 X X XWin2000 multilingual processor unit without keyboard 1 687 022 958 X X Xinc. standard (inline/dist. pumps) and common rail softwareAlternatively: upgrade kit if EPS processor unit already has 1 687 001 555 (X) (X) (X)Win MeRiser retrofit kit (12-channel for old KMA up to approx. 3/2001) 1 687 001 544 (X) (X) (X)Special accessory set CP1 (clamping sets for CP1 pumps) 1 687 010 133 XSpecial accessory set CP2 (clamping sets for CP2 pumps) 1 687 010 134 XSpecial accessory set CP3 (clamping sets for CP3 pumps) 1 687 010 135 XA drive flange is also required if accessory set CP1 is not available 1 685 702 084 XHeat exchanger Important! Required for CRS 845 and VPM 844 1 687 010 130 X X XUpgrade kit for heat exchanger. Measurement set split from 6 to 12 channels 1 687 001 557 (X) (X) (X)Note: required for testing of pumps with delivery rate >160 l/hSpecifications test data CD for CR injectors (passenger car/commercial vehicle) 1 687 370 270 X X Xand CR/VP-M pumps. Note: Update subscription from ESI[tronic] service lineTools CATalogue 1 987 729 257

Retrofit kit CRI 846

Designation Order no.

Retrofit kit CRI 846 incl. special accessory set for passenger car common rail injectors (CRS 845 required) 1 687 001 846Note: Before commissioning the test unit for the first time, it is necessary to calibrate the rail pressure sensor on the EPS 815Precision voltage stabiliser 1 687 022 873Note: Only required if no test unit VPM 844 is availableVoltage stabiliser kit (only for new stabiliser purchase) 1 687 016 043Transformer conversion kit 400–500V for EPS 815 (only necessary for VP 29/30/44) 1 687 001 800Transformer conversion kit 200–240V for EPS 815 (only necessary for VP 29/30/44) 1 687 001 801Special accessory set CRIN for commercial vehicle common rail injectors (CRI 846 required) 1 687 001 599Specifications test data CD for CR injectors (passenger car/commercial vehicle) and CR/VP-M pumps 1 687 370 270Note: Update subscription from ESI[tronic] service lineTools CATalogue 1 987 729 257


Our knowledge, your success.Bosch Diagnostics

Diagnostics – the key to theautomotive workshop of thefuture Motor vehicle systems are

becoming increasingly complex;

the demands placed on qualified

diagnosis in workshops are rising.

For professional service on mod-

ern 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

diagnostics and service

• Simple operation

• Rapid access

• Modular structure

• Comprehensive market

coverage

• Continually updated

• Universal operation re-

gardless of manufacturer

Test technology – matched

to each workshop type

• Optimized combination of

hardware and software for

rapid troubleshooting,

qualified repair and high

time savings

• PC-based, testing techno-

logy of the latest generation

with extendable modules

Service training –

knowledge as a factor for

success

• Comprehensive training

program for automotive

workshops

• Practical training courses

• Highly qualified trainers

with a great deal of

practical experience

Technical hotline –

support from the system

developer

• Support in difficult

technical situations

• Skills covering all brands

and manufacturers


Bosch – skilled partner forworkshop business

Developments from Bosch stand for innovative progress in automobilemanufacturing 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.

ECU Diagnostics KTS

Engine System Testing FSA

Diesel System Testing EPS

Emissions Analysis BEA

Where to find Original Bosch Quality:

Robert Bosch GmbH

Automotive Aftermarket

D-76227 Karlsruhe I www.bosch-diagnostics.com

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Brake Testing BSA

Wheel Alignment FWA

Air Conditioning Service ACS

Battery Service BAT


Retrofit test kits for diesel systems of the latest … test kitsfor diesel systems of the latest...

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