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EPS 205CP4

For today and tomorrow:Everything for Diesel Service

2

Everything for Diesel Service:Contents

3 Test equipment overview

Test bench EPS 815 4 EPS 815 6 Designation / scope of delivery 7 Measuring technology

Test bench EPS 708 8 EPS 708 9 Designation / scope of delivery

Test bench EPS 625 10 EPS 625 11 Designation / scope of delivery

Retrofit kits for EPS 815 / EPS 625 12 Basis set mechanical pumps 13 H and R pumps 14 H, R, P and M pumps 16 A pumps 18 M-MW pumps 20 P pumps 22 VE pumps

Retrofit kits for EPS 815 / EPS 708 24 Solenoid valve controlled distributor pumps 26 Basis Set CR components (CP / CRI) 27 CRI from Bosch and basis set CR Injectors 28 CRI / CRIN from Bosch and basis set CR Injectors 29 CRI / CRIN from Bosch with CRI 846 H 30 CRI / CRIN from Bosch

33 CRIN by Bosch from Japan and USA production34 CP1 / CP1H 35 CP1 / CPN2 36 CP3 38 CP4 41 CB18 42 CB2843 CP Delphi / Denso / Siemens / Coninental44 CRI Piezo from Bosch / Denso / Siemens / Coninental45 CRI from Delphi / Denso46 UI / UP

50 Tester EPS 20552 Tester EPS 100

53 Denoxtronic systems57 Component repair: Starters and generators57 Common Rail System: In the vehicle diagnostic test equipment

Appendix60 Space and work area requirements EPS 81561 Space and work area requirements EPS 70862 Space and work area requirements EPS 62563 Test equipment technical data67 Product offer sheet EPS 81573 Product offer sheet EPS 70876 Product offer sheet EPS 62577 Product offer sheet EPS 20578 Software and Training

3

Overview test devices

EPS 815 with KMA 822 and CRS 845 HUniversal test bench for diesel component testing:

f Conventional system: H / R / A / M-MW / P / VE pumps f Solenoid-valve-controlled system: VP 29 / 30 / 44 f Unit injector / unit pump system: UI-P / UI-N / UP f Common Rail System: CP1, CP2, CP3, CP4, CB18, CB28, CP Delphi / Denso / Siemens /

Continental f Solenoid valve CRI Bosch / Delphi / Denso f Solenoid valve CRIN Bosch f CRI Piezo Bosch / Siemens / Denso

More information see page 6 onwards

EPS 708Specialized test bench for Common Rail testing:

f Common Rail System: CP1, CP3, CP Delphi / Denso / Siemens,

f Solenoid valve CRI Bosch / Delphi / Denso f Solenoid valve CRIN Bosch f CRI Piezo Bosch / Siemens / Denso


EPS 205Automatic injector test bench for testing the following:

f CRI Piezo from Bosch / Siemens / Denso / Continental f Solenoid valve CRI from Bosch f Solenoid valve CRIN from Bosch f Solenoid valve CRI from third-party manufacturers f DHK and UI nozzles f Step holder


EPS 100Manual injector tester for nozzle and holder testing:

f Nozzle sizes P, R, S, T f 1-spring / 2-spring nozzle-holder assembly (DHK) f Stepped nozzle holder f UI nozzles with mounting adapter

More information see page 52

EPS 625Universal diesel component test bench for testing the following:

f Conventional inline injection pumps and governors in the following sizes: PE(S) x A, PE(S) x M, PE(S) x MW, PE(S) x P, PE(S) x H and PE(S) x R

f Conventional distribution injection pumps in the following sizes: VA . A, VA . B, VA . C, VE . F, VE . E with mechanical and electronic governors


4

Test bench overview:EPS 815

1. Basic test bench EPS 815 (with KMA 802)

3. Special accessories kits

H / R pump set1 687 005 023

A pump set1 687 005 019

CP21 687 010 342

CP11 687 010 341

2. Retrofit kits

M-MW pump set1 687 005 020

P pump set1 687 005 021

VE pump set1 687 005 022

Basis set1 687 005 018

VPM 8441 687 002 844

Designation Order number

EPS 815 0 683 815 00x

KMA 802 0 683 802 001

5

CRIN1 687 001 925

CP31 687 010 182

CRI / CRIN 848 H1 687 002 848

CRI 846 H1 687 002 846

CAM 8471 687 001 847

CRS 845 H1 687 002 845

CRI PiezoBosch / Denso / Sie-

mens / Continental

1 687 010 333

CRI Delphi /Denso1 687 010 186

CP Delphi /Denso / Siemens/ Continental1 687 010 183

CB281 687 010 496

CP41 687 010 490

New

CB181 687 010 402

New New

6

Universal test bench: EPS 815

For today and tomorrow, fully equipped for testing diesel components with the EPS 815

EPS 815 – universal component test benchFuture-proof and flexible design

f ISO compliant when specified f Efficient components of the latest generation both

from Bosch and from other manufacturers can be tested

f Expansion possible with different retrofit kits and special accessories sets: - KMA - VPM 844 / CRS 845 H / CRI 846 H / CAM 847 / CRI / CRIN 848 H - CP1 / 2 / 3 / 4 / CB 18 / CB 28 / CRI /CRIN - Systems from other manufacturers

f Continuous development of optional accessory kits for new products

f Three-dimensional adjustment of the measuring unit reduces testline reforming (rebending) which lowers maintenance costs and set up time

User and environmentally friendly f Through oil vapor and oil mist reduction

Efficient work f Excellent speed stability assure high repeatability,

especially during the injection cycle because of: - Direct drive - High flywheel mass - Rotational-speed control with an extremely short governing time - Position control

f A maintenance-free high efficiency drive element f A counterbalanced measuring unit makes height

adjustments easier and less time-consuming f Fully automatic test sequence 1 in conjunction with

KMA 802 / 822

1 Applies to Bosch VP and CR components.

Scope of deliveryTest bench EPS 815, selector valve with flushing valve for distributor injection test, hose lines for selector valve and testing oil, socket wrench for calibration nozzle holder, T-bar for flywheel mass, screwdriver set, 12 / 24 Volt internal power supply and connection lines for additional fuel Start-Stop solenoids and for temperature sensor, insulation boards for test bench installation, drive coupling in accordance with ISO with protective guard, small parts set (banjo union, banjo bolts, gaskets, etc.), technical documentation

2 Max. permissible asymmetry (L:L or L:N) < 20 V


EPS 815 0 683 815 001 400 V; ± 10 %2; 50 / 60 Hz

EPS 815 0 683 815 002 200 / 220 / 230 / 240 V; ± 10 %2; 50 / 60 Hz

EPS 815 0 683 815 003 440 / 460 / 480 / 500 V; ± 10 %2; 50 / 60 Hz

Special accessories

Lubricating oil supply for CP2 / CP 3.4; UI / UP 1 687 001 977 necessary as CAM 847

7

Measuring technology:KMA 802 / 822

Test equipment EPS 815

1 Incl. operating system2 Please see offer sheets


KMA 802 0 683 802 001

KMA 822 0 683 822 001

Special accessories

Computer1 without keyboard, 1 687 023 692 incl. CR and VP software

Keyboard (country-specific)2 1 687 023 7xx

Hardcopy printer PDR 375 incl. USB 1 687 001 850 connecting line

KMA – Kontinuierliche Mengen-Analyse (continuous fuel delivery analysis) The computer-based measurement system for conven-tional and new Diesel injection systems. Absolutely necessary for testing modern Diesel injection systems is the electronic fuel quantity measurement. It guarantees a high reproducibility of measured values.

Efficient operation f Short setting times thanks to measurement display

on the monitor f Clearly arranged display of the measured values in a

column chart with colored identification of tolerance transgressions

f User-friendly software EPS 945: All important settings can be preselected and test steps can be defined

f Automated test sequence through import of specified data from the TestData CD and the Diesel ESI[tronic]-W

Scope of delivery KMA 802 / 822Continuous fuel quantity measurement, display unit with 19" TFT monitor for assembly on test bench (KMA 802) or incl. trolley for assembly beside the test bench (KMA 822)

Electronic reading of the measured values

8


1.Basic test bench EPS 708(incl. 2,500 bar rail)0 683 708 0xx

CP1 / CP31 687 010 346

CP Delphi /Denso/Siemens/ Continental1 687 010 183

CRIN1 687 001 925

CRI Delphi /Denso1 687 010 186

CRI PiezoBosch / Denso / Sie-

mens / Continental

1 687 010 333

CRI / CRIN 848 H1 687 002 848

CRI 846 H1 687 002 846


2. Retrofit kits

CP41 687 010 390

CB181 687 010 402

New New

9

Test bench for Common Rail pumps and injectors: EPS 708

Ready for the future with the Common Rail test bench EPS 708


EPS 708 400 V; ± 10 %; 50 / 60 Hz with integrated cooling 0 683 708 020

EPS 708 200 / 220 / 230 / 240 V; ± 10 %; 50 / 60 Hz with integrated cooling 0 683 708 021

EPS 708 400 V; ± 10 %; 50 / 60 Hz without integrated cooling 0 683 708 001

EPS 708 200 / 220 / 230 / 240 V; ± 10 %; 50 / 60 Hz without integrated cooling 0 683 708 002

Special accessories

Special accessory set lubrication supply 1 687 001 931

EPS 708: Forward-looking and efficientThe injection pressures on which modern Common Rail Diesel engines run have risen constantly over the last few years. 2,000 bar is already normal nowadays – with a rising tendency. The Diesel test bench EPS 708 from Bosch specially for Common Rail injection pumps and injectors therefore enables testing with up to 2,200 bar. Its newly developed rail is designed for pressures up to 2,500 bar, which means that the test bench is prepared for future developments in Diesel technology.

Precise and comfortable: f Electronic quantity measurement for cost-effective

testing of Common Rail components f Electronic supply pressure control for pump and lube

oil supply f Simple pump assembly without clutch cover

Non-polluting: f Integrated cooling system reduces water consumption

in the workshop (water-cooling available as an option)

Safe: f Immediate engine shutdown if hood is opened f Hood protects against loose parts

Efficient: f Electronic monitoring and display of service intervals

(e.g. test oil change) f Self-diagnosis system indicates necessary filter

change

Scope of deliveryTest bench, monitor, mouse, computer units, mains connection lead, hydraulic hoses, software package, protective cover, 2,500 bar rail

10


1. Basic test bench EPS 625

EPS 625 HMI version:415 Volt F 002 DG0 921220 Volt F 002 DG0 922

EPS 625 PC version:415 Volt F 002 DG0 923220 Volt F 002 DG0 924

H / R pump set1 687 005 023

A pump set1 687 005 019

M-MW pump set1 687 005 020

P pump set1 687 005 021

VE pump set1 687 005 022

Basis set1 687 005 018

EPS 865 0 684 200 615EPS 910 1 687 022 281

For activating and testing distributor injection pumps VE.E (VP26, VP36, VP37) these two devices are necessary:


2. Retrofit kits

11

Test bench:EPS 625

Optimally equipped for the testing of conventional diesel injection pumps with the new EPS 625 HMI test bench


EPS 625 HMI Version 400 - 440 Volt F 002 DG0 921

EPS 625 HMI Version 200 - 240 Volt F 002 DG0 922

EPS 625 PC Version without HMI 400 - 440 Volt F 002 DG0 923

EPS 625 PC Version without HMI 200 - 240 Volt F 002 DG0 924

PC without keyboard 1 687 023 699

Trolley 1 688 003 254

TFT monitor 19 '' 1 687 023 684

Protocol printer PDR 375 1 687 001 850

Special accessories

Lube oil supply 1 687 001 977

EPS 625: Your ticket to diesel testing technologyBy using the EPS 625 universal component test bench, powerful conventional inline and distribution injection pumps, both from Bosch as well as other manufacturers, can be tested. As a result, the specifications from the engine and vehicle manufacturers can be maintained. Because of its robust and easy-to-use technology, the EPS 625 is a cost effective and long-lasting investment for the workshop.

Versatile: f For testing conventional inline fuel injection pumps

and controls in the following sizes: PE(S) x A, PE(S) x M, PE(S) x MW, PE(S) x P, PE(S) x H and PE(S) x R

f For testing convention distributor injection pumps in the following sizes: VA . A, VA . B, VA . C, VE . F, VE . E with mechanical and electrical controllers

f Compatible with existing EPS 815 retrofit kits f Can be upgraded with a PC for acquisition of set-

up / test values and for test protocol management

Wide range of features: f Maintenance-free drive element with high efficiency f Long service life for the high pressure lines, since the

measuring unit can be adjusted in three dimensions f Excellent smooth running characteristics and

rotational speed stability ensure high repeatability f High flywheel mass f Rotational speed control with an extremely short

governing time f Integrated load pressure control unit f Automatic test oil heating controlled via the supply

or return f Easy operation via a high definition 5.7 inch LCD display

for showing the setpoint / actual values of the drive rpm, the set and actual stroke values, the test oil tank tem-perature, and the supply and return temperatures

Scope of deliveryTest bench, LCD display unit, measuring glass carrier with 12 measuring glasses 44 ml / 260 ml, measuring glass holder with light, mains connection lead

12

Mechanical pumps:Basis set for H / R / A / M-MW / P/ VE pumps

Base retrofit kitBosch has rearranged conventional Diesel technology for you. Thanks to the systematic pump-based structure, duplication of components was reduced considerably. You only buy what you really need, and save money at the same time.

The basis of conventional Diesel test equipment is the basis set. This set contains all parts that are also used for the extension kits.


Basis set 1 687 005 018

Scope of delivery

Test nozzle-and-holder assembly 0 681 343 009

Measuring, bracket 11 mm measuring mechanism 1 682 329 038

Measuring, bracket 13 mm measuring mechanism 1 682 329 080

Spacer for test pressure line 1 682 386 002

Coupling half cone Ø 17 mm 1 686 430 022



Accessory set for rack travel measuring device 1 687 000 053

Accessory set for rack travel measuring device 1 687 000 061 with manifold-pressure compensator on drive side

Dial gauge 1 687 233 012

Angle plate 1 688 010 129

Dial gauge holder (tripod) for 1 687 233 015 1 688 130 095

Dial gauge 0.1 mm, scale division, 30 mm measurement range 1 687 233 015

Rack travel measuring device 1 688 130 130

Angle measuring device for controller 1 688 130 183

Accessory set for control-rack travel and piston stroke measurement 1 688 130 030

Magnet base 1 688 130 134

Fitting M 14 x 1,5 1 683 457 082

Fitting M 12 x 1,5 1 683 457 081

Test equipment EPS 815 / EPS 625

13

Mechanical pumps:H / R pumps


Required additional accessories

Test device for control evaluation (old)1 0 986 610 101

Test device for control evaluation (new) 0 986 610 741

Measurement cable for rack-travel 0 986 610 102 sensor (old)1

Measurement cable for rack-travel 0 986 610 742 sensor (new)

Adapter line with RE24, RE30 0 986 610 104

Adapter line with RE30 0 986 610 107

Adapter line with RE33 0 986 610 124

Bench stand for in-line fuel-injection pump 0 986 611 248


Additional items required for testing and control of EDC-Bosch in-line pump of the type: PE (S) x P, PE(S) x H, PE(S) x R and PE(S) x M


Special accessories set for H/R pumps 1 687 005 023

Scope of delivery

Clamping set 1 687 001 314

Flat-base bench stand 1 688 030 170

Coupling assembly 1 685 702 075

Coupling assembly 1 685 702 076

Measuring pin H pump 1,000 1 682 012 015

Measuring pin H pump 1 1 682 012 004

1 No longer available

Evaluation is used in PE (S) x H / R / P / M

New

14

Mechanical pumps:H / R / P / M pumps

Repair tools


Tool set, tool box equipped 0 986 614 400

Scope of delivery

Tool tray, tool box empty

Setting gauge

Tracing gauge

Assembly gauge

Guide pin for short-circuiting ring

Retaining device

Retaining device prestroke shaft, start of delivery, rack-travel sensor short-circuiting ring

Mounting sleeve for sealing ring in the prestroke shaft bearing

Disassembly tool for wedge bolt

Mounting wrench for threaded sleeves

Measuring device for solenoid armature stroke

Setting gauge

Tracing gauge

Cover plate (accessory part)

Cover for prestroke solenoid

Puller


Required additional tools

Assembly wrench for camshaft 0 986 612 071

Assembly device for roller tappet 0 986 612 072

Assembly sleeve for radial shaft seal 0 986 612 085

Support ring for pump housing 0 986 612 106

Locking pin for pump plunger 0 986 612 114

Tool kit for bottom end cap 0 986 612 119

Pump plunger caliper 0 986 612 120

Forcing plate for camshaft bearing 0 986 612 134

Assembly mandrel for end caps of 0 986 612 156 bore for holding up tappet

Retaining device for speed pulse 0 986 612 305 generator RE24, RE30

Spring clamp for control rack return spring 0 986 612 311

Removal device for barrel-and-valve assembly 0 986 612 397

Roller tappet holder 0 986 612 482

Socket wrench for tappet holder 0 986 612 489

Centering mandrel for roller tappet 0 986 612 492

Guide sleeve for roller bearing 0 986 612 493

Press-in tool for roller bearing 0 986 612 494

Removal device for bearing cap 0 986 612 505

Mounting sleeve for O-ring on the 0 986 612 606 delivery-valve holder

Pressure tester, constant-pressure valves 0 986 612 619

Retaining device for drive flange 0 986 612 694

Locating pin for drive flange 0 986 612 697

Adapter for coupling assembly 0 986 612 710

Measuring device, axial clearance measuring device 0 986 612 837

Directional-control valve for fuel 0 986 615 111 pressure measurement

Tool kit for repair, testing and adjustment of positioners(RE positioners) of electronically controlled governors for inline injection pumps of types H / R / P and M

15

Mechanical pumps:H / R / P pumps

Tool kit for repair of type H, R and P inline injection pumps


Required additional tools

Test device for rack-travel evaluation 0 986 610 101

Measurement cable for rack-travel sensor 0 986 610 102

Adapter line for RE24, RE30 0 986 610 104

Bench stand 0 986 611 248

Removal hook for sealing rings 0 986 611 292


Assembly device for barrel-and-valve assembly 0 986 611 356

Combined tool holder for flange mounting 0 986 611 358

Retainer 0 986 611 441

Socket wrench for delivery-valve holder 0 986 611 451

Ring wrench 0 986 611 452

Socket wrench for auxiliary spring 0 986 611 459

Puller for end caps 0 986 611 668

Sleeve for lateral end caps 0 986 611 676

Wrench for control sleeves 0 986 611 738

Locking device for controller flyweights 0 986 611 746


Assembly sleeve 0 986 612 060

Spacer plate for barrel-and-valve assembly 0 986 612 061

Press-in tool, set 0 986 612 394


Tool set, tool box equipped 0 986 614 415

Scope of delivery

Tool tray, tool box empty

Puller for swivel-joint roller bearings

Angle bracket for roller tappets

Adapter for camshaft bearings

Press-out mandrel for roller bearings

Clamping fixture / drive assembly for sump and flatbed mounting

Connecting flange for test oil supply of the test bench

Press-in tool for roller bearings (H / R pumps)

Press-in tool for roller bearings (R pumps)

Mandrel for roller bearings

Repair tools

16

Mechanical pumps:A pumps

Special accessories set for testing Bosch A pumps



Special accessories set for A pumps 1 687 005 019

Scope of delivery

Bench stand radius 45 mm 1 688 030 147

Clamping flange Ø 92 mm and 68 mm 1 685 720 017

Reduction ring Ø 72 mm 1 680 103 007



Prestroke measuring device 1 688 130 041

Test pressure line 1 680 750 014

17

Mechanical pumps:A pumps

Repair of in-line fuel-injection pumps of the model series PE(S)..A..D / S 1 000, - / S 2 000, - / 3 000 with-out governor, charge-pressure-dependent full-load stop (LDA) and timing device

Repair of in-line fuel-injection pumps of the model series PE(S)..A..D / S 1 000, - / S 2 000, - / 3 000 with-out governor, charge-pressure-dependent full-load stop (LDA) and timing device

Repair tools


Repair tools for A pumps (I)

Tool set, tool board equipped 0 986 614 150

Scope of delivery

Tool tray, tool board empty

Assembly sleeve for radial shaft seal Ø 17 mm


Measuring device for camshaft longitudinal clearance

Measuring block for camshaft

Wrench for camshafts

Tappet holder

Pump plunger caliper

Puller

Roller tappet holder

Handheld milling cutter for element seats (11 x 14 mm)

Handheld milling cutter for element seats (14 x 18 mm)

Reamer for control rack guide bushes

Wrench set, fork wrench set

Mandrel for bottom end cap


Repair tools for A pumps (II)


Scope of delivery


Puller (pressure valve lifter)

Power screwdriver for control rack stop sleeve

Puller (pressure valve lifter)

Tappet holder for fast-running pumps

Adapter for dial gauge rest

Forcing plate for camshaft bearing

Sleeve for camshaft bearing

Tool kit for bottom blanking plug

Handheld milling cutter for element seats

18

Mechanical pumps:M-MW pumps

Special accessories set for testing Bosch M-MW / RW pumps


Special accessories set for M-MW pumps 1 687 005 020

Scope of delivery


Trestle 1 688 030 161


Prestroke measuring device for M pump 0 681 440 017

Prestroke measuring device for MW pump 1 688 130 135

Coupling half for DB Typ 190 1 686 432 022

Coupling half for DB Typ 191 1 685 720 208


Connection set 1 687 010 083

Test nozzle-and-holder assembly (with perforated plate 0,6 mm / Test nozzle 1 688 901 990) 1 688 901 101

Test nozzle-and-holder assembly (without perforated plate/ Test nozzle 1 688 901 988) 1 688 901 111

Accessory set for rack travel measuring device for M pump 1 688 130 042


19

Mechanical pumps:M-MW pumps

Repair of in-line fuel-injection pumps of model series PE(S) ..M.. with and without port-closing sensor system (FBG system), without governor, atmospheric-pressure-dependent full-load stop (ADA) and timing device

Repair of in-line fuel-injection pumps of model series PE(S) ..MW.. S1 (8 mm stroke) ..S1000 (10 mm stroke) and ..S1 500, without governor, charge-pressure- dependent full-load stop (LDA) and timing device

Repair tools


Repair tools for M pumps


Scope of delivery


Handheld milling cutter for element seats

Reamer for control rack guide bush

Tappet holder

Socket wrench for delivery-valve holder

Press-in tool for camshaft bearing

Tappet holder (Pumps with port-closing sensor system)

Stamping tool for control rack screw cap

Socket wrench for armature on full-load screw

Measuring device for camshaft longitudinal clearance1

Measuring block for camshaft projection1

Wrench for camshaft1

Pump plunger caliper1

Puller

Tappet holder1 (Pumps with port-closing sensor system)

Setting device for control lever


Repair tools for MW / RW pumps


Scope of delivery


Puller


Repair tools for MW / RW pumps:

Scope of delivery continued



Separating tube for fuel gallery (4-cyl. pumps)

Separating tube for fuel gallery (5-cyl. pumps)

Assembly sleeve for camshaft in needle bearing (Conus Ø 17 mm)

Assembly sleeve for camshaft in needle bearing (Conus Ø 20 mm)

Puller for end cap

Plate for pump housing and barrel-and-valve assembly

Press-in tool for needle bearing

Press-in tool for deep groove ball bearing

Setting device for control sleeve

Socket wrench for locknut

Socket wrench for auxiliary idle-speed spring


Measuring device for pin projection

Assembly mandrel for compression spring

Locking device for controller flyweights

Puller

Mandrel for spacer rings

Assembly sleeve for locking ring

Sleeve for shaft seal

Assembly sleeve for radial shaft seal1


Adapter1

Roller tappet holder1 1 Not included in the tool board equipment. A corresponding position has been reserved on the board.

20

Mechanical pumps:P pumps

Test equipment EPS 815 / EPS 625 Repair tools


Repair tools for P pumps (I)


Scope of delivery





Assembly wrench for camshaft clutch dogs

Assembly sleeve for shaft seal

Measuring block for camshaft projection

Assembly device for barrel-and-valve assembly


Puller1

Socket wrench for threaded sleeves

Measuring block for camshaft projection

Socket wrench for delivery-valve holder

Ring wrench

Tappet holder

Tool kit for locking ring on baffle plate

Socket wrench for control rack slotted nut

Removal device for barrel-and-valve assembly

Assembly sleeve


Special accessories set for P pumps 1 687 005 021

Scope of delivery

Clamping flange Ø 95 mm 1 685 720 060



Flat-base bench stand 1 688 030 141

Trestle 1 688 030 184






Fitting 1 683 457 082

Fitting 1 683 457 084




Collar nut for 1 688 130 130 1 683 315 022

Coupling assembly, zero backlash 1 686 401 024

Coupling assembly, zero backlash 1 685 702 073

Guard ring 1 685 510 176

Clamping flange accessory set 1 687 000 065

1 Not included in the tool board equipment. A corresponding position has been reserved on the board.

Tool set for P pumps (I) Tool set for P pumps (II)

Tool set for P pumps (III) Tool set for P pumps (IV)

21

Mechanical pumps:P pumpsRepair tools


Repair tools for P pumps (II)


Scope of delivery


Removal device for flywheels

Retainer

Measuring block for camshaft projection1

Tool kit for bottom end caps1


Wrench for control sleeve

Mandrel (5.8 mm) for pump plunger

Mandrel (8.5 mm) for pump plunger

Forcing plate for camshaft bearing1

Sleeve for camshaft bearing1

1 Not included in the tool board equipment. A corresponding position has been reserved on the board.


Repair tools for P pumps (III)


Scope of delivery


Sleeve for lateral end caps

Assembly sleeve for roller bearing

Spacer plates for element assembles

Press-in tool for roller bearing

Press-in tool for roller bearing camshaft and pump housing bearing

Roller tappet holder size PE(S) x P, ... x S7100/7800

Tappet clamping for roller tappet (2 parts)1

Puller for end cap1

Assembly wrench for camshaft1

Removal device for drive flange

Assembly sleeve for radial shaft seal

Support ring for pump housing

Removal device for swivel-joint roller bearing

Locking pins for pump plunger

Pump plunger caliper

Assembly mandrel


Repair tools for P pumps (IV)


Scope of delivery


Assembly device for roller tappet

Tool kit for bottom end caps

Compensating ring for injection pump drivetrain

Mandrel for camshaft

Assembly sleeve for anti-erosion cap circlip

Sleeve for camshaft

Assembly mandrel for bearing outer race


Socket wrench for tappet holder

Mandrel for locking ring and tappet roller

Guide sleeve for camshaft

Press-in tool for roller bearing

Assembly device for element seal

Removal device for anti-erosion caps

Removal device for bearing cap

Assembly sleeve for O-ring on delivery-valve holder


Repair tools for fuel injection governors of RQ, RQV, RSV and MPC (LDA)


Mechanical governors for A, M, MW, P and R pumps

22

Mechanical pumps:VE pumps


EPS 865 in combination with the EPS 910 for testing distributor injection pumps with HDK sensors.For use with EPS 815 or EPS 625.

Test device EDC-VE EPS 865By using the EPS 865, electronically controlled distributor injection pumps (VE.E) can be tested on the injection component test bench by using a potentiometer.

Distributor injection pumps (VE.E) with HDK sensors must be tested in combination with the EPS 910 activation unit.


EPS 865 – test device EDC-VE 0 684 200 615

Special accessories

EPS 910 – activation unit with half-differential 1 687 022 281 short-circuit ring travel sensor for EPS 865


Special accessories set for VE pumps 1 687 005 022

Scope of delivery


Injection timing tester EP / VA..C.. 1 688 130 121

Injection timing tester EP / VE.. 1 688 130 227


Support device KDEP 1140 0 986 611 876








Banjo bolt 1 683 456 000

Banjo bolt 1 683 370 011

Flushing valve 1 687 010 126

23

Mechanical pumps:VE pumps


Repair tools for VE pumps (II)


Scope of delivery



Mandrel for drive shaft

Adjustment plate for timing device position

Sleeve for manifold-pressure compensator strokew

Shifting square

Set for drive shaft bearing bush (17 mm)

Set for drive shaft bearing bush (20 mm)

Mandrel for coupling half

Screw for speed control lever

Spring clamp for shifting point

Setting wrench for controller axis

Mandrel for end cap

Twist drill bit for ball sealing bore

Mandrel for spring retainer

Lead sealing device for synthetic seals

Drill bush for lateral threaded bore

Assembly plate for sliding bolt

Socket wrench for triangular screw

Stop screw for potentiometer voltage and delivery quantity


Removal hook for sealing rings and tappet springs1


Repair tools for VE pumps (I)


Scope of delivery


Puller for clamping sleeve

Male triangular wrench for plug screw

Pin socket wrench for controller shaft

Spacer for start-quantity position

Socket wrench for pressure-control valve

Socket wrench for triangular shoulder screw

Measuring device

Press-in tool for delivery valve

Press-in tool for clamping sleeve

Assembly wrench for setting shaft

Assembly mandrel for eccentric ring

Protective sleeve for roller ring

Assembly shell for impeller

Clamping device for diaphragm sliding bolt

Alignment pin for alignment

Puller for bearing bush

Measuring sleeve

Stamping tool for control lever

Puller for radial shaft seal (17 mm)

Puller for radial shaft seal (20 mm)

Dial gauge holder for locating collar

Spacer for stop lever

Tool set for bronze bearing bush

Measuring device for MS dimension

Dial gauge holder for locating collar 1 Not included in the tool board equipment. A corresponding position has been reserved on the board.

Repair tools

Tool set for repair of mechanically controlled(VE.F) and electronically controlled (VE.E and VE.M)distributor injection pumps

24

Solenoid valve controlled distributor pumps:VP29 (VE.M), VP30 (VE.M) and VP44 (VR.M)

VPM 844 Retrofit kit for testing and programming solenoid valve controlled Bosch distributor pumpsThe basis for Bosch component testing is the injection component test bench EPS 815 plus KMA measurement technology. Only the use of the VPM 844 retrofit kit can guarantee pump testing in accordance with manufacturer's specifications.

Automatic programming with VPM 844 f Automated test sequence f All adjusting tasks carried out through control unit

programming f Exact power supply by means of precision stabilizer f Calibration and programming by PC

Please note additional test set accessories and accessories for test benches (see offer sheets)

Scope of delivery VPM 844Special connecting cables, clamp-on sensors, flanges, connection unit, speed sensor, precision voltage stabilizer, various small parts


Retrofit kit VPM 844 for solenoid valve controlled distributor pumps 29 / 30 / 44 1 687 002 844 Important: Coolant temperature for tests of VP 29 / 30 / 44 permissible up to maximum 17 °C. Additional measures may be necessary on site if the temperature is exceeded. Note: Only for EPS 815 as of manufacturing date 01/2001

Accessories

Computer unit WIN 7 Ultimate 64 bit Celeron 2,2 GHz, VP 44 multilingual, without keyboard 1 687 023 634 Note: If WIN 2000, PC 1 687 022 958 is already present, only order the VP-M retrofit kit

The VP-M retrofit kit for the conversion of CR (PC) to VP 44 (PC) includes CAN plug-in card 1 688 400 305, 1 687 001 949 SVTW plug-in card 1 688 400 292, ISO communications module 1 687 023 524, SVTW plug-in card 1 688 400 292, ISO communications module 1 687 023 524

Transformer conversion kit 400 - 500 V for EPS 815. Required up to production data 07 / 2005 1 687 001 800

Transformer conversion kit 200 - 240 V for EPS 815. Required up to production data 07 / 2005 1 687 001 801

Test pressure line L= 350 mm (Ford / Rover VP 29 / 30) 1 680 750 100

Test pressure line L= 450 mm (Audi / BMW / Ford / Nissan / Opel VP 44) 1 680 750 101

Test pressure line L= 845 mm (Cummins / John Deere / MAN / Nissan / VM Motori / Volvo VP 44) 1 680 750 102

Test pressure line L= 450 mm (Opel VP 29 / SISU, Perkins VP 30) 1 680 750 103

Calibration nozzle holder combination model IX Passenger car / commercial vehicle (d= 0.5), 6 units recommended 1 688 901 116

Calibration nozzle holder combination model X Passenger car (d= 0.4), 6 units recommended (only VP 44) 1 688 901 118

Calibration nozzle holder combination model X Commercial vehicle (d= 0.5), 6 units recommended (only VP 44) 1 688 901 119

Calibration nozzle holder combination model X Commercial vehicle (d= 0.55), 6 units recommended 1 688 901 120

Bench stand Audi, 2 units necessary (only VP 44) 1 688 030 186

Heat exchanger (2,500 bar) 1 687 010 336

Update set for old heat exchanger 1 687 010 130 (1,800 bar) for customers who use retrofit kit CRS 845 H (2,500 bar) 1 687 010 337

Cable clip set 1 680 190 018

Specified data on CD TestData for CR injectors (passenger car / commercial vehicle) and CR / VP-M pumps. 1 687 P15 015 Update subscription via ESI[tronic] ServiceLine


Retrofit kit VPM 844For testing VP29 (VE.M), VP30 (VE.M) and VP44 (VR.M)

25

Solenoid valve controlled distributor pumps: VP29 (VE.M), VP30 (VE.M) and VP44 (VR.M)

Tool set for repair of electronically controlled distributor injection pumps VP29 (VE.M), VP30 (VE.M) and VP44 (VR.M)


Repair tools VP29 (VE.M), VP30 (VE.M) and VP44 (VR.M)


Scope of delivery


Striking tool for drive pinion

Assembly device for locking ring

Assembly mandrel for vane-type supply pump

Press-in tool for flange shaft seal


Dynamometer for press-in force

Puller for shaft seal

Press-in tool

Assembly mandrel for high-pressure sealing ring

Socket wrench for overflow valve

Sleeve for drive shaft

Mandrel for coupling assembly

Disassembly tool for PCB track film

Assembly device for distributor body

Assembly device for timing device plunger

Press-on plate for angle-of-rotation sensor film

Power screwdriver for clamping nut

Bolt for cam ring

Puller for deep groove ball bearing

Press-off device for diaphragm

Test device for drive shaft position

Measuring device

Piston stroke measuring equipment VE.E

Repair tools

Solenoid valve controlled distributor pumps:VP29 (VE.M), VP30 (VE.M) and VP44 (VR.M)

26

Common Rail System:Basis set for CR components (CP/CRI)

Retrofit kit CRS 845 H (in EPS 708 already included)Basis for testing Common Rail components

f Software-controlled test f Return flow pressure control by regulating valve f Adaptation and fixtures for various components

with corresponding special accessories f High-pressure rail that functions as a pressure

accumulator, including pressure sensor and integrated controller.

f Distributor for separation of the volume flow before cooling and volume measurement

The retrofit kit CRS 845 H enables reliable testing of Diesel components up to a pressure of 2,500 bar. The corresponding special accessories sets are available for testing various high-pressure pumps.

Scope of delivery CRS 845 HSplash protection, control unit, test rail 2,500 bar, various adapters and connecting lines, regulating valve, various small parts



Retrofit kit CRS 845 H for Common Rail components 1 687 002 845

Special accessories

Update set to 1,800 bar 1 687 001 612 required for existing CRS 845 with manufacturing date before 05 / 2006

Update set CRS 845 H 1 687 010 334 required if CRS 845 (1,800 bar) 1 687 001 845 is already present and upgrade to 2,500 bar is requested CRS 845 (1,800 bar) => CRS 845 H (2,500 bar)

CP1 / CP1H pump set 1 687 010 341

CP2 pump set 1 687 010 342 (lube oil supply required)

CP3 pump set 1 687 010 182 (lube oil supply is required for CP3.3 / 3.4)

CP4 pump set for EPS 815 1 687 010 490 (CP4 pump set for EPS 708 1 687 010 390)

CP third-party pump set Delphi / Denso / Siemens /Continental 1 687 010 183 Successor set for 1 687 010 161 / 162 / 166

Lube oil supply, required for CP2 / CPN2 / CPN2.2 / CP3.4 pumps and / or CAM 847 1 687 001 977


27

Common Rail System:CRI1 from Bosch and basis set for CR injectors1 Solenoid valve controlled injectors

Retrofit kit CRI 846 H for passenger cars, six-way clamping / for commercial vehicles, two-way clamping, including passenger cars special accessories set for testing Common Rail injectors

f Up to six passenger car injectors (1st and 2nd generation) can be fixtured for one test sequence

f High measurement accuracy and tight manufactur-ing tolerances for future reclassification of injectors after repair, as well as testing of injectors with IMA2

technology

Scope of delivery CRI 846 HHigh-pressure pump CP3, distributor rail, injection chambers for CRI, high-pressure hose 250 MPa, electronic control unit (already prepared for UI / UP) with fixture device for up to six passenger car injectors, set of electrical connecting cables and test pressure lines, TestData CD with current test values.


2 Injector delivery compensation



Retrofit kit CRI 846 H incl. special accessories set for Common Rail injectors on passenger cars (CRS 845 required) 1 687 002 846 For testing Bosch solenoid-valve injectors on passenger cars (100 %) and base set for Piezo, 3rd-party and commercial vehicle injectors. Prior to commissioning of the test kit, calibration of the rail pressure sensor at the EPS 815 is necessary

Special accessories

Update set swivel device, required for existing CRI 846 with manufacturing date before 06/2006 1 688 120 174 (for adaptation of Common Rail injectors). As of delivery date 06/2006, the swivel device is included in the CRI 846

Update set CRI 846 H, 1 687 010 335 required if CRI 846 (1,800 bar) 1 687 001 846 is already present and upgrade to 2,500 bar is requested CRI 846 (1,800 bar) => CRI 846 H (2,500 bar)

High-pressure hose 250 MPa 1 000 mm 1 687 016 064

Adapter (thread adaption and restricts system to 1,800 bar), required if set combination CRS 845 (1,800 bar) and 1 681 032 094 CRI 846 H (2,500 bar) or CRS 845 H (2,500 bar) and CRI 846 (1,800 bar) are used

CRIN test set 1 687 001 925 For Bosch commercial vehicle injectors. For CRIN clamping device, 1x CRIN set 1 687 001 925 is required. For two CRIN clamping devices, 2x CRIN sets 1 687 001 925 and 1x adapter line 1 684 463 711 are required

CRIN holding bracket for injector return volume measurement on the EPS 708 in connection with CRI 846 H 1 687 016 080

CRI Delphi / Denso for passenger car injectors 1 687 010 186

CRI Piezo for testing Piezo injectors from Bosch, Siemens and Denso 1 687 010 333

28



Retrofit kit CRI / CRIN 848 H 1 687 002 848

Special accessories

Adapter set for new injector generation CRI 2.5 (CRI 2-18, 2-20), see photo above 1 687 010 494

Update set for customers with CRI 846 H to 1 687 010 368 CRI / CRIN 848 H

High pressure hose 2,500 bar 1,000 mm 1 687 016 064 (for EPS 815: see product offer sheet) (for EPS 708: see product offer sheet)

High pressure hose 2,500 bar 750 mm, 1 687 016 070 (for EPS 815: see product offer sheet ) (for EPS 708: see product offer sheet )

CRI Delphi / Denso for passenger car 1 687 010 186 injectors

CRI Piezo for testing Piezo injectors 1 687 010 333 from Bosch, Siemens and Denso

Adapter and cover plates for CRI / CRIN Bosch offers an extensive line of adapters and adjustable cover plates for testing CRI / CRIN injectors. By using these adapters and plates, the injectors are centered securely and several injectors can be quickly installed and tested at the same time. Which adapter or mounting plates are to be applied, please refer to the CD TestData.

Common Rail System:CRI / CRIN1 from Bosch and basis for CR injectors1 Solenoid valve controlled injectors


Retrofit kit CRI / CRIN 848 H for passenger cars, six-way clamping / for commercial vehicles, four-way clampingDesigned for Common Rail injectors. The multiple clamping permits testing of Bosch CRI / CRIN and CRIs from other manufacturers. In the future, it will be possible to test CRIN units from other manufacturers. The exclusive adapter and quick-action locking mechanism ensure rapid operational readiness. The retrofit kit is perfectly designed for efficient Diesel component testing of injectors in passenger cars and commercial vehicles.

f CRI / CRIN 848 H: Alternative to the CRI 846 H f Can be upgraded to CRI / CRIN 848 H for current

CRI 846 and future CRI 846 H customers f Flexible: Modular concept for the EPS 815 and

EPS 708

Scope of delivery CRI / CRIN 848 HHigh-pressure pump CP3, distributor rail, universal injection chamber for CRI and CRIN, hose line HD 250 MPa, electronic control unit (already prepared for UI/UP) with clamping fixture for up to six passenger car injectors and up to four commercial vehicle injectors, set with electrical connection cable and test pressure lines, CD TestData with current test setpoint values

Adapter set CRI 2.5 (CRI2-18, 2-20)

29

Common Rail System:CRI / CRIN1 from Bosch (for use with CRI 846 H)1 Solenoid valve controlled injectors

The special accessories set CRIN permits testing of commercial vehicles injectors of 1st and 2nd generation (without HEX-NIMA).A precondition for the use of the special accessories set CRIN is the availability of retrofit kit CRI 846 or CRI 846 H.

Scope of delivery CRIN 3 assembly frames with high-pressure connection, clamping pieces, injection chamber with adapter sleeves, injector backflow line connection set,electric connection cable and CD TestData with current test values


CRIN special accessories set for Bosch 1 687 001 925 commercial vehicle injectors of 1st and 2nd generation. Includes 1 687 016 060 and 1 687 016 062 Note: CRI 846 or CRI 846 H required. If existing CRIN set 1 687 001 599 is used, use corresponding extension sets (1 687 016 060 and 1 687 016 062)

Special accessories CRIN ADD ON – adapter line for 1 684 463 711 simultaneous testing of 2 CRINs

High-pressure hose 2,500 bar 1,000 mm 1 687 016 064

Update sets for existing 1 687 016 060 CRIN set 1 687 001 599 Update set: Includes extended return line for future CRIN with larger return volume

CRIN holding bracket for injector return line 1 687 016 080 volume measurement on EPS 708 in connection with CRI 846 H and 1 687 001 925, see photo above

Adapter set for new injector generation 1 687 010 494 CRI 2.5 (CRI 2-18, 2-20)



Common Rail System:CRI / CRIN1 from Bosch and basis for CR injectors

30

Level 1 – assembly fixtureAssembly fixture for nozzles or nozzle-retaining nuts of Common Rail and UI injectors.


Assembly fixture for use 0 986 613 600 with 0 986 613 650

CRI / CRIN set 1, carrying case 0 986 613 650 Note: The foam inserts are already prepared to fit tools of level 1.

Accessory set for CRIN injectors 0 986 613 699 (space available in the carrying case 0 986 613 650)

Level 2 – CRI / CRIN set 1, carrying case Carrying case contains tools for replacing high-pressure sealing ring on the CRI. Assembly fixture 0 986 613 600 for use with tool set 0 986 613 650 for replacement of the high-pressure sealing ring. Extension for CRIN injector with 0 986 613 699

Repair tools CRI / CRIN / UI

Common Rail System:CRI / CRIN1 from Bosch


Assembly fixture for nozzle and 0 986 610 130 retaining nut replacement CRI / CRIN

Assembly set for O-ring assembly 0 986 612 930 CRI / CRIN

Alternative

Assembly fixture for nozzle and 0 986 613 400 retaining nut replacement UI and base assembly fixture for CRI / CRIN (accessory set 0 986 613 500 necessary)

Accessory set 0 986 613 500 for base assembly fixture necessary for CRI / CRIN

Removal and installation tools CRI / CRIN


Rotating device for injector 0 986 611 481

Puller for CRI 0 986 611 499

Striking tool for injector (CR) 0 986 612 727

Cleaning set for compressed air adapter 0 986 612 729

Sealing bolt for combustion chamber 0 986 612 734

Puller for injector 0 986 612 782

Removal claw for CRI (MB, PSA) 0 986 612 872

1 Solenoid valve controlled injectors

31

Common Rail System:CRI / CRIN1 from Bosch

Full repair of passenger car Common Rail injectors (CRI) and commercial vehicle Common Rail injectors (CRIN). Collection (packages) of repair and measuring tools, assembly tools, and testers in line with requirements and according to customer profiles.


For first-time users / workshops that have so far not carried out any injector repairs.

Repair tools

Retrofit set

Retrofit setDesignation Order number

Retrofit kit CRI, level 3 0 986 610 715

Set of shims CRI F 00Z C99 009

Level 3 – tools for complete repair of solenoid-valve-controlled Bosch injectors


First-time user package: CRIN level 3 0 986 610 710

Equipment supplied:

Carrying case CRI / CRIN set 2 (measurement and calibration)

Carrying case CRI / CRIN set 3 (assortment of measurement accessories)

Carrying case CRI / CRIN set 4 ("first-time users")

Carrying case, torque wrench with CRI-specific content

Control unit, CRR 120 (pneumatic activation), manual

Control unit, CRR 220 (electric activation), manual

Power screwdriver for removal of the injector

Clamping fixture for injector mounting

Conversion kit

Required tools

Base set of shims, containing F 00Z C99 170, -171, -172 Note: Always order all three part numbers

Set of shims CRIN F 00R J02 760

Precision voltage regulator 1 687 022 873


First-time user package: CRI level 3 0 986 610 700

First-time user package. CRI level 3 0 986 610 703 (carrying case variant)

Equipment supplied:









Conversion kit

Assembly fixture CRR 130 (CRI 2.1)

Carrying case CRI Shim, complete 0 986 610 940

Required tools




First-time user package: CRI level 3 First-time user package: CRIN level 3


Retrofit kit CRIN, level 3 0 986 610 705


Carrying case CRIN Shim, complete 0 986 610 950

32

Repair tools

For workshops that already perform injector repair levels 1 (nozzle replacement) and 2 (high-pressure ring replacement).

Retrofit set Retrofit set


Retrofit kit CRI level 3 0 986 610 735



Retrofit kit CRIN, level 3 0 986 610 725



Upgrade kit CRIN, level 3 0 986 610 760

Equipment supplied:






Conversion kit

Carrying case CRIN (without content)

Required tools





Upgrade kit for CRI, level 3 0 986 610 750

Equipment supplied:






Conversion kit

Carrying case CRI (without content)

Assembly fixture CRR 130 (CRI 2.1)

Required tools




Upgrade kit for CRI, level 3 Upgrade kit for CRIN, level 3

Common Rail System:CRI / CRIN1 from Bosch1 Solenoid valve controlled injectors

33

First-time users / workshops that already have the repair tools CRI / CRIN Level 3 (as of Page 31) can use the extension set 0 986 610 845 to also repair injectors from Japan and USA production.

Repair tools

Level 3 - tools for complete repair of solenoid-valve-controlled Bosch injectorsTo complete or for exclusive processing of solenoid-valve-controlled injectors from Japan and USA production (0 445 120 047, -048, -049, -058, -072, -073, -076, -090, -091, -093, -095, -109, -126, -243 and 0 445 120 008)


Extension set CRIN Japan / USA 0 986 610 845

Required special accessories

Set of shims available shortly

First-time users / workshops that have so far not repaired injectors and that want to exclusively repair injectors from Japan and USA production can do this with the specific tool set 0 986 610 965.

Extension set for CRIN Japan and USA production


First-time user package: CRIN level 3 0 986 610 710Equipment supplied: Carrying case CRI / CRIN set 2 (measurement and calibration)








Conversion kit

Required special accessories




Set of shims available shortly

First-time user package: CRIN level 3

Tool set for CRIN Japan and USA production


Tool set CRIN Japan / USA 0 986 610 965

Common Rail System: CRIN1 by Bosch from Japan and USA production1 Solenoid valve injectors for commercial vehicles

Full repair of commercial vehicle Common Rail injectors (CRIN) from Japan and USA production. Collection of repair and measuring tools, assembly tools, and testers in line with requirements and according to customer profiles.

34

Common Rail System:CP1 / CP1H

Scope of delivery of special accessories set CP1Drive flange, cone 20 CP1, Drive flange Oldham CP1, Clamping flange CP1, Connection set CP1 pumps DC


Scope of delivery of special accessories set CP1 / CP3Drive flange, cone 20 CP1, drive flange Oldham CP1, clamping flange CP1, connection set CP1 pumps DC, drive flange cone 25 CP3, M14 x 1.5, clamping flange CP3, pressure hose for connection of volume flow measurement, fitting, O-ring, 8 x 2,5, retaining plate, drive flange cone 25, M18 x 1.5, drive flange CP3 Oldham, ring fitting, T fitting, hose clamp, adapter 1 x CP3, pressure gauge 0…600 KPa, pressure gauge -100…250 KPa, parts set throttle, metering unit ZME 0928B00561 for 1L/H, software package, CD-ROM, hose line NW12.5 AD15 length 600 mm, union nut M22 x 1.5 x 17, cutting ring, installation instructions,operating instructions, various small parts

Repair tools


1(Iveco) 2(Renault passenger cars) 3(Standard)

Special accessories set CP1 permits testing of Common Rail high-pressure pumps of the first generation.

Repair of Common Rail high-pressure pumps of the model series CP1 and CP1H


Special accessories set CP1 1 687 010 341 Can be used on EPS 815 (can also be used for EPS 708, but is not specially recommended for the EPS 708, as parts are delivered that are not required on the EPS 708)

Special accessories set CP1 / CP3 1 687 010 346 Can only be used specifically on EPS 708 (the CP1 and CP3 set scope of delivery has been adapted and grouped for the EPS 708)


High-pressure hose 2,500 bar 700 mm 1 687 016 070


Repair tools CP1 / CP1H


Scope of delivery


Puller for radial shaft seal

Puller for pressure-control valve

Press-in tool for low-pressure connection1



Puller for barrel-and-valve assembly

Dummy plug for housing bore

Parts set for shaft seal

Adjusting screw for cylinder-head cover

Guide pin for short-circuiting ring

Assembly sleeve for shaft

Assembly sleeve for O-ring

Spacer tube

Support flange

Puller for flange

Assembly sleeve for cone shaft

Press-in tool for low-pressure connection

Assembly mandrel for gear pump (CP1H)

Assembly mandrel for gear pump (CP1H)

Press-in tool for low-pressure connector

35

Common Rail System:CP2 / CPN2

With its CP2 Common Rail pump, Bosch has a special commercial vehicle application in its range. It is currently used for Mitsubishi and RVI.

The special accessories set CP2 permits testing of these commercial vehicle Common Rail pumps.

Scope of delivery CP2Throttle, banjo union for D=16, AD15, hose line NW12.5, AD15, L=1100, M14 x 1.5-A15, M14 x 1.5, T-threaded connection AD15-10-15, swiveling screw-fitting AD15-M18 x 1.5, pressure gauge 2.5 MPa, steel pipe AD15, hose line NW8 AD10, L=1350, screw connec-tion, speed sensor adapter line, adapter line for DMV, connecting line to CP2, pressure hose ID8, PVC hose, printed circuit board equipped, single-stage box filter, plug screw M18 x 1.5, temperature sensor, clamping flange, O-ring 12.5 x 2.5, bracket, flat sealing ring A18 x 22, intake line retrofit kit, CD-ROM, software package, installation instructions, operating instructions, various small parts


Repair tools CP2

Assembly sleeve for radial shaft seal 0 986 611 037


Assembly sleeve 0 986 611 992


Clamp block 0 986 611 096

Tool kit for bottom blanking plug 0 986 612 139

Assembly device for drive gear 0 986 612 857

Tappet holder 0 986 612 858

Puller for drive bearing cap 0 986 612 859

Puller for barrel-and-valve assembly 0 986 612 860

Assembly sleeve for upper element sealing ring 0 986 612 861

Assembly sleeve for lower element sealing ring 0 986 612 862

Support ring for shaft seal 0 986 612 863

Assembly mandrel for shaft seal 0 986 612 864

Press-in tool for barrel-and-valve assembly 0 986 612 865

Guide pin for drive bearing cap 0 986 612 866

Guide pin for housing assembly 0 986 612 867

Assembly device for bearing cap/housing 0 986 612 868

Assembly mandrel for bottom blanking plug 0 986 612 869

Repair toolsTest equipment EPS 815


Locking device for crankshaft 0 986 612 741

Spacer for belt pulley 0 986 612 744

Removal and installation tools


Special accessories set CP2 1 687 010 342

High-pressure hose 2,500 bar 1,000 mm 1 687 016 064 for CP2 testing, two hoses are necessary

Printed circuit board for testing CP2. 1 688 400 320 Required for already existing CRS 845 with production date before 04/2004

Lube oil supply, required for CP2 / CPN2 / CPN2.2 / CP3.4 pumps and / or CAM 847 1 687 001 977


36

Common Rail System:CP3

Repair tools CP3 flange Repair tools CP3 housing



Repair tools CP3 flange


Scope of delivery


Guide sleeve for press-in tool

Support for press-in tool

Support for pre-pressing / pressing in housing bush

Downholder for pre-pressing / pressing in housing bush

Support for holder

Screw clamp

Rail

Plunger for housing bush





Press-in tool for housing bush

Axial measuring device for measuring axial clearance

Axial measuring device for measuring axial clearance

Clamp block for measuring axial clearance

Adapter for measuring axial clearance

Sleeve for extending the bell

Fastening

Screw for guide piece

Scope of delivery continued on next page

Scope of delivery CP3Drive flange, cone 25 CP3, M14 x 1.5, clamping flange CP3, fitting, O-ring, 8 x 2.5, retaining plate, drive flange, cone 25, M18 x 1.5, drive flange CP3 Oldham, banjo union, T-adapter, hose clip, adapter 1 x CP3, pressure gauge 0…600 KPa, pressure gauge -100…250 KPa, throttle parts set, metering unit ZME 0928B00561 for 1L/H, software package, CD-ROM, hose line NW12.5 AD15, length 600 mm, cap nut M22 x 1.5 x 17, cutting ring, installation instructions, operating instructions, various small parts


Special accessories set CP3 1 687 010 182 Can be used on EPS 815 (can also be used for EPS 708, but is not specially recommended for the EPS 708, as parts are delivered that are not required on the EPS 708)

Special accessories set CP1 / CP3 1 687 010 346 Can only be used specifically on EPS 708 (the CP1 and CP3 set scope of delivery has been adapted and grouped for the EPS 708)

Required special accessories:


Update set CP3.4 return line connection1 1 687 016 061

Lubrication supply EPS 815 1 687 001 977


1 CP3.4 return line connection, included as of 09 / 2009 in the scope of delivery of the CP3


37

Common Rail System:CP3Repair tools


Repair tools CP3 flange: Scope of delivery continued

Stud bolt

Stud bolt

Stud bolt

Collet for removing housing bush




Test adapter for leak test of outer shaft seal


Additional repair tools CP3

Load sensor for shaft seals, bushes, etc. 0 986 612 878

Force transducer for pressures 0 986 612 997

Puller for shaft seals 0 986 612 465


Repair tools for CP3 housing


Scope of delivery


Washer for flange bush

Plunger for flange bush


Wrench socket, Torx T50 IP

Washer for disassembly of thrust rings

Guide pin for disassembly of thrust rings

Nut for disassembly of thrust rings

Washer for calking thrust rings

Washer for calking thrust rings

Sleeve for calking thrust rings



Guide sleeve for pressing in flange bushes





Support for pressing in flange bushes



Assembly sleeve for O-ring of cascade overflow valve




Assembly sleeve for O-ring of metering unit

Assembly sleeve for overflow valve

Assembly sleeve for O-ring of metering unit


Press-in tool for inner flange shaft seal

Stamping tool for eliminating distortion in the flange



Repair tools for CP3 housing: Scope of delivery continued









Press-in tool

Rotary button for pump shaft

Socket wrench for low-pressure connections

Socket wrench for low-pressure connections




Support for flange bush



Plunger for washer

Fastener for flange bush

Screw for guide piece

Piston ring for calking the flange thrust ring






Disassembly tool for removing the flange thrust ring


Plunger for guiding the press-in tool for flange bush



Washer for calking the friction washer

Support for aligning the load sensor



38

Common Rail System:CP4 for EPS 708


Scope of delivery CP4 / EPS 708CP4 PCB and electrical components, Installation Parts Set: Mounting plate for all standard CP4 HP pumps, Drive Parts Set: Five different drive shafts, HP Connection Parts Set: M16 x 1.5; M16 x 1.0, Adapter with M16 nut in order to use the existing high-pressure pipes, NP Connection Parts Set: Inlet / Backflow connection line with snap closure on Delta temperature sensor block including bracket, Pressure Transfer Parts Set: Pressure sensor block to absorb CP4 pressure transfer and suction pressure in case of various common rail high-pressure pumps, connection pipe.

CP4 Special accessory set for EPS 708 f Delta temperature measurement for the diagnosis of

the pump drive (roller tappets, bushings, ...) f Inlet/backflow pressure control with low tolerances f Customized vent function: flow testing only possible

if CP4 and the HP system are completely vented f ZME venting function: This feature was introduced in

order to shorten the test time (50%) f Digital pressure transfer gauge at CP4 with integrated

gear pump f Mounting flange suitable for all CP4 pumps

(470 different part numbers) f Five different drive flanges f High pressure adapter: To cost effectively enable all

the different HP connections


CP4 Special accessory set 1 687 010 390 Only for EPS 708

Additional special accessories

High pressure pipe 2,500 bar 1,000 mm 1 687 016 064

Hydraulic pipe for transfer pressure measuring 1 680 712 327

Lube oil supply EPS 708 1 687 001 931

New opportunities for the diesel workshop:Powerful modern Common Rail Systems are becoming more popular on the market. One of the latest high-pressure pump generations, the volume-controlled CP4, is being applied.The CP4 Bosch special accessory sets enable the work-shop to give a professional diagnosis and repair the latest diesel systems. The Bosch know-how is available for the diesel specialist, even in cases of repairing the most sophisticated components.

39

Common Rail System:CP4 for EPS 815


Scope of delivery CP4 / EPS 815Inlet / backflow control module with CP4 PCB,Installation Parts Set: Mounting plate for all standard CP4 HP pumps, Drive Parts Set: Five different drive shafts, HP Connection Parts Set: M16 x 1.5; M16 x 1.0, Adapter with M16 nut in order to use the existing high-pressure pipes, NP Connection Parts Set: Inlet / backflow connection line with snap closure on Delta temperature sensor block including bracket, Pressure Transfer Parts Set: Pressure sensor block to absorb CP4 pressure transfer and suction pressure in case of various common rail high-pressure pumps, connection pipe integrated in the set, lube oil pressure recording: Pressure sensor for electronic pressure recording of the lube oil pressure.

CP4 Special accessory set for EPS 815 f Delta temperature measurement for the diagnosis of

the pump drive (roller tappets, bushings, ...) f Inlet / Backflow pressure control with low tolerances

(+/- 0.05 bar) f Customized vent function: flow testing only possible

if CP4 and the HP system are completely vented f ZME venting function: This feature was introduced in

order to shorten the test time (50%) f Digital pressure transfer gauge at CP4 with integrated

gear pump f Mounting flange suitable for all CP4 pumps

(470 different part numbers) f Five different drive flanges f High pressure adapter: To cost effectively enable all

the different HP connections


CP4 Special accessory set 1 687 010 490 Only for EPS 815

Additional special accessories:

CRS 845 H 1 687 002 845

Heat exchanger 1 687 010 336

Upgrade kit CRS 845 for CRS 845 H 1 687 010 334

Upgrade kit for heat exchanger 2,500 bar 1 687 010 337




40

Common Rail System:CP4

Repair tools


Repair tool kit 1 and 2 0 986 610 740

Scope of delivery repair tool kit 1


Adjusting device

Pressing device

Pressure sleeve

Test adapter (leak test)

Tool Set (RWDR)

Tool Set (pressure sleeve)

Tool Set (adapter)


Repair tool kit 1 and 2 0 986 610 740

Scope of delivery repair tool kit 2


Installation device (CP4 fixture)

Drift Pin

Extractor device (flange)

Extractor device (flange)

Remover (cross-coupling)

Locating pin (M6)

Locating pin (M8)

Installation aid (O-ring)

Installation tool (cross-coupling)

Tool kit (installation sleeves)

Adapter block (cylinder installation)

Adapter (camshaft)

Socket wrench (temperature sensor)

Socket wrench insert

Adapter (pressure gauge)

Installation sleeve (ZME O-ring installation)

41

Common Rail System:CB18



CB18 Special accessory set 1 687 010 402 Only for EPS 815 and EPS 708

Scope of delivery

Mounting flange 68 mm

Bushing

Drive coupling

Mounting cap

Holding key

Inlet pipe with 2.4 mm throttle

Vent nipple fitting

Rectus nipple

Ring piece 10 mm

Screw clamp

Lube oil inlet connection






NP gauge (16 kPa) Diesel set 1 0 986 613 102

NP gauge (-100 … 500 kPa) Diesel set 1 0 986 613 103


Old Ham drive coupling with mounting- 1 687 010 493 flange for Chery (Chinese vehicle)


Repair tool kit 0 986 614 081

Scope of delivery

Mounting flange for CB18 / CB28, including screws

Installation sleeve HP element

Installation sleeve CB18

Installation sleeve CB18

Press tool

Corkscrew

Studs (2 pcs)

Drift Pin

Installation sleeve ZME O-ring 4.0

Accessories (high pressure pumps of the "Chery" vehicle manufacturer 0 445 025 015): Adapter (measuring camshaft's axial clearance) 1 681 335 118 Drift pin 1 683 120 096


Flange 0 986 611 358

KDEP 2919 0 986 611 249

Please note additional test set accessories and test bench related accessories (please refer to offer sheets)

Test equipment and repair tools for CB18 Pumps

42

Common Rail System:CB28

CB28 Basic repair tool kit CB28 Additional repair tool kit

Test equipment and repair tools for CB28 pumps

Test equipment EPS 815 Repair tools


CB28 Special accessory set 1 687 010 496 Only for EPS 815 Scope of deliveryMounting flange 85 mm

Drive coupling

Mounting cap

Holding key

Inlet pipe with throttle

Inlet pipe

Ring piece M14 x 1.5

Test adapter M14 x 1.5

Hollow screw M14 x 1.5

Threaded fitting

Lube oil inlet connection

Backflow pipe


Repair tool kit CB28 basic kit 0 986 614 082Scope of deliveryInstallation sleeve O-ring HP element

Installation sleeve O-ring HP element

Press-in pin shaft seal

Alignment bolts

Dismantling pin

Installation / dismantling pin M10

Additional repair tool kit, 0 986 614 083 if no CB18 basic kit is availableScope of delivery Mounting flange for CB18 / CB28

Corkscrew

Protective sleeve shaft seal

Press tool shaft seal

Newcomers / workshops that have never conducted CP1, CP3 repairs, and exclusively seek to repair CB28 high-pressure pumps:Repair tool kit CB28 0 986 614 082Repair tool kit CB18 / CB28 0 986 614 083Accessories: Axial clearance measurement device 0 986 610 282, installation sleeve ZME O-ring 0 986 611 815, pressure gauge 1 687 233 012, driving pin 1 683 521 035, installation sleeve ZME O-ring 0 986 611 851, extracting device for shaft seal 0 986 612 465, extraction clamp Ø 31.5 mm 0 986 619 255, extracting bell 0 986 619 216, clamping device 0 986 619 250

43

Common Rail System:CP from Delphi / Denso / Siemens / Continental

Common Rail – the future of the Diesel engineAs early as 1997, the first Diesel vehicle series was fitted with a Common Rail System. Since then, the triumphal progression of this technology is unstoppable.In the field of Diesel fuel injection, Bosch is the worldwide leading partner of the automobile industry, with high market shares in vehicle initial equipment. In the meantime, systems from other suppliers, e.g. Delphi, Denso and Conti / Siemens, are also being used by various vehicle manufacturers.

These components can be tested using the special accessories set CP Delphi / Denso / Siemens / Continental

Test equipment for Common Rail components from other manufacturersWith its component test benches EPS 815 and EPS 708, Bosch offers Diesel specialists an extensive, complete solution, which also permits testing of Common Rail pumps and injectors from other manufacturers. For that, the test equipment range has been extended by further accessory sets.

Special accessories set CP Delphi / Denso / Siemens / ContinentalThis special accessories set enables testing of Common Rail high-pressure pumps from the manufacturers Delphi / Denso / Siemens / Continental on the EPS 815.A requirement is the retrofit kit CRS 845 (1,800 bar) or CRS 845 H (2,500 bar).

In addition to our own test values CD "TestData", test values for Diesel components from Delphi, Denso and Continental / Siemens for EPS 815, EPS 708 and EPS 205 are available from the data provider Refdat and can be downloaded from the workshop under www.refdat.netNote: The accuracy of the third party data is up to the data provider. Robert Bosch GmbH assumes no liability for any test procedure and data.



Special accessories set CP Delphi / Denso / Siemens / Continental 1 687 010 183



Update set for existing 1 687 010 184 special accessories sets for pumps of other manufacturers 1 687 010 161, 1 687 010 162, 1 687 010 166




Newcomers / workshops that have never conducted CP1, CP3 repairs, and exclusively seek to repair CB28 high-pressure pumps:Repair tool kit CB28 0 986 614 082Repair tool kit CB18 / CB28 0 986 614 083Accessories: Axial clearance measurement device 0 986 610 282, installation sleeve ZME O-ring 0 986 611 815, pressure gauge 1 687 233 012, driving pin 1 683 521 035, installation sleeve ZME O-ring 0 986 611 851, extracting device for shaft seal 0 986 612 465, extraction clamp Ø 31.5 mm 0 986 619 255, extracting bell 0 986 619 216, clamping device 0 986 619 250

44

Common Rail System:CRI Piezo from Bosch / Denso / Siemens / Continental

Special accessories set for testing Delphi and Denso passenger car Common Rail Piezo injectors

f Bosch components of the latest generation can be tested with test software and TestData CD

f Test specifications from systems from other manufacturers are available via www.refdat.net



Puller for CRI 0 986 611 499

Adapter for UP, CRI Piezo 0 986 612 885

Removal and installation tools

Special accessories set CRI Piezofor diagnosing passenger car Common Rail Piezo injectors from manufacturers:

f Bosch f Denso f Siemens / Continental f Delphi

The new test kit is designed for efficient and highly accurate testing of Bosch systems and systems from other external manufacturers. Testing of competitors' components is still in preparation. The workshop thus guarantees a wide base in the long-term for a reliable business growth area.

Piezo Common Rail injector testing at a glance: f Air-tightness test f Check of coupler filling f Check for insulating faults in the Piezo module f Injection quantity measurement at the test points:

- pre-injection (VE) - idling (LL) - emission (EM) - full load (VL) - fuel return quantity

f IMA coding (incl. ISA Code) (injector voltage adjustment)

f Activation up to 220 V



Special accessories set CRI Piezo 1 687 010 333


Hose lines 1 687 016 055 for testing CRI Piezo Denso. Required if CRI Delphi / Denso set 1 687 001 609 or 1 687 010 186 not present

Injection chamber set 1 685 438 631 for testing Denso / Siemens CRI Piezo and CRI Delphi / Denso solenoid valve. Required if CRI Delphi / Denso set 1 687 001 609 or 1 687 010 186 (production date before 12 / 2010) not present

Test pressure line 1,800 bar 1 687 010 185 for testing Bosch CRI Piezo and Delphi / Denso solenoid valve up to 1,800 bar. Required if "old" CRI Delphi / Denso set 1 687 001 609 not present. Can only be used with CRI 846 (1,800 bar)

Test pressure line 2,500 bar 1 687 016 065 for testing Bosch CRI Piezo and Delphi / Denso solenoid valve up to 2,500 bar. Only to be used with CRI 846 H or CRI / CRIN 848 H

45

Common Rail System:CRI Piezo from Bosch / Denso / Siemens / Continental

Common Rail System: CRI1 from Delphi / Denso

Special accessories set CRI Delphi / DensoThis special accessories set enables Common Rail passenger car injectors (solenoid valve) from the manufacturers Delphi and Denso to be mounted and tested on the EPS 815 or EPS 708.A requirement is the retrofit kit CRI 846 / CRI 846 H or CRI / CRIN 848 H.Test above 1 Ω is possible.

Special accessories set for testing Delphi and Denso Common Rail injectors





Special accessories CRI Delphi / Denso 1 687 010 186


Update set for former 1 687 010 187 CRI Delphi / Denso set 1 687 001 609. For testing injectors above 1 Ω

Injection chamber set 1 685 438 631 for testing Denso / Siemens CRI Piezo and CRI Delphi / Denso solenoid valve. Required if CRI Delphi / Denso set 1687 001 609 or 1 687 010 186 (production date before 12/2010) not present

Test pressure line 1,800 bar 1 687 010 185 for testing CRI Piezo Bosch and solenoid valve Delphi / Denso up to 1,800 bar. Note: Required if "old" CRI Delphi / Denso set 1 687 001 609 is not present. Can only be used with CRI 846 (1,800 bar)

Test pressure line 2,500 bar 1 687 016 065 for testing Bosch CRI Piezo and Delphi / Denso solenoid valve up to 2,500 bar. Can only be used with CRI 846 H or CRI / CRIN 848 H

New: In addition to our own test values CD "TestData", test values for Diesel components from Delphi, Denso and Continental / Siemens for EPS 815, EPS 708 and EPS 205 are available from the data provider Refdat and can be downloaded from the workshop under www.refdat.netNote: The accuracy of the third party data is up to the data provider. Robert Bosch GmbH assumes no liability for any test procedure and data.

46

Unit injector / unit pump system: UI / UP

CAM 847 retrofit kit for testing Unit Injector and Unit Pump systemsThe basis for testing Unit Injector and Unit Pump systems is the injection component test bench EPS 815 from Bosch. The CAM 847 retrofit kit guarantees that the functional test of Bosch systems is in accordance with manufacturer's specifications. Testing of competitors' systems is in preparation.

CAM 847retrofit kit – complete testing of UI and UP systemsFull performance development, high injection pressures and a long service life are trademarks of Unit Injector and Unit Pump systems. With the CAM 847 retrofit kit, Bosch now rounds off the use of EPS 815 as a universal test bench, allowing UI and UP systems to be tested.

Flexible design Bosch offers two versions of the CAM 847 retrofit kit:

f Complete package with Camboxes and 12 adaptations for test Bosch UI and UP systems

f Individual package for customized and market-oriented compilation of the necessary adapter sets

Efficient work f Space-saving Cambox f Timesaving by testing with universal cam f Significantly reduced setup times in the workshop

thanks to the simulation of all relevant system strokes via adaptations

f Automated test sequence



47

The basis for testing Unit Injector and Unit Pump systems is the complete package. It contains the Cambox and 12 adapters required for testing UI and UP systems from Bosch.

Individual package see page 48.

Unit injector / unit pump system:UI / UP Complete package


Retrofit kit CAM 847 Complete package


Retrofit kit CAM 847 including 12 adaptations 1 687 001 847 Note: For testing UI-P, UI-N and UP. Only for EPS 815 as of manufacturing date 01/2001

Special accessories

Test nozzle-holder assembly 1 688 901 119 required for CAM 847 if retrofit kit VPM 844 not present

Test nozzle-holder assembly 1 688 901 120 required for CAM 847, if test DHK 1 688 901 034 + nozzle-retaining nut 1 683 373 081 not present


48

Flexible arrangement with the CAM 847 Individual package: Purchase only to match your workshop requirements

f Selection of three adapter sets for customized market adaptation

- UI-P adapter set - UI-N adapter set - UP adapter set

Adapter set UI-P Adapter set UI-N Adapter set UP Nozzle-and-holder assembly suspension

Unit injector / unit pump system: UI / UP Individual package


Retrofit kit CAM 847 Individual package


Retrofit kit CAM 847 without adapter sets 1 687 001 849 Note: Only for EPS 815 as of manufacturing date 01 / 2001

UI passenger car adapter set (consisting of 2 adapters for testing Bosch UI passenger cars) 1 687 016 051

UI commercial vehicle adapter set (consisting of 6 adapters for testing Bosch UI commercial vehicles) 1 687 016 052

UP adapter set (consisting of 4 adapters for testing Bosch UP) 1 687 016 053

Nozzle-and-holder assembly suspension required for testing UP components 1 687 016 049

Injection chamber required for testing UI components 1 682 312 044

Test nozzle-holder assembly required for CAM 847 if VPM 844 not present 1 688 901 119

Test nozzle-holder assembly required for CAM 847, If test DHK 1 688 901 034 + nozzle-retaining 1 688 901 120 nut 1 683 373 081 not present


49


Assembly device for nozzle replacement 0 986 613 400

Force transducer in conjunction with 0 986 612 997 assembly device

Support plate for UI passenger car 0 986 613 237

Support plate for UI commercial vehicle 0 986 613 499

Assembly sleeve set for assembly of 0 986 613 824 O-rings on UI-P1.x

Assembly sleeve set for assembly of 0 986 611 490 O-rings on UI-P2

Box wrench set, 28 a / f for 0 986 613 238 nozzle clamping nut

Box wrench set, 32 a / f for 0 986 613 240 nozzle clamping nut

Wrench socket, 38 a / f for 0 986 613 239 solenoid clamping nut

Load sensor for shaft seals, bushes, etc. 0 986 612 878

Force transducer for pressures 0 986 612 997

Force transducers for pressuresAssembly device for nozzle replacement

Efficient work with the assembly device UI-P: f Optional adaptations for repair of commercial

vehicles injectors and CR injectors (0 986 613 500) available

f Simple disassembly and assembly of the UI thanks to assembly device for nozzle replacement 0 968 613 400 in spite of forces between 9,000 N and 16,000 N

f Precise measured results with the already widely used force transducer 0 968 612 997


Assembly sleeve set for O-ring UI 0 986 611 490

Striking tool for removal and installation 0 986 611 492 of the UI for Scania

Measuring device for measuring 0 986 611 493 the UI for Scania

Puller for removing 0 986 611 494 the UI for VW (passenger car)

Wrench socket for screwing in 0 986 612 747 the UI in cylinder head for VW (passenger car)

Assembly sleeve for sealing rings (UI) 0 986 612 748

Puller for removal of UI from 0 986 612 750 cylinder head of VW (passenger car)

Sealing plug for sealing the 0 986 612 751 cylinder head for Volvo

Measuring device for measuring 0 986 612 777 the UI for Volvo

Wrench socket for toothed belt tensioner 0 986 612 778

Adapter for UP, CRI 0 986 612 885

Removal and installation toolsRepair tools

Unit injector / unit pump system:UI / UP

50

EPS 205 – Testing diesel components safely and easily:

f CRI Piezo from Bosch, Denso, Siemens, Continental f Solenoid valve CRI from Bosch f Solenoid valve CRIN from Bosch f Solenoid valve CRI from third-party manufacturers f DHK and UI nozzles (warranty assessment possible) f Step holder

More power in a compact format f Single clamping and injection chamber for all

components f Easy handling during injector clamping

operation, e.g. due to large protective hood f CRIN clamping operation using the existing

CRI / CRIN 848 H adapter f Measuring injectors > 1,800 bar

(with reduced test step) f Accurate measuring technology

Test bench for Common Rail injectors and nozzle-and-holder assemblies: EPS 205

The test value CD "TestData" for components from Bosch is included in the scope of delivery. Test values for diesel components from other manufacturers are available from data provider Refdat and can be downloaded from www.refdat.net from the workshop.

Efficient Common Rail injector testFlow-based injector test using a piezo CRI test as example: f Leak testf Injector start behavior (without return flow

counter-pressure)fISA tuningf Full-load quantity (VL)f Pilot injection quantity (VE)f Idle quantity (LL)f Emission quantity (EM)f Actuator resistance

Conventional nozzle test (DHK and UI nozzle)f Combination leak test (inner leak test)f Seat leak testf Electric buzz testf Measurement of nozzle opening pressure

Updates on CRI/CRIN components are available on the TestData CD

51

Automatic test sequence with touch-screen operation Graphical and numerical display of measurement results

EPS 205 – the benefits at a glance:

Environmental and user-friendliness: Minimal oil mist in the workshop through integrated suction device

Efficient working: f Very high economic feasibility through automatic

testing, simple menu with graphical and numerical display of measurement results

f Integrated database for storage of test values and customer data

f Test values "on board" (CD TestData) on delivery of the device1, selection via part numbers

f Integrated flushing program for clean diesel components in DHK and UI testing

f Realistic operating state from pressure generation up to 1,800 bar via the integrated Common Rail high-pressure pump

Efficient operation and functional design: f Intuitive user interface with touch-screen operation f Simple shutdown of the return flow

counter-pressure f Space-saving compact form f Windows XP embedded operating system f Interface for printer, monitor, CD/DVD drive,

keyboard, mouse, network connection

EPS 205 – versions P / N Testable components

EPS 205 (200 V) 0 683 803 206 CRI Piezo Bosch, CRI soleno-id valve Bosch, CRIN Bosch,UI nozzle, DHK

EPS 205 (400 V) 0 683 803 205 CRI Piezo Bosch, CRI soleno-id valve Bosch, CRIN Bosch,UI nozzle, DHK

EPS 205 – retrofit kits P / N Testable components

CRI solenoid valve third-party manufacturer

1 687 010 399 Delphi, Denso

CRI piezo third-party manufacturer

1 687 010 400 Siemens, Denso

1 Test values for CRI / CRIN and opening pressures of the UIs and DHKS (possibly at 1st and 2nd nozzle opening pressure) are included in the database. Updates are made via CD TestData subscription. General note: The device is not approved for repair or warranty assessment of Common Rail injectors. IMA encodings are not feasible.


Testing of diesel injection components – automatically, safely and economically

52

Test device:EPS 100


EPS 100 0 684 200 704

Scope of delivery

Test pressure line M 14 x 1.5 / M 12 x 1.5 1 680 750 014


Pressure gauge 0 - 40 MPa 100 dia., 1 687 231 211 strength class 0.6, M 20 x 15

Test equipment

The Bosch injector test device EPS 100:Future-proof and flexible design

f Testing and adjustment of injection-nozzle opening pressure

f Assessment of the injection spray with regard to shape and atomization (injection-spray pattern)

f Checking for leaks in injection nozzles, and checking the chatter properties on two-spring nozzle holders, stepped nozzle holders, and UI / UP applications

Efficient work f Reduced total error (+ / - 2.4 bar) through high

read-off (1 bar) and pressure gauge accuracy f Idling vibrations of the engine can be avoided by

extremely accurate analysis of the smallest possible leaks

User and environmentally friendly thanks toextraction device EPS 738 as special accessories

f Direct extraction of the oil mist when testing injection nozzles


Special accessories

EPS 738 – extraction device 230 V / 50 Hz 0 684 200 702


Reducing adapter M 14 x 1.5 / M 18 x 1.5 1 680 362 000





Injector needle test accessories for 1 688 130 153 hole pintle nozzle

Metal oil tank with cover 1 685 400 029

UI AdapterKit for commercial vehicle Scania, 1 687 010 147 Iveco and Volvo

UI AdapterKit for commercial vehicle Iveco 1 687 010 338 and Detroit

UI AdapterKit for passenger car Volkswagen 1 687 001 857

UI adapter for Nissan 1 681 335 111

53

Diagnostic tools

Denoxtronic 1The Denoxtronic set 1 is designd for work on the exhaust-gas treatment system DeNOx 1. It is used when performing the function tests via the system diagnostics and for field repairs of the delivery module.

Denoxtronic 2The Denoxtronic set 2 is designd for work on the exhaust-gas treatment system DeNOx 2. It is used to evaluate the hydraulic system leaks as well as to test the metering and supply volumes in the Denoxtronic diagnostics.

Denoxtronic PC / LDThe Denoxtronic set PC / LD is designd for work on the exhaust-gas treatment system DeNOx in passenger cars and in light duty commercial vehicles. It is used with Denoxtronic diagnostics.

Denoxtronic systems:Denoxtronic 1

Denoxtronic 1

Exhaust-gas treatment DeNOx systemsDeNOx stands for the exhaust-gas treatment for diesel fuel-injection systems to remove most of the nitrous oxides from exhaust gases.

The diagnostics at the vehicle / system are carried out primarily with a diagnostics tester (e.g. KTS 540). However, this is not sufficient to detect hydraulic, pneumatic or mechanical faults in the system. This is why the additional diagnostics technology (offboard test equipment) is necessary to perform advanced troubleshooting on components, lines, interfaces etc.

Bosch offers three tailored Denoxtronic tool sets for this purpose.


Denoxtronic 1 0 986 610 800

Scope of delivery

Storage case "Denoxtronic 1" with foam inserts

Pressure gauge (0 - 1,6 kPa)

Test pressure line, pneumatic

Measuring cup (100 ml with cover)



Hanger

Spray nozzle

Magnet holder for spray nozzle

Test module, measuring volume of fluid

Adapter module, system control (MAN, Volvo, DAF, Iveco)

Scale

Calibrating weight for scale

Special accessories:

Pressure gauge (100 - 500 kPa) 0 986 613 103

Test pressure line, line to 0 986 613 078 pressure gauge 0 986 613 103

54

Denoxtronic systems:Denoxtronic 2, Denoxtronic PC / LD

Denoxtronic 2 Denoxtronic PC / LD

Diagnostic tools



Scope of delivery

Storage case "Denoxtronic 2" with foam inserts

Metering module, measuring volume of fluid

Set of measuring containers (500 ml, 250 ml, 100 ml) incl. retaining strap

Hydraulic line for delivery module

Extension line, metering module test

Sealing plug, closing off plug connection

Hydraulic line for metering module (feed)

Hydraulic line for metering module (return)

Sealing component, metering module return

Sealing component, metering module feed

Pressure gauge (–100 kPa - 900 kPa)

Refractometer, determining density of Adblue

Test pressure line, Y hose

Oil test strips (with container)

Scale

Calibrating weight for scales

Special accessories:

Metering module DeNOx 2.2 0 986 610 522


Denoxtronic PC / LD 0 986 610 500

Scope of delivery (continued)

Hydraulic line for metering module test (standard)

Hydraulic line for metering module test (Daimler)

Test pressure line Y adapter (standard connection)

Test pressure line Y adapter (Daimler connection)

Pressure gauge, measurement range –100 kPa - 900 kPa

Adapter for delivery module on test tank

Scale disk (special paper for spray test)

Extension line, testing metering module

Holding clip for metering module (GM / Ford)

Extension cable for metering module test on test tank, 3 m

Refractometer, determining density of Adblue

Hydraulic line for volume measurement on the delivery module (standard connection)

Hydraulic line for volume measurement on the delivery module (Daimler connection)

Bottle

Chain for bottle

Extension cable for metering module test (passenger cars)

Extension cable for metering module test (passenger cars / commercial vehicles)

Oil tests strips (with container)

Scale

Calibrating weight for scales

Hydraulic line



Denoxtronic PC / LD 0 986 610 500

Scope of delivery

Storage case "Denoxtronic PD / LD" with foam inserts

Holding device, incl. adapter

Measuring device for assessment of spray pattern

55

Kits consist of repair, assembly and test tooling, which meet field repair requirements.

The kit contents correspond to the application profile. Below listed kits are examples.

Exact scope of delivery is listed in the offer documents.

Denoxtronic systems:Denoxtronic components



Scope of delivery

Cover plate DeNOx 1

Test equipment

Storage case "Denoxtronic 1", complete

Set of lines, pneumatic

Bench stand, clamping on delivery module

Test adapter, leak test cover

Assembly plate for delivery module

Assembly mandrel, pressing out plenum chamber (venturi) (old)

Assembly mandrel, pressing out plenum chamber (venturi) (new)

Set of lines, pneumatic

Test adapter, simulating system parameters

Accessories Test equipment 0 986 613 880

Special accessories (Scania) Adapter module 0 986 610 173

Test adapter 0 986 610 174


Extension set Denoxtronic 1 to Denoxtronic 2 0 986 610 865

Scope of delivery





Adapter cable, testing primary pressure (air)

Extractor, replacing filter element



Set of hoses, pneumatic

Puller

Test pressure line, testing primary pressure (hydraulics)

Adapter module, system diagnostics

Test adapter, system diagnostics

Cover plate DeNOx 2

Repair tools

56

Denoxtronic systems:Denoxtronic components


Denoxtronic 2.2 0 986 610 863

Scope of delivery

Servicebox

Pipe kit DeNOx 2.2

Mounting plate DeNOx 2.2

Mounting frame DeNOx 2.2

Drift Pin DeNOx 2.2

Sealing device

Pressure gauge holder

Pressure gauge (-100 to 1500 kPa)

Hand Pump

Control unit (12 Volt)

Control unit (24 Volt)

Test adapter (KTS)

Bush bearings (12 Volt)

Bush bearings (24 Volt)

Locking piece

Dispensing module

Weighing device

Measuring cup set

Parts kit, drain valve

Clamping support

Weight

Clamp

Suction device

Accessories Test equipment 0 986 613 880



Scope of delivery

Wrench

Puller

Power screwdriver

Retaining device

Repair tools



Scope of delivery







Storage case "Denoxtronic® 1", complete

Test equipment

Set of hoses, pneumatic

Bench stand, clamping on delivery module

Sealing device, testing cover tightness

Puller

Test pressure line, testing primary pressure (hydraulics)

Adapter module, system diagnostics (Volvo, Iveco, Renault, Sisu)

Test adapter, system diagnostics (Volvo, Iveco, Renault)

Adapter cable, testing primary pressure (air)

Extractor, replacing filter element

Cover plate DeNOx 2

57

Component repair:Starters and generators

Tailored tool sets for the repair of starters and generators for workshop field repairs.These tool sets enable the repair of starter series: DA (12 V), DM (12 V), DB (12 V), DW (12 V), EV (12 V),HEF95-L (24 V), HX (24 V), HXF95-L (24 V), GVB / HEF109-M (24 V), CF 70, SCF 70 and SC 70.In addition to generator series: GC / KC / NC (14 V), KC / NC (28 V), GCB / KCB / NCB (14 V), H7, -8, -10P (14 V), NBL / CL (14 V, 28 V), EL 7, -8 (14 V), HD8, -9, -10 (28 V).


Tool kit (Starter) 0 986 617 060

Tool tray

Installation tools

Socket wrench (octagon)

Pin (Ø 22 mm)

Installation device

Installation device

Slotted spring pin

Adapter

Installation tool (8 notches)



Installation sleeve

Dismantling tools

Tensioning Tool

Collet (8 notches)

Collet (9 and 10 notches)

Installation sleeve (Ø 12 mm)

Dismantling tools

Installation sleeve (Ø 10 mm)

Dismantling tools

Holding device


Tool kit (starters and generators) 0 986 617 050

Tool tray

Plate washer

Sleeve (Ø 11 mm)

Sleeve (Ø 12 mm)

Sleeve (Ø 12.5 mm)

Support legs

Centering bushing

Installation device

Installation gauge

Pin (Ø 26 mm)

Pin (Ø 20 mm)

Plate washer

Installation device

Retracting device

Pliers (Ø 12.6 mm)

Pliers (Ø 10.4 mm)

Pliers (Ø 14.3 mm)

Installation tools

Socket wrench (SW 24)

Socket wrench (SW 22)

Press tool

Dismantling tools

Repair tool kit

58

Diesel Set 1For in vehicle low-pressure measurement on all passenger cars and commercial vehicles fuel systems.

Diesel Set 2Ventilation for fuel systems with radial-piston distributor pumps and Common Rail Systems.

Diesel Set 3.1 Check pressure build-up on high-pressure pumps CP1, CP1H, CP3, CP4.1 and CP4.2 for Common Rail Systems under engine starting conditions. Rail-pressure sensor comparison test in the Common Rail System.

Diesel Set 3 add on kitIn the framework of offboard system diagnosis, the extension set allows you to carry out a rail-pressure sensor test on engines with less than four cylinders (e.g. Smart). Measurements are possible in the complete operating range of the engine.

Upgrade kit from diesel Set 3 to diesel Set 3.1Upgrading existing diesel Set 3, for testing CP4.1 and CP4.2 high pressure pumps.

Volume measuring deviceReturn flow measurement on Common Rail injectors on passenger car and commercial vehicle systems and Piezo injectors. Adapters allow connection to many injectors to the volume measuring device.

Diesel Set 1 Diesel Set 2

Common Rail System:In vehicle diagnostic test equipment


Diesel Set 2, bleed low-pressure circuit 0 986 610 234

Scope of delivery

Hand pump

Connecting piece

Adapter

Banjo bolt


Diesel Set 1, low-pressure circuit test 0 986 613 100

Scope of delivery

Storage case, empty, with foam inserts

Pressure gauge, 0 - 1600 kPa

Pressure gauge, –100 - 500 kPa

Parts set drain valve

Test pressure line Y hose, connector 90°

Test pressure line Y hose, coupling 90°






Test pressure line Y hose, Hose connector 10 mm

Test pressure line Y hose, Hose connector 8 mm

Tool set, double hollow screws

Tool set, threaded hollow screws

Tool set, threaded hollow screws

Test line for return pressure measurement (Bosch Piezo injectors)

Diagnostic tools

59

Common Rail System:In vehicle diagnostic test equipment

Diesel Set 3.1 Quantity measuring device


Upgrade kit from diesel-Set 3 to diesel Set 3.1 0 986 614 310

Diesel Set 3 extension set 0 986 612 925

Diesel Set 3.1 extension set (from FD 109) 0 986 613 925

Diesel Set 3.1 extension set 0 986 613 925


Quantity measuring device 0 986 612 950

Adapter, screw adapter (6 pieces) 0 986 613 952

Adapter, Piezo injectors 0 986 612 922

Adapter, Piezo injectors (6 pieces) 0 986 613 922

Adapter, Delphi injectors 0 986 612 902

Adapter, Delphi injectors (6 pieces) 0 986 613 902

Adapter, Denso injectors 0 986 612 923

Adapter, Denso injectors (6 pieces) 0 986 613 923

Adapter, Siemens injectors 0 986 612 906

Adapter, Siemens injectors (6 pieces) 0 986 613 906

Adapter, Bosch injectors CRI 2-18, 2-20 0 986 613 926 (straight type, 6 Adapter and 6 sealing caps)

Adapter, Bosch injectors (CRI 2-18, 2-20) 0 986 613 696 (angled type, 6 Adapter and 6 sealing caps)

Sealing parts set, return line (6 pieces) 0 986 612 900

Adapter, screw adapter 0 986 613 952

Tool set for connection 0 986 613 951 of return quantity measuring device (CRIN)

Upgrade kit from diesel Set 3 to diesel Set 3.1

Diagnostic tools

Further diagnostic tools


Coil, triggering signal for solenoid valve injectors 0 986 612 793 (passenger car / commercial vehicle)

Test device, triggering of CRI (Piezo) 0 986 610 099

Coil, triggering signal for solenoid injectors 0 986 612 745 Delphi


Diesel set 3.1, testing high-pressure circuit 0 986 614 301

Scope of delivery

Case with foam inserts

Display unit

Pipe kit

Pipe kit

Pressure transducer

Pressure pickup module

Distribution pipe

Container

Manual (CD-ROM)

60

Space and work area requirementsEPS 815

5 m

Test

EPS 815(Height 1,9 m)

7 m

0,63 m

1,1 m

0,6

m

Op

erat

ion

area

2,3

m

0,7

m

1,4

m

2 m

1,5 m

1,5 m0,81 m

1,5 m

0,5 m4

m3

m

0,7 m

400 Volt 3 phase

The ideal work bench for Diesel service (0 986 613 300)The workplace for servicing Diesel pumps and components must meet the highest requirements with regard to cleanliness, clarity and functionality, as even the smallest dirt particles can lead to malfunctions in the Diesel systems.

The area should be equipped as follows: f Floor of sealed concrete with damping at the test bench bases f Sufficient ventilation through an exhaust air system for carrying away vapors f Noise insulation is recommended f A water connection with supply and drain line or circulation cooler

0,5 m

Servicing

Circulation cooler

Cab

inet

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tion

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(Hei

ght

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m)

Wor

k b

ench

(Hei

ght

2,16

m)

KMA

61


5 m

7 m

1,1 m

0,6

m

Op

erat

ion

area

2,

1 m

0,7

m

0,7 m

0,8 m

2 m

1,5 m

1,5 m0,81 m

1,5 m

0,5 m4

m3

m

400 Volt 3 phase



Test

0,5 m

Servicing

Circulation cooler

Cab

inet

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libra

tion

nozz

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m)

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ench

(Hei

ght

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m)

EPS 708

62


5 m

Test

Servicing

7 m

1,1 m

0,6

m0,7

m

2 m

1,5 m

1,5 m0,81 m

1,5 m

0,5 m

0,5 m4

m3

m

EPS 625 PC

Op

erat

ion

area

2,3

m

1,4

m

0,7 m 0,95 m

400 Volt 3 phase



Cab

inet

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(Hei

ght

2,16

m)

Circulation cooler

EPS 625 PC

63

Technical data: EPS 815

Technical data EPS 815

L x H x W mm 2,260 x 1,588 x 860

Weight approx. kg 1,000

Drive: Special motor with full protection (thermal and overload) Clutch output, standard version Power output (duration) kW 10.2

Power output (20 min) kW 15

Power output (60 s) kW 17.5

Customer-provided in-series fuse A 35

GFC protection mA 300

Torque limiting clutch (duration) 0 to 590 rpm Nm 164

0 to 850 rpm Nm –

at 1,500 rpm Nm 65

at 2,500 rpm Nm 38

Torque limiting clutch (60 s) 0 to 590 rpm Nm 280

0 to 850 rpm Nm –

at 1,500 rpm Nm 111

at 2,500 rpm Nm 67

Speed range rpm 0 – 4,000

Speed range accuracy rpm < ± 1

Speed reaction time µs 250

Speed adjustment rate rpm / s 250

Direction of rotation: left / right Positioning accuracy (closed-loop control) <)° 0.1

Moment of inertia of graduated disk kg / m2 1.5

Axis height (clamping bed height mm 125

to injection pump axis center)

Coupling assembly Zero-backlash multiplate clutch as per ISO Nm /° 2,600

Power supply

12 / 24 V for start / stop solenoids A 7

Delivery pump capacityTest oil, low pressure kPa 0 – 600 l / min 0 – 22

Test oil, high pressure MPa 0 – 6 l / min 0 – 1.4

Lube oil pressure (special accessories) kPa 0 – 600 l / min 0 – 5.8

Pressure gauge Low pressure kPa 0 – 600

High pressure MPa 0 – 6

Vacuum / pump internal pressure kPa -100 0 250

Delivery pump pressure MPa 0 – 1.6

Lube oil pressure (special accessories) MPa 0 – 1

Heating / cooling

Test oil heating: electric approx. kW 2,2

Test oil heating: Water connection ISO 288 G1/2

Coolant consumption approx. l / min 9

Coolant temperature max. °C 17

Filling quantities Test oil approx. l 50

Reservoir for contaminated oil approx. l 6

Lube oil (special accessories) approx. l 12

Testing coloursgreen RAL 6018

Max. designed space of

measurement cell carrier

with KMA 802

Max. design spaceof monitor and keyboardwith KMA 802

max. designed space for

PC housing with KMA 802

Main connection

Water connection

min. 1500 m

m

max. 1840 m

m

987 mm

1565 mm

12 mm 1765 m

m

Supply line Return line

Water connection G1 / 2" A ISO 228-1

200

mm

200

mm

*Note:If the coolant temperature in the

supply line exceeds 17 °C, apart

from the installation of a circulation

cooler (see Special accessories) it

may be necessary to introduce

additional onsite measures. Please

consult your Bosch sales partner

before doing this.

Swing area dia. 2003 mm

Mai

ns c

onne

ctio

n

1270 mm

773 mm

656 mm

40 mm

310

mm

2937

mm

2306

mm

Fuel quantity

measuring

system

630 mm

max.

17°C*

Dimensions of the EPS 815

64

Technical data:KMA 8xx

Scope of delivery KMA 802 / KMA 822 f Fuel delivery measurement device f 19" TFT-monitor on a rotary console f Support for keyboard f Assembly and fixing parts power supply lines

f KMA 802 for assembly on the test bench incl. DVD drive

f KMA 822 with system carrier (trolley) for assembly beside the test bench

Technical data KMA 802 / KMA 822

Weight kg 68 / 100

Dimensions L x H x W mm 840 x 630 x 290 / 630 x 1,700 x 630

Speed range 0 - 5,000

Speed measurement accuracy rpm < ± 0.25% ± 1 digit

Temperature measurement °C -40 - +150 range

Temperature control range °C +30 - +60

Temperature measurement °C 40 ± 0.5; 80 ± 1.2 accuracy

Overflow quantity measurement l / h 15 - 400

Number of measurement points 12

Measurement range l / h 0.03 - 30

Max. / Min. quantity mm3 / 0.2 - 3,000 within measurement range stroke

Measurement accuracy l / h 0.03 - 0.1 < ± 3 % l / h 0.1 - 1 < ± 2 % l / h 1 - 30 < ± 1 %

Maximum permitted ambient temperature °C 40

Operating hours counter 40 years in 0.25 hour cycles

Mains voltage 230 V – 50 / 60 Hz – 3 A (present on EPS 815) 28 V – 50 / 60 Hz – 5 A 20 V – 50 / 60 Hz – 3 A

65

Technical data: EPS 708 / EPS 625


L x H x W mm 2,070 x 1,850 x 790

Weight with cooler without / with operating supplies approx. kg 850 / 920

Weight (with packaging, without operating supplies) approx. kg 950

Three-phase current – nominal voltage 400 V VAC 380 - 440

Three-phase current – nominal voltage 230 V VAC 200 - 240

Number of phase P / PE 3

Input frequency Hz 50 / 60

Rated current for 400 V A 30 (fuse 35 A gG)

Rated current for 230 V A 60 (fuse 35 A gG)

Rated output kVA 21

Customer-provided in-series fuse A 40

GFC protection mA 500

Drive:

Standstill torque (motor) Nm 23

Maximum torque (motor) Nm 61

Speed range rpm 0 - 4,000

Direction of rotation: Left / right

Axis height (clamping bed height mm 110 to injection pump axis center)

Drive coupling:

Zero-backlash multiplate clutch as per ISO Nm / ° 2,600

Supply pump output:

Test oil low-pressure kPa 500 l / min 3 - 6

Test oil high-pressure MPa 220 l / min 58

Lubrication oil pressure kPa 0 - 600 (special accessories) l / min 0 - 5,8

Pressure setting:

Rail designed for up to MPa 250

Test pressure MPa 18 - 220

Pre-supply-pump pressure kPa 10 - 500

Lube oil pressure (special accessories) kPa 100 - 600

Heating / cooling:

Test oil heating: electrical approx. kW 2,1

Test oil cooling: Water connection ISO 288 2.5 bar at G1/2"

Coolant consumption approx. °C 17

Filling volumes:

Test oil approx. l 55

Retaining capacity for contaminated oil approx. l 10

Lubrication oil (special accessories) approx. l 8

Test bench colors:

Green RAL 6018

Measuring technology:

Temperature control range °C 30 – 50

Temperature measurement accuracy °C ±0,5


Pump volume measurement l / h 0.03 - 300

Pump overflow volume measurement l / h 15 - 150

Injector volume measurement mm3/stroke 0.03 - 30

Measurement accuracy l / h 0.03 - 0.1 < ± 3% l / h 0.1 - 1 < ± 2% l / h 1 - 30 < ± 1% l / h 30 - 100 < ± 1.5% l / h 100 - 300 < ± 1%

Maximum permitted ambient temperature °C 40

Separate operating hour meter for test bench, motor and measurement cells

Scope of delivery EPS 708Test bench, monitor, mouse, computer units, mains connection lead, hydraulic hoses, software package, protective cover, 2,500 bar rail


Dimensions:

L x H x W mm 2,320 x 1,730 x 950

Weight kg 1,000 (220 V Version) 950 (415 V Version)

Drive / motor:

Voltage range V 200 - 240 Volt

V 400 - 440 Volt

Frequency Hz 50 / 60

Access control IP IP32 HMI

IP43 electrical control cabinet

Motor overload protection °C 155

Output kW 18.5

Current (at max. output) A 27

Rpm range 1 / min 50 - 4000

Efficiency % 92.4

Accuracy 1 / min + / -1 for rpm > 50 1 / min

Torque:

Rpm 0 - 1,500 1 / min Nm 115

Rpm 1,500 - 4,000 1 / min Nm 115 - 40

Test bench

Moment of inertia, graduated disk kg / m² 0.75

Axis height to EP axis center mm 125 + / - 0.1

Zero backlash clutch in accordance with ISO Nm /° 2,600

Logic Board

Stroke counter Stroke 1 - 9,999

Delivery pump capacity

Test oil low pressure kPa 0 - 350 l / min 16.5

Test oil high pressure MPa 0 - 4 l / min 1.8

66

Technical data: EPS 625 / EPS 205 / EPS 100

Lube oil pressure (special accessory) kPa 0 - 600 l / min 5.8

Test oil heating kW 2.5

Test oil cooling water connection ISO 288 G 1/2

Cooling water consumption at 17 °C l / min 15

Control range heating °C 30 - 60

Pressure gauge

Low pressure kPa 0 - 250

Intake pressure kPa 0 - 350

High pressure MPa 0 - 4

Delivery pump pressure kPa 0 - 1,600

Pneumatic pressure gauge kPa -100 - 200

Lube oil pressure (special accessory) MPa 0 - 1

Filling quantity

Test oil tank l 50

Retaining capacity for contaminated oil approx. l 10

Lube oil tank (special accessory) l 12

Min. test oil volume l 30

HMI (Human Machine Interface)

Color LCD display size inches 5.7

Rotatable HMI instrument R / L 45° on in degrees each side

Noise

Sound pressure level maximum dB-A 70

Additional power supplies

12 / 24 V for start / stop magnet A 7

Additional power supply

50 Hz AC V 230

Max. current A 3.5

Temperature range

Max. ambient temperature °C 40

Operating range °C 5 - 40

Accuracy °C 10 - 35

Storage temperature °C -25 - 60

Scope of delivery:Test bench, LCD display unit, measuring glass carrier with 12 measuring glasses 44 ml / 260 ml, measuring glass holder with light, mains connection lead


Safety information for EPS 205:The grounded, symmetrical 400 Volt three-phase power system and the 200 Volt three-phase power system must be protected by a residual current circuit-breaker with rated residual current of 30 mA. The 230 Volt basic device must be protected by a 32-ampere fuse and the 400 Volt basic device by a 16-ampere fuse.

Technical data EPS 205 / 206

Three-phase current - nominal voltage EPS 205 - 400 V VAC 380 - 460

Three-phase current - nominal voltage EPS 205 - 230 V VAC 200 - 240

Number of phases P / PE 3

Input frequency Hz 50 / 60

Rated current for EPS 205 - 400 V A 15

Rated current for EPS 205 - 230 V A 27

Rated output kW 4,2

Compressed air MPa 0,5 - 0,8

Operating temperature °C 0 - 40

Degree of protection - IP 34

Oil pressure MPa 180

Maximum speed rpm 3,500

Control voltage VDC 24

Capacity of testing oil tank l 7

Noise emission dB(A) < 71,5 Workplace-related emission soundpressure level as per DIN EN ISO 11201

Sound power level as per DIN EN ISO 3744 dB(A) < 84,1

EPS 205 (H x W x D) mm 580 x 560 x 780

Weight of EPS 205 / 206 with packaging kg 253 /245

Weight of EPS 205 / 206 kg 138 / 134 (without testing oil and packaging)

Oil catcher pan (H x W x D) mm 30 x 570 x 720


For nozzle sizes - P, R, S, T

Pressure gauge bar 0 - 400

Pressure gauge MPa 0 - 40

Connecting thread for test pressure line - M 14 x 1,5

Weight kg 4

67

Product offer sheet:EPS 815

Item Designation Order number Price excl. VAT

Test benches

1 Injector component test benches – without measuring system

Please choose a test bench:

1.1a EPS 815 400 Volt 0 683 815 001

1.1b EPS 815 200 / 220 / 230 / 240 Volt 0 683 815 002

1.1c EPS 815 440 / 460 / 480 / 500 Volt 0 683 815 003

Test sets (for mechanical and electronic systems)

2 Test sets for conventional systems (mechanical inline fuel injectionpumps, distributor injection pumps)

2.1 Basic set 1 687 005 018

2.1.1 A-pump set 1 687 005 019

2.1.2 P-pump set 1 687 005 021

2.1.3 VE set 1 687 005 022

2.1.4 M-MW set 1 687 005 020

2.1.5 H-pump set 1 687 005 023

2.2 EDC-VE EPS 865 0 684 200 615

2.2.1 Special accessories for EDC-VE ballast unit, required for testing EDC-VE pumps with HDK sensors 1 687 022 281

3 Test sets for VP systems (VP 29, VP 30, VP 44)

3.1 VPM 844 test set (VP 29 / 30 / 44), only for EPS 815 from production date 01/2001. When testing VP 29 / 30 / 44, maximum cooling water temperature allowed is 17 °C 1 687 002 844

3.2 Retrofit kit CR / UI / UP / VPM for PC 1 687 023 692: included in scope of supply: CAN plug-in card 1 688 400 305, SVTW plug-in card 1 688 400 292, ISO communications module 1 687 023 524 1 687 001 949

3.3 Test pressure line L= 350 mm (Ford / Rover VP 29 / 30) 1 680 750 100

3.4 Test pressure line L= 450 mm (Audi / BMW / Ford / Nissan / Opel VP 44) 1 680 750 101

3.5 Test pressure line L= 845 mm (Cummins / John Deere / MAN / Nissan / VM Motori / Volvo VP 44) 1 680 750 102

3.6 Test pressure line L= 450 mm (Opel VP 29 / SISU / Perkins VP 30) 1 680 750 103

3.7 Calibration nozzle holder combination type IX pass. veh. / comm. veh. (d= 0.5), qty. 6 recommended, used with: VPM 844 (VP 44) 1 688 901 116

3.8 Calibration nozzle holder combination type X pass. veh. (d= 0.4), qty. 6 recommended, used with: VPM 844 (VP 44) 1 688 901 118

3.9 Calibration nozzle holder combination type X comm. veh. (d= 0.5), qty. 6 recommended, used with: VPM 844 (VP 44) 1 688 901 119

3.10 Calibration nozzle holder combination type X comm. veh. (d=0.53 mm), qty. 6 recommended, used with VPM 844 (VP 44) and CAM 847 (UP, PLD) 1 688 901 120

3.11 Bench stand Audi, qty. 2 required (only VP 44) 1 688 030 186

3.12 Cable clip set 1 680 190 018

3.13 Support device KDEP 1140, required if VE pump test set 1 687 005 022 not already present 0 986 611 876

3.14 Fixture adapter for PDHK type X Caution! 6 x 0 986 612 269 required 0 986 612 269

4 Test sets for UI / UP systems (UI-P, UI-N, UP)

Please choose between complete package (item 4.1a) and individual package (item 4.1b):

4.1a CAM 847 complete package incl. 12 adaptions for testing UI-P, UI-N and UP from Bosch. Only for EPS 815 from production date 01/2001 1 687 001 847

4.1b CAM 847 Individual package Cambox without adapter sets. Only for EPS 815 from production date 01/2001 1 687 001 849

4.1b.1 UI pass. veh. adapter set, comprising 2 adapters for testing Bosch UI pass. veh. 1 687 016 051

4.1b.2 UI comm. veh. adapter set, comprising 6 adapters for testing Bosch UI comm. veh. 1 687 016 052

4.1b.3 UP adapter set, comprising 4 adapters for testing Bosch UP 1 687 016 053

4.1b.4 DHK mounting, required for testing UP components 1 687 016 049

4.1b.5 Injection chamber, required for testing UI components 1 682 312 044

68



4.2 Precision constant voltage regulator (included in retrofit kit VPM 844), required for CRI 846 H, CRI / CRIN 848 H and CAM 847 1 687 022 873

4.3 Test DHK, required for CAM 847 if VPM 844 not present 1 688 901 119

4.4 Test DHK, required for CAM 847 if test DHK 1 688 901 034 + nozzle-retaining nut 1 683 373 081 not present 1 688 901 120

5 Test sets for CP Common Rail pumps

5.1 CRS 845 H basis test set for CR components (CP, CRI and CRIN) 1 687 002 845

5.1.1 Update set from 1, 600 bar to 1,800 bar, required for existing CRS 845 with production date before 05 / 2006 1 687 001 612

5.1.2 Update set CRS 845 H, required for upgrading CRS 845 (1,800 bar) 1 687 001 845 to CRS 845 H (2,500 bar) 1 687 002 845 1 687 010 334

5.1.3 CP1 / CP1H pump set 1 687 010 341

5.1.4 CP2 pump set 1 687 010 342

5.1.4.1 Printed board to test CP2, required for existing CRS 845 with production date before 04 / 2004 1 688 400 320

5.1.5 CP3 pump set Note: For CP3.3 / CP3.4 lube oil supply required (included 1 687 016 061) 1 687 010 182

5.1.5.1 Update set CP3.4 return connection for CP3.4 pumps for customers with "old" CP3 set 1 687 010 135. 1 687 010 135 + 1 687 016 061 = 1 687 010 182 1 687 016 061

5.1.5.2 Supplement set MAN CP3.4 for CP3.4 MAN applications (CP3 or CP1 / CP3 pump set is prerequisite) 1 687 001 619

5.1.6 CP4 pump set. Note: Testing with CP4 pump set requires CRS 845 H or upgradingwith 1 687 010 334 1 687 010 490

5.1.7 CB18 pump set. Note: Testing possible with CRS 845 and CRS 845 H 1 687 010 402

5.1.8 CB28 pump set 1 687 010 496

5.1.9 CP Delphi / Denso / Siemens (other brand pump set), successor kit for 1 687 010 161 / ...162 / ...166 1 687 010 183

5.1.9.1 Update set CP Delphi / Denso / Siemens (other brand pump set) with new adapters for other brand CP pumps for customers with "old" other brand CP pump sets 1 687 010 161 / ...162 / ...166. 1 687 010 161 / ...162 / ...166 + 1 687 010 184 = 1 687 010 183 1 687 010 184

5.1.10 Test sets for CR injectors (CRI1, CRI2.x, CRIN1, CRIN2 and CRIN3 from Bosch)

Please choose between CRI 846 H (item 5.1.10a) and CRI / CRIN 848 H (item 5.1.10b):

5.1.10a CRI 846 H test set For testing Bosch CRI (solenoid valve) passenger car + basis set for CRI Piezo, other brand and commercial vehicle (CRS 845 or CRS 845 H is prerequisite). When commissioning, a calibration of the rail pressure sensor is required 1 687 002 846

5.1.10a.1 Adapter set for testing CRI 2-18, CRI 2-20 (CRI 2.5) Set comprising 6 adapter lines 1 683 351 066 1 687 010 494

5.1.10a.2 Update set for swivel device (for adaption of Common Rail injectors), required for existing CRI 846 with production date before 06 / 2006 1 688 120 174

5.1.10a.3 Update set CRI 846 H, required for upgrading CRI 846 (1,800 bar) 1 687 001 846 to CRI 846 H (2,500 bar) 1 687 002 846 1 687 010 335

5.1.10a.4 Adapter (thread adaptation and restricts system to 1,800 bar), required if set combination CRS 845 (1,800 bar) and CRI 846 H (2,500 bar) or CRS 845 H (2,500 bar) and CRI 846 (1,800 bar) are used 1 681 032 094

5.1.10a.5 CRIN test set Only required if customer chooses not to opt for CRI / CRIN 848 H (item 5.1.10b). For Bosch commercial vehicle injectors generation CRI 846 or CRI 846 H required: for 1x CRIN clamp: 1x CRIN set 1 687 001 925, for 2x CRIN clamps: 2x CRIN sets 1 687 001 925 + 1x adapter line 1 684 463 711 1 687 001 925

5.1.10a.5.1 Adapter line, required if customer clamps 2x CRIN set 1 687 001 925 1 684 463 711

5.1.10a.5.2 Update set return line CRIN (extended return line), required for "old" CRIN set 1 687 001 599. 1 687 001 599 + 1 687 016 060 + 1 687 016 062 = 1 687 001 623 1 687 016 060

69


5.1.10b CRI / CRIN 848 H test set Suitable for the testing of 6 Bosch CRI passenger car injectors, 6 CRI Piezo injectors and 4 Bosch CRIN commercial vehicle injectors with additional basis set for CRI Piezo. (CRS 845 H is required) 1 687 002 848

5.1.10b.1 Update set of CRI 846 H to CRI / CRIN 848 H for a test expansion from up to 4 CRIN, includes no distribution rail 2,500 bar, for upgrading CRI 846 H (2,500 bar) 1 687 002 846 to CRI / CRIN 848 H. (CRS 845 H is prerequisite) 1 687 010 368

5.1.10b.2 Adapters and cover plates for CRI / CRIN 848 H (1 687 001 934, 1 687 002 848, 1 687 010 349 and 1 687 010 368)

5.1.10b.2.1 Adapter set - A1i 1 687 016 072

5.1.10b.2.2 Adapter set - A2i (Valtra Tractors, SISU Motors) 1 687 016 081

5.1.10b.2.3 Adapter set - A3i (Iveco, New Holland, Cummins, CDC, Dongfeng, MAN, Dodge, KamAZ, VW, Ford) 1 687 016 111

5.1.10b.2.4 Adapter set - A4i (Renault, MAN, Dongfeng, MAZ, LiaZ, MZKT, Tonar, Ural, YamZ) 1 687 016 082

5.1.10b.2.5 Adapter set - A5i (MAN, Liebherr) 1 687 016 099

5.1.10b.2.6 Adapter set - A6i (MAN) 1 687 016 083

5.1.10b.2.7 Adapter set - A7i (Ford Otosan Türky) 1 687 016 084

5.1.10b.2.8 Adapter set - A8i (DHIM, Yuchai, Doosan) 1 687 016 085

5.1.10b.2.9 Adapter set - A9i (Deutz, MAZ, YaMZ) 1 687 016 086

5.1.10b.2.10 Adapter set - A10i (FAW) 1 687 016 087

5.1.10b.2.11 Adapter set - A11i (DCD, Dongfeng) 1 687 016 088

5.1.10b.2.12 Adapter set - A12i (MAZ, YaMZ, Ashok Leyland) 1 687 016 089

5.1.10b.2.13 Adapter set - A13i (Renault, Fendt, Deutz, FAW, Volvo, Weihai, Yuchai, Foton) 1 687 016 090

5.1.10b.2.14 Adapter set - A14i (MAN, International Harvester, Shanqi, Foton, CNHTC, Weichai, Liebherr, MTU) 1 687 016 091

5.1.10b.2.15 Adapter set - A15i (Shanqi, Foton, CNHTC, Weichai) 1 687 016 092

5.1.10b.2.16 Adapter set - A16i (DHIM, Yuchai, Doosan) 1 687 016 093

5.1.10b.2.17 Adapter set - A1e (Deutz) 1 687 016 094

5.1.10b.2.18 Adapter set - A3e (Iveco, New Holland) 1 687 016 096

5.1.10b.2.19 Adapter set - A4e (Mitsubishi Fuso) 1 687 016 097

5.1.10b.2.20 Cover plate set - K1 (Fiat, Iveco, Volvo, Deutz) 1 687 016 101

5.1.10b.2.21 Cover plate set - K2 (Valtra Tractors, SISU Motors, FAW, Ashok Leyland, Northbenz, Weichai, GAZ, PAZ, MAz, MTZ, MMZ, Yuchai, Shanqi, Foton, CNHTC, Amur, KayZ, MFDPL) 1 687 016 102

5.1.10b.2.22 Cover plate set - K3 (Fiat, Iveco, Renault, Peugeot, Citroen, VW, Marcopolo, Agrale, MWM, Weichai, Volvo) 1 687 016 103

5.1.10b.2.23 Cover plate set - K4 (Chevrolet, General Motors, Valtra Tractors, SISU Motors, GMC, KamAZ) 1 687 016 104

5.1.10b.2.24 Cover plate set - K3i (Iveco, Cummins, VW, Ford, Case New Holland) 1 687 016 110

5.1.10b.2.25 Cover plate set - K5 (Renault, MAN, Dongfeng) 1 687 016 105

5.1.10b.2.26 Cover plate set - K6 (Ford Otosa-Türky, DHIM, Renault, Deutz, Fendt, FAW, Yuchai, Shanqi, Foton, CNHTC, Weichai, Dongfeng DCD, Volvo, Doosan, MAZ, NAV-INTL, YamZ, Ashok Leyland, DHTM) 1 687 016 106

5.1.10b.2.27 Cover plate set - K7 (MAN, Dongfeng, International Harvester, Liebherr, MAZ, LiaZ, MZKT, Tonar, Ural, YamZ, Shanqi, Foton, CNHTC, MTU) 1 687 016 107

5.1.10b.2.28 Cover plate set - K8 (Mitsubishi Fuso, Iveco, Case New Holland) 1 687 016 108

5.1.10b.2.29 Cover plate set - K1i 1 687 016 073

5.1.10b.2.30 Cover plate set - K11 (Mazda) Japan CRI 1 687 016 115

5.1.10b.2.31 Cover plate set - K12 (Iveco, Cummins, Case New Holland, VW/Ford Brasil) 1 687 016 117

5.1.10b.3 Retrofit kit with 6 rotatable connections, which are used for injection volume measurements and an intermediate plate on the distributor rail for travel path increase (only for CRI / CRIN 848 H 1 687 001 934 or 1 687 010 349). Already included in CRI / CRIN 848 H 1 687 002 848 or 1 687 010 368 1 687 016 112

5.1.10b.4 Retrofit kit: 6 holding bodies with lowered spring chamber and cover plate guide with beveled surface (only for 1 687 001 934 or 1 687 010 349). Already included in CRI / CRIN 848 H 1 687 002 848 or 1 687 010 368 1 687 016 113

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5.1.11 Test sets that can be used on CRI 846 H (item 5.1.10a) or on CRI / CRIN 848 H (item 5.1.10b)

5.1.11.a Adapter set for testing CRI 2-18, CRI 2-20 (CRI 2.5) Set comprising 6 adapter lines 1 683 351 066 1 687 010 494

5.1.11.1 CRI Delphi / Denso set for passenger car injectors, will be delivered without injection chamber 1 687 010 186

5.1.11.1.1 Update set CRI Delphi / Denso with hose lines and software (above 1 Ohm testing), required for "old" CRI Delphi / Denso 1 687 001 609. 1 687 001 609 + 1 687 010 187 = 1 687 010 186 1 687 010 187

5.1.11.2 Piezo CRI (for piezo CRI from Bosch, Siemens and Denso) 1 687 010 333

5.1.11.2.1 Hose lines (6 pc.) required for CRI Piezo test set (Denso injectors), if CRI Delphi / Denso set 1 687 001 609 is present 1 687 016 055

5.1.11.2.2 Update set piezo CRI before 05 / 2012 1 680 290 999

5.1.12 Accessories for Delphi / Denso CRI (item 5.1.11.1) and piezo CRI (item 5.1.11.2)

5.1.12.1 Injection chamber (OLD), order 6 pc., please use these injection chambers as long as the new injection chamber set 1 685 438 631 is not available or instruct your customers that SOL will be in Dec., 2010 1 682 312 042

5.1.12.2 Injection chamber set (NEW), (scope of delivery 6 pc.), required for test set CRI Piezo (Denso / Siemens injectors) and CRI Delphi / Denso (solenoid valve). Not required, if CRI / CRIN 848 H present. Required, if CRI Delphi / Denso set 1 687 001 609 or 1 687 010 186 (with production date before 12 / 2010) not present 1 685 438 631

5.1.12.3 Test pressure line set 1,800 bar (6 pc.), to be used only with CRI 846 (1,800 bar), required for test sets CRI Piezo (Bosch injectors) and CRI Delphi / Denso (solenoid valve). Scope of delivery: 6 pc. test pressure line 180° M14 x1.5 to M14 x1.5 1 687 010 185

5.1.12.4 Test pressure line set 2,500 bar (6 pc.), only to be used with CRI 846 H (2,500 bar) or CRI / CRIN 848 H. Required for test sets CRI Piezo (Bosch injectors) and CRI Delphi / Denso (solenoid valve). Scope of delivery: 6 pc. test pressure lines 180° M16x1.5 to M14x1.5 1 687 016 065

6 Accessories for Common Rail test sets (under item 5)

6.1 High pressure hose 2,500 bar, length: 1,000 mm, usable for: CP1, CP2, CP3, CP1 / CP3, CP Delphi / Denso / Siemens, CRI 846 H, CRI / CRIN 848 H. Caution! If CP2 is used: 2 x 1 687 016 064. Scope of delivery: High pressure hose M16x1.5 to M16 / M14 / M12x1.5, Adapter curved M16x1.5 to M12x1.5, Nuts 1 687 016 064

6.2 High pressure hose 2,500 bar, length: 750 mm, required for: CRI / CRIN 848 H, CRIN test set Caution! If CRI / CRIN 848 H is used: 4 x 1 687 016 070, if 1 CRIN test set is used: 1 x 1 687 016 070, if 2 CRIN test sets are used: 2 x 1 687 016 070. Scope of delivery: High pressure hose M16x1.5 to M16 / M14 / M12x1.5, Adapter curved M16x1.5 to M12x1.5, Nuts 1 687 016 070

6.3 High pressure hose 1,800 bar, length: 1,000 mm, usable for: CP with screw adaption M14 - straight, required if up to 1,800 bar will be tested and the hose set 2,500 bar 1 687 016 064 is not present. Scope of delivery: Hose line M14x1.5 to M14x1.5 - straight 1 680 712 227

6.4 High pressure hose 1,800 bar, length: 1,000 mm, usable for: CP, CRIN test set with screw adaption M12 - straight, required if up to 1,800 tested and the hose set 2,500 bar 1 687 016 064 is not present. If 1 CRIN test set is used: 1 x 1 687 016 070, If 2 CRIN test sets are used: 2 x 1 687 016 070. Scope of delivery: High pressure line M14x1.5 to M12x1.5 - straight 1 680 712 229

6.5 High pressure hose 1,800 bar, length: 1,000 mm, usable for: CP with screw adaption M12 - 90°, required if tested up to 1,800 bar and the hose set 2,500 bar 1 687 016 064 is not present. Scope of delivery: High pressure line M14x1.5 to M12x1.5 - 90° 1 680 712 230

71


6.6 Adapter, application for pumps and CRIN adaption. Hose side M12 -> M14 pump or CRIN, optional on offer if no hose M14 / M14 1,800 bar is present. Scope of delivery: Adapter M12x1.5 to M14x1.5 1 681 032 077

Accessories for test benches

7 Accessories for test benches

7.1 Drive coupling without play, required for CRS 845 H and CAM 847 1 686 401 024

7.1.1 Intermediate flange, required for CRS 845 H and CAM 847 1 685 700 140

7.2 Clamping bracket, required for all VE, VR, CR pumps 1 688 010 129

7.3 Riser retrofit kit, required for KMA with production date before 04/2001 1 687 001 544

Please choose a transformer 400-500 V or transformer 200-240 V (item.7.4a and item 7.4b):

7.4a Transformer conversion kit 400-500 V / EPS 815, required for VPM 844, CRI 846 H, CRI / CRIN 848 H only for EPS 815 with production date before 07/2005 1 687 001 800

7.4b Transformer conversion kit 200-240 V / EPS 815, required for VPM 844, CRI 846 H, CRI / CRIN 848 H only for EPS 815 with production date before 07/2005 1 687 001 801

7.5 Lube oil supply retrofit kit voltage 200 to 500 Volt. Note: for CP2 / CP3.4 pumps, CAM 847 required 1 687 001 977

7.5.1 Lube oil supply conversion kit 1 687 001 362, if filter is mounted in the suction side. Note: Required for upgrade of lube oil supply to 1 687 001 977, if CAM 847 is used 1 687 001 910

7.5.2 Lube oil supply conversion kit 1 687 001 362, if filter is mounted in the return. Note: Required for upgrading the lube oil supply to 1 687 001 977, if CAM 847 is used 1 687 001 979

7.6 Heat exchanger, required for CRS 845 H, VPM 844 and CAM 847 1 687 010 336

7.6.1 Update set heat exchanger (2,500 bar), required for update set CRS 845 H (1 687 010 334). 1 687 010 130 + 1 687 010 337 = 1 687 010 336 1 687 010 337

7.6.2 Heat exchanger supplement to 12 channel, required for testing CR pumps with delivery capacity > 160 l / h 1 687 001 557

7.7 Precision constant voltage regulator (included in retrofit kit VPM 844), required for CRI 846 H, CRI / CRIN 848 H and CAM 847 1 687 022 873

7.7.1 Assembly set, required when purchasing precision constant voltage regulator (1 687 022 873) 1 687 016 043

7.8 CRI 800 (CRI 846 control unit), required for CAM 847 if CRI 846 not present 1 687 023 369

7.9 Speed sensor, required for CAM 847 if VPM 844 not present 1 687 224 963

7.10 Connection line for speed sensor, required for CAM 847 if VPM 844 not present 1 684 465 499

7.11 EMV kit, required for CAM 847 if VPM 844 not present 1 687 016 042

7.12 Temperature sensor, required for CAM 847 if CRI 846, CRI 846 H or CRI / CRIN 848 H not present 1 687 016 033

8 Test instrument

8.1a KMA – Continuous measuring systems

Please choose as follows between KMA 802 (item 8.1a.1) or KMA 822 (item 8.1a.2):

8.1a.1 KMA 802 continuous measuring system, 19" TFT display unit for assembly on test bench, required for VPM 844, CRS 845 H, CAM 847 0 683 802 001

8.1a.2 KMA 822 continuous measuring system, 19" TFT display unit for assembly incl. trolley required for VPM 844, CRS 845 H, CAM 847 0 683 822 001

9 Computer unit (essential for KMA)

9.1.1 Desktop for EPS 815 Celeron G540 2 x 2,5 GHz, HD 500 GB, CD- / DVD-burner, 4 GB DDR-REM, 10 x USB 2.0 and 2 x USB 3.0, WIN7 Ultimate 64 bit without keyboard. Required for KMA 8xx, CAM 847, CRS 845 H and VPM 844 1 687 023 692

9.1.2 Retrofit kit CR / UI / UP / VPM for PC 1 687 023 692: included in scope of delivery: CAN plug-in card 1 688 400 305, SVTW plug-in card 1 688 400 292, ISO communications module 1 687 001 949

9.1.3 Interface module VPM 844-ISO, required, if printed board V 25-ISO 1 688 400 304 defective in "old" computer 1 687 022 959 or interface module defective in computer 1 687 023 582 1 687 023 524

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9.2 Keyboard

Please choose suitable keyboard:

9.2.a ASCII keyboard (German) 1 687 023 710

9.2.b ASCII keyboard (US) 1 687 023 712

9.2.c ASCII keyboard (French) 1 687 023 716

9.2.d ASCII keyboard (Spanish) 1 687 023 714

9.2.e ASCII keyboard (Italian) 1 687 023 717

9.2.f ASCII keyboard (Danish) 1 687 023 715

9.2.h ASCII keyboard (Finnish / Swedish) 1 687 023 719

9.2.i ASCII keyboard (Greek) 1 687 022 392

9.2.j ASCII keyboard (Turkish) 1 687 022 378

9.2.k ASCII keyboard (Polish) 1 687 023 721

9.2.l ASCII keyboard (UK) 1 687 023 713

9.2.m ASCII keyboard (Czech) 1 687 023 720

9.3 Printer

9.3.1 Inkjet printer PDR 375 inc. USB connecting line 1 687 001 850

10 Software (database of test specifications, ESI)

10.1 CD ESI[tronic]-A 1 987 P12 410

10.2 CD ESI[tronic]-D 1 987 P12 455

10.3 CD ESI[tronic]-K1 1 987 P12 475

10.4 CD ESI[tronic]-W 1 987 P12 500

10.5 CD TestData – update subscription required for VPM 844, CRS 845 H or CAM 847 1 687 P15 015

11 Maintenance tools

11.1 Dial gauge, service dept. calibration tool for CAM 847 1 687 233 112

12 Service

12.1 User training

12.2 Freight, packaging disposal

12.3 Installation, initial operation, instruction, training courses

12.4 Travel flat rate

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Test benches

1 Test benches for CR pumps and CR injectors incl. measuring system

Please choose a test bench:

1.1 Test benches – incl. integrated cooling system

1.1a EPS 708 400 Volt 0 683 708 020

1.1b EPS 708 200 / 220 / 230 / 240 Volt 0 683 708 021

1.2 Test benches – without internal cooling system (external water connection)

1.2a EPS 708 400 Volt 0 683 708 001

1.2b EPS 708 200 / 220 / 230 / 240 Volt 0 683 708 002

Test sets (for Common Rail system, CRS 845 H included in items supplied with EPS 708)

2.1 Test sets for CRS = Common Rail system (CP, CPN, CRI, CRIN)

2.1.1 Clamping bracket (required for all VE, VR, CR pumps) 1 688 010 129

2.1.2 CP1 / CP1H / CP3 pump set Note: For CP3.3 / CP3.4, lube oil supply required, present CP1 or CP3 set is also usable on EPS 708 1 687 010 346

2.1.3 Update set CP3.4 Return connection for CP3.4 pumps for customers with "old" CP3 set 1 687 010 135. 1 687 010 135 + 1 687 016 061 = 1 687 010 182 1 687 016 061

2.1.3.1 Supplement set MAN CP3.4 for CP 3.4 MAN applications (CP3 or CP1 / CP3 pump set is prerequisite) 1 687 001 619

2.1.4 CP4 Pump set 1 687 010 390

2.1.5 CB18 Pump set 1 687 010 402

2.1.6 Lube oil supply 1 687 001 931

2.1.7 CP Delphi / Denso / Siemens (External pump set) Downstream set for 1 687 010 161 / ...162 / ...166. 1 687 010 183

2.1.7.1 Upgrade set for CP Delphi / Denso / Siemens if xxx 161 / ... 162 / ... 166 is available 1 687 010 184

2.1.8 For testing CP external pumps please additionally order the drive coupling as noted in delivery scope EPS 815 1 686 401 026

2.1.8.1 High pressure pipe 250 MPa (2,500 bar), Length 1,000 mm, for use with Pump set CP1, CP3, CP1 / CP1 / CP3, CP4, CP-Delphi / Denso / Siemens, CRI 846 H and CRI / CRIN 848 H 1 687 016 064

2.2 Test sets for CR injectors (CRI and CRIN from Bosch and other brands)

Please choose between CRI 846 H (item 2.2.1a) and CRI / CRIN 848 H (item 2.2.1b):

2.2.1a CRI 846 H test set For testing Bosch CRI (solenoid valve) passenger car + basis set for CRI Piezo, other brand and commercial vehicle (CRS 845 H is prerequisite). For commissioning, a calibration of the rail pressure sensor is required 1 687 002 846

2.2.1a.1 Adapter set for testing CRI 2-18, CRI 2-20 (CRI 2.5) Set comprising 6 adapter lines 1 683 351 066 1 687 010 494

2.2.1a.2 CRIN test set Only required if customer does not choose CRI / CRIN 848 H (item 2.2.1b). For Bosch commercial vehicle injectors generation CRI 846 or CRI 846 H is required: for 1x CRIN clamp: 1x CRIN set 1 687 001 925, for 2x CRIN clamps: 2x CRIN sets 1 687 001 925 + 1x adapter line 1 684 463 711 1 687 001 925

2.2.1a.3 Holding bracket for CRIN return volume measurement on EPS 708 (holding bracket essential for CRIN 1 687 001 925) 1 687 016 080

2.2.1a.4 Adapter line, required if customer clamps 2x CRIN set 1 687 001 925 1 684 463 711

2.2.1a.5 High pressure hose 250 MPa (2,500 bar), length 750 mm, required for CRIN test set for CRI 846 H and CRI / CRIN 848 H. Caution! If a CRIN test set 1 687 001 925 is used: 1 x 1 687 016 070 two CRIN test sets are used: 2 x 1 687 016 070 1 687 016 070

2.2.1b CRI / CRIN 848 H test set for testing Bosch CRI (solenoid valve) passenger car, Bosch commercial vehicle injectors + basis set for CRI Piezo (CRS 845 H is prerequisite) 1 687 002 848

2.2.1b.1 Adapter set for testing CRI 2-18, CRI 2-20 (CRI 2.5) Set comprising 6 adapter lines 1 683 351 066 1 687 010 494

74



2.2.1b.2 Update set from CRI 846 H to CRI / CRIN 848 H for a test expansion from up to 4 CRIN, does not include distributor rail 2,500 bar for upgrading from CRI 846 H (2,500 bar) 1 687 002 846 to CRI / CRIN 848 H (CRS 845 H is prerequisite) 1 687 010 368

2.2.1b.3 Retrofit kit: 6 rotatable connectors, to be used for injector volume measurements and Intermediate plate on distributor rail for travel path increase (only for CRI / CRIN 848 H 1 687 001 934 or 1 687 010 349) already included in CRI / CRIN 1 687 002 848 or 1 687 010 368. 1 687 016 112

2.2.1b.4 Retrofit kit: 6 holding bodies with lowered spring chamber and cover plate guide with beveled surface (only for CRI / CRIN 848 H 1 687 001 934, already included in CRI / CRIN 848 H 1 687 002 848) 1 687 016 113

2.2.1b.5 High pressure hose 250 MPa (2,500 bar), length: 750 mm, required for CRIN test set for CRI 846 H and CRI / CRIN 848 H. Caution! If 1 CRIN test set 1 687 001 925 is used: 1 x 1 687 016 070 if 2 CRIN test sets are used: 2 x 1 687 016 070 1 687 016 070

2.2.2 Adapters and cover plates for CRI / CRIN 848 H (1 687 001 934, 1 687 002 848, 1 687 010 349, 1 687 010 368).

2.2.2.1 Adapter set - A1i 1 687 016 072

2.2.2.2 Adapter set - A2i (Valtra Tractors, SISU Motors) 1 687 016 081

2.2.2.3 Adapter set - A3i (Iveco, New Holland, Cummins, CDC, Dongfeng, MAN, Dodge, KamAZ, KaVZ, VW, Ford) 1 687 016 111

2.2.2.4 Adapter set - A4i (Renault, MAN, Dongfeng, MAZ, LiaZ, MZKT, Tonar, Ural, YamZ) 1 687 016 082

2.2.2.5 Adapter set - A5i (MAN, Liebherr) 1 687 016 099

2.2.2.6 Adapter set - A6i (MAN) 1 687 016 083

2.2.2.7 Adapter set - A7i (Ford Otosan Türky) 1 687 016 084

2.2.2.8 Adapter set - A8i (DHIM, Yuchai, Doosan) 1 687 016 085

2.2.2.9 Adapter set - A9i (Deutz, MAZ, YaMZ) 1 687 016 086

2.2.2.10 Adapter set - A10i (FAW) 1 687 016 087

2.2.2.11 Adapter set - A11i (DCD, Dongfeng) 1 687 016 088

2.2.2.12 Adapter set - A12i (MAZ, YaMZ, Ashok Leyland) 1 687 016 089

2.2.2.13 Adapter set - A13i (Renault, Fendt, Deutz, FAW, Volvo, Weihai, Yuchai, Foton) 1 687 016 090

2.2.2.14 Adapter set - A14i (MAN, International Harvester, Shanqi, Foton, CNHTC, Weichai, Liebherr, MTU) 1 687 016 091

2.2.2.15 Adapter set - A15i (Shanqi, Foton, CNHTC, Weichai) 1 687 016 092

2.2.2.16 Adapter set - A16i (DHIM, Yuchai, Doosan) 1 687 016 093

2.2.2.17 Adapter set - A1e (Deutz) 1 687 016 094

2.2.2.18 Adapter set - A3e (Iveco, New Holland) 1 687 016 096

2.2.2.19 Adapter set - A4e (Mitsubishi Fuso) 1 687 016 097

2.2.2.20 Cover plate set - K1 (Fiat, Iveco, Volvo, Deutz) 1 687 016 101

2.2.2.21 Cover plate set - K2 (Valtra Tractors, SISU Motors, FAW, Ashok Leyland, Northbenz, Weichai, GAZ, PAZ, MAZ, MTZ, MMZ, Yuchai, Sanqi, Foton, CNHTC, Amur, KayZ, MFDPL) 1 687 016 102

2.2.2.22 Cover plate set - K3 (Fiat, Iveco, Renault, Peugeot, Citroen, VW, Marcopolo, Agrale, MWM, Weichai, Volvo) 1 687 016 103

2.2.2.23 Cover plate set - K3i (Iveco, Cummins, VW, Ford, Case New Holland) 1 687 016 110

2.2.2.24 Cover plate set - K4 (Chevrolet, General Motors, Valtra Tractors, SISU Motors, GMC, KamAZ) 1 687 016 104

2.2.2.25 Cover plate set - K5 (Renault, MAN, Dongfeng) 1 687 016 105

2.2.2.26 Cover plate set - K6 (Ford Otosan-Türky, DHIM, Renault, Deutz, Fendt, FAW, Yuchai, Shanqi, Foton, CNHTC, Weichai, Dongfeng DCD, Volvo, Doosan, MAZ, NAV-INTL, YamZ, Ashok Leyland, DHTM) 1 687 016 106

2.2.2.27 Cover plate set - K7 (MAN, Dongfeng, International Harvester, Liebherr, MAZ, LiaZ, MZKT, Tonar, Ural, YamZ, Shanqi, Foton, CNHTC, MTU) 1 687 016 107

2.2.2.28 Cover plate set - K8 (Mitsubishi Fuso, Iveco, Case New Holland) 1 687 016 073

2.2.2.29 Cover plate set - K1i 1 687 016 073

2.2.2.30 Cover plate set - K11 (Mazda) Japan CRI 1 687 016 115

2.2.2.31 Cover plate set - K12 (Iveco, Cummins, Case New Holland, VW/Ford Brasil) 1 687 016 117

75


2.2.3 Test sets that can be used on CRI 846 H (item 2.2.1a) or on CRI / CRIN 848 H (item 2.2.1b)

2.2.3.1 CRI Delphi / Denso for passenger car (supplied without Injection chamber) 1 687 010 186

2.2.3.1a Adapter pipe K: to test CRI3 injectors with FSA 050 „Bosch socket“ 1 687 463 849

2.2.3.1a Adapter pipe AK: to test CRI3 injectors with FSA 050 „Kostal socket“ 1 687 463 850

2.2.3.1.1 Update set CRI Delphi / Denso with hose lines and software (over 1 Ohm test), required for "old" CRI Delphi / Denso 1 687 001 609. 1 687 001 609 + 1 687 010 187 = 1 687 010 186 1 687 010 187

2.2.3.2 CRI Piezo (for piezo CRI from Bosch, Siemens and Denso) 1 687 010 333

2.2.3.2.1 Hose line 6 pcs.) required for CRI Piezo test set (Denso injectors), if CRI Delphi / Denso set 1 687 001 609 is present. 1 687 016 055

2.2.4 Accessories for Delphi / Denso CRI (item 2.2.3.1) and CR Piezo (item 2.2.3.2)

2.2.4.1 Injection chamber set (NEW) (6 pcs. included in items supplied), required for the test set CRI Piezo (Denso / Siemens injectors) and CRI Delphi / Denso (solenoid valve). Not required if CRI / CRIN 848 H is present. Required if CRI Delphi / Denso set 1 687 001 609 or 1 687 010 186 (with production date before 12 / 2010) not already present 1 685 438 631

2.2.4.2 Test pressure line set 2,500 bar (6 pcs.) can only be used with CRI 846 H (2,500 bar) or CRI / CRIN 848 H. Required for test sets CRI Piezo (Bosch injectors) and CRI Delphi / Denso (solenoid valve). Scope of delivery: 6x test pressure lines 180° M16x1.5 to M14x1.5 1 687 016 065

Accessories for test benches


3.1 Computer unit (computer included in items supplied with EPS 708)

3.2 Keyboard

Please choose suitable keyboard:

3.2a ASCII keyboard (German) 1 687 023 710

3.2b ASCII keyboard (US) 1 687 023 712

3.2c ASCII keyboard (French) 1 687 023 716

3.2d ASCII keyboard (Spanish) 1 687 023 714

3.2e ASCII keyboard (Italian) 1 687 023 717

3.2f ASCII keyboard (Danish) 1 687 023 715

3.2g ASCII keyboard (Dutch) 1 687 023 718

3.2h ASCII keyboard (Finnish / Swedish) 1 687 023 719

3.2i ASCII keyboard (UK) 1 687 023 713

3.2j ASCII keyboard (Czech) 1 687 023 720

4 Printer

4.1 Inkjet printer PDR 375 inc. USB connecting line 1 687 001 850


5.1 CD ESI[tronic]-A 1 987 P12 410

5.2 CD ESI[tronic]-D 1 987 P12 455

5.3 CD ESI[tronic]-K1 1 987 P12 475

5.4 CD ESI[tronic]-W 1 987 P12 500

5.5 CD TestData - update subscription, required for VPM 844, CRS 845 H or CAM 847 1 687 P15 015

6 Service

6.2 User training




76



1 Injector component test benches – with measuring system HMI

1.1 EPS 625 HMI 400 - 440 Volt F 002 DG0 921

1.2 EPS 625 HMI 200 - 240 Volt F 002 DG0 922

1.3 EPS 625 PC 400 - 440 Volt without HML F 002 DG0 923

1.4 EPS 625 PC 200 - 240 Volt without HMI F 002 DG0 924

1.5 Trolley 1 688 003 254

1.6 PC Mini Tower for FSA 7xx, BEA xx and EPS 625: Win 7 64 bit, HD 500 GB, DVD writer, 10x USB 2.0, 2x USB 3.0 1 687 023 699

1.7 TFT monitor 19" 1 687 023 684

1.8 Multi-pole socket at EPS 1 684 485 173

1.9 Keyboard (country specific, such as EPS 815)


2.1 Zero-backlash multiplate clutch for H / R pump required 1 686 401 024

2.2 Clamping bracket required for all VE and PES inline pumps 1 688 010 129

2.3 Accessory set for rinsing VE pumps if test equipment set 1687005022 not present 1 687 010 126

2.4 Support device KDEP 1140, required if VE pump test equipment set 1 687 005 022 not present. 0 986 611 876

2.5 Supply / return connection set PES 4M with RSF III governor 1 687 010 083

2.6 Lube oil supply retrofit kit voltage 200 to 500 Volt 1 687 001 977

3 Test sets for conventional systems (mechanical inline injection pumps and distribution pumps)

3.1 Basis set 1 687 005 018

3.1.1 A-pump set 1 687 005 019

3.1.2 P-pump set 1 687 005 021

3.1.3 M-MW set 1 687 005 020

3.1.4 H-pump set 1 687 005 023

3.2 VE set 1 687 005 022

3.2.1 EPS 865 controller VE-E (EDC), basis instrument for potentiometer response 0 684 200 615

3.2.2 EPS 910 controller VE-E (EDC), additional instrument for HDK response 1 687 022 281


4.1 CD ESI[tronic]-A 1 987 P12 410

4.2 CD ESI[tronic]-D 1 987 P12 455

4.3 CD ESI[tronic]-K1 1 987 P12 475

4.4 CD ESI[tronic]-W 1 987 P15 150

5 Service

5.1 User training




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1 Test equipment 1.1 EPS 205 (400 Volt) for testing of DHK / UI nozzles, CRI / CRIN solenoid valve, CRI-Piezo, universal injector installation and injection chamber for DHK / UI nozzles, CRI / CRIN; CD / DVD drive, EPS-System-Software, Recovery-CD, CD TestData 0 683 803 205

1.2 EPS 205 (200 Volt) for testing of DHK / UI nozzles, CRI / CRIN solenoid valve, CRI-Piezo, universal injector installation and injection chamber for DHK / UI nozzles, CRI / CRIN; CD / DVD drive, EPS-System-Software, Recovery-CD, CD TestData 0 683 803 206

2 Special accessories adapter EPS 205 2.1 Adapter for testing Nissan UI nozzles 1 681 335 111

2.2 3 piece UI adapter set for testing Scania, Iveco and Volvo UI nozzles (Bosch applications) 1 687 010 147

2.3 3 piece UI adapter set for testing Iveco and DDC UI nozzles (Bosch applications) 1 687 010 338

2.4 3 piece UI adapter set for testing Volkswagen roup UI nozzles (Bosch applications) 1 687 001 857

2.5 DHK radial connecting piece 1 683 391 193

2.6 DHK axial connection piece, Opel 1 683 391 194

2.7 DHK bushing M16x1.5 (Nfz special) 1 680 362 047






2.13 Adapter Set - A1i (Cummins, VW, Ford, DCEC, Dongfeng, Kamaz) 1 685 720 297

2.14 Adapter Set - A2i (Valtra Tractors, SISU Motors) 1 685 720 314

2.15 Adapter Set - A3i (Iveco, New Holland, Cummins, CDC, Dongfeng, MAN, Dodge, KamAZ, KaVZ, VW, Ford in delivery scope CRI / CRIN 848 H) 1 685 720 296

2.16 Adapter Set - A4i (Renault, Dongfeng, MAZ, LiaZ, MZKT, Tonar, Ural, YamZ) 1 685 720 316

2.17 Adapter Set - A5i (MAN, Liebherr) 1 685 720 300

2.18 Adapter Set - A6i (MAN) 1 685 720 318

2.19 Adapter Set - A7i (Ford Otosan Türky) 1 685 720 320

2.20 Adapter Set - A8i (DHIM, Yuchai, Doosan) 1 685 720 322

2.21 Adapter Set - A9i (Deutz, MAZ, YamZ) 1 685 720 324

2.22 Adapter Set - A10i (FAW) 1 685 720 326

2.23 Adapter Set - A11i (DCD, Dongfeng) 1 685 720 328

2.24 Adapter Set - A12i (MAZ, YamZ, Ashok Leyland) 1 685 720 330

2.25 Adapter Set - A13i (Renault, Fent, Deutz, FAW, Volvo, Weichai, Yuchai, Foton) 1 685 720 332

2.26 Adapter Set - A14i (MAN, International Harvester, Shanqi, Foton, CNHTC, Weichai, Liebherr, MTU) 1 685 720 334

2.27 Adapter Set - A15i (Shanqi, Foton, CNHTC, Weichai) 1 685 720 336

2.28 Adapter Set - A16i (DHIM, Yuchai, Doosan) 1 685 720 338

2.29 Adapter Set - A1e (Deutz) 1 685 720 340

2.30 Adapter Set - A2e 1 685 720 342

2.31 Adapter Set - A3e (Iveco, New Holland) 1 685 720 344

2.32 Adapter Set - A4e (Mitsubishi Fuso) 1 685 720 346

2.33 CRI Solenoid valve foreign trademark kit (Delphi, Denso) 1 687 010 399

2.34 CRI Piezo Foreign trademark kit (Denso, Siemens) 1 687 010 400

3 Special accessories EPS 205 3.1 Ink-jet printer PDR incl. USB connection cable 1 687 001 850

3.2 Operating software EPS 200 Vers. 2.xx 1 687 005 050

3.3 CD TestData - Update Abo 1 687 P15 015

3.4 Recovery-CD 1 687 005 049

3.5 Calibrating oil 25 l - At initial commissioning in EPS 815: 50 l is required, At initial commissioning in EPS 708: 55 l is required, At initial commissioning in EPS 205: 7 l is required Non-Bosch product, Reference address: Zeller & Gmelin GmbH & Co. KG, Schloßstrasse 20, 73054 Eislingen; Tel: 07161 802-0; Fax: 07161 802-290; www.zeller-gmelin.com

4 Service 4.1 User training




78

Software for replacement and repair,Training for success

Well equipped for Diesel and electrical systems with the timesaving ESI[tronic] software

ESI[tronic]-K "Components repair instructions" f Repair instructions, service information and telegrams

for Diesel and electrical system components f Direct interaction of information from ESI[tronic]-D

and ESI[tronic]-E, e.g. spare parts, and ESI[tronic]-W, e.g., test values for conventional VP and RP

ESI[tronic]-D "Diesel replacement parts" f Most comprehensive catalogue for Bosch Diesel

products f Around 51,000 spare-parts lists with over 380,000

individual parts f Exploded drawings in highest quality f Stepless zoom function

ESI[tronic]-W "Diesel test data" f Test specifications of around 12,000 inline fuel-in-

jection pump combinations and for approx. 2,000 VE pumps

f Complete test operation from obtaining measured values to log printing

f All test steps are displayed in optimized order f Transfer of test values into the EPS 945 program in the

EPS 815

ESI[tronic]-K / W "Archive"Every new customer receives the archive data of ESI[tronic]-K and W once, and free of charge, with the ESI[tronic] subscription.

The TestData CDTest specifications for Bosch Common Rail high-pres-sure pumps, Common Rail injectors and VP 29 / 30 / 44 distributor injection pumps (obtainable by subscrip-tion, can be ordered via the ESI[tronic] ServiceLine).In addition to our own test values CD "TestData", test values for Diesel components from Delphi, Denso and Continental / Siemens for EPS 815, EPS 708 and EPS 205 are available from the data provider Refdat and can be downloaded from the workshop under www.refdat.net

With selective technical training, always one step ahead of the competitionTraining in one of our training centers provides the theory and practice of the necessary basic knowledge for successful diagnosis and repair.

f Comprehensive transfer of knowledge of modern Diesel systems by the system developer Bosch

f Instruction in methodical procedures during troubleshooting

f Learning by doing: Practical training in groups on active vehicles and operational engines

f Firsthand instruction in the newest systems and components

f Modern, extensive training equipment f Highly qualified practice-oriented trainers and insider

know-how f Training according to the most modern didactical

methods

79

Our knowledge, your success:Bosch Diagnostics

Diagnostics – the key to the automotive workshop of the future Motor vehicle systems are becoming increasinglycomplex; the demands placed on qualified diagnosis in workshops are rising. For professional service on mod ern vehicles, Bosch provides every thing at one stop, perfectly coordinated: test technology, software, technical training and hot-line, supplemented by parts in initial equipment quality.

ESI[tronic] 2.0: Software for diagnostics and servicef Simple operationf Rapid accessf Modular structuref Comprehensive market coveragef Continually updatedf Universal operation regardless of manufacturer

Test Equipment: Matched to each workshop typef Optimized combination of hardware and software for rapid troubleshooting, qualified repair and high time savingsf PC-based test technology of the latest generation with extendable modules

Service Training: Knowledge as a factor of successf Comprehensive training programs for automotive workshopsf Practical training coursesf Highly qualified trainers with practical experience

Technical Hotline: Support from the system developerf Support in difficult technical situationsf Skills covering all brands and manufacturers

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What drives you, drives us.

Technology from Bosch is used in practically every vehicle in the world. For us, the focus is on people and helping them to stay mobile.

We have been dedicated to people for more than 125 years with our pioneering spirit, research, production and expertise.

Our dedication is an unwaivering commitment to providing them with a unique combination of parts, diagnostics, workshop equipment and services:

fstate-of-the-art solutions for efficient vehicle repairs

finnovative workshop equipment and software – also available on favorable lease terms

fthe world’s largest range of new and remanufactured spare parts

ffast, reliable delivery service

fexpert customer care via our hotline

fextensive range of training courses

fspecific sales and marketing support

fplus many other services

Robert Bosch GmbHAutomotive AftermarketBusiness Unit Automotive Service Solutions

73201 PlochingenGermanywww.bosch-workshopworld.de

Bosch products and servicesfDiagnosticsfDiesel systemsfGasoline systemsfBrake systemsfSpark plugsfEnergy systemsfBatteriesfFiltersfWiper systemsfLight technologyfComfort electronicsfHybrid / e-mobilityfTechnical hotlinefKnowledge databasefService trainingfWorkshop concepts

Bosch electronic repair service

fFair repair: repairs in line with the market valuefFast and reliable: most work completed within 48 hoursfQuality remains priority: Bosch is committed to this as a globally leading original equiment manufacturer

Find out more at:https://www.bosch-repair-service.com/

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