Retrofit test kits for diesel systems of the latest generation

Retrofit test kits for diesel systems
of the latest generation
Prüftechnik

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

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

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

The high pressure route to success – CRS 845
5.1 High pressure rail 5.2 Distributor
2005/1
2004/1
EPS 945 30.10.2003
V1.0.1.0
EPS 944 31.10.2003
V1.0.0.8
FD 2003/11
Starten mit
“Setup.exe“
Bilder von
Pumpen
Bosch Diagnostics Software
CD-TestData
The retrofit kit for testing common rail
pumps.
The main externally visible feature is the splash guard
(3.1), which is essential at a continuous pressure of 1600
bar. The high pressure rail (5.1), including pressure sensors,
serves as a pressure accumulator with an integral regulator.
The distributor (5.2) splits the volumetric flow upstream of
the cooling and quantity measurement stages. The control
unit controls the sensors and valves of the test specimen
and of the rail. The control valve regulates the back pressure
of the pump under test and thereby simulates the vehicle
situation. The adapters for mounting of the various pumps
are available as accessories.
The heat exchanger (5.3) is required to cool the test oil
prior to measurement in both systems.
WiNDOWS 2000 CD-ROM: 1 68737027 ©2005RobertBosch GmbH Bosch Automotive Aftermarket D-73207 Plochingen
CD-
TestData
5.3 Heat exchanger

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

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

Repairs made easy
8.1
8.2
Well equipped for component replacement and repair
for diesel and electric thanks to easily understood repair
manuals and quick location of spare parts. This special
software (DVD with quarterly updates as subscription)
helps you save time and increase profit per order (8.1 – 8.2).
ESI[tronic]-K "Component repair instructions"
Repair and test manuals, service information and service
telegrams for diesel and electrical system components
assist in fault analysis.
ESI[tronic]-D "Diesel spares"
Comprehensive overview of diesel products, unique with
detailed exploded views.
8.3
Tools
CATalogue
2005/1 2004/1
Service Werkzeuge/
Service Tools/
Diagnostic Equipment
Bosch / Zexel
Deutsch, English
Français, Español
Italiano, Português,
Svenska
WINDOWS 95/98/NT/ME/2000/XP CD-ROM:1987729257/200401 ©2005RobertBoschGmbH BoschAutomotiveAftermarketD-73207Plochingen
Bosch Diagnostics Software
ToolsCATalogue
ESI[tronic]-W "Diesel test values"
For testing and setting inline and distributor fuel injection
pumps for diesel units.
ESI[tronic]-K/W "Archive"
Each new customer receives one free copy of the archive
data of ESI[tronic]K and W with the ESI[tronic] subscription.
The ToolsCATalogue CD provides information about all
customer service tools and special accessories (8.3).
It contains around 2200 Bosch and Zexel tools for repairing
starters, alternators, and also diesel fuel injection systems,
including information on how to use them. It also contains
a special accessories catalogue for test benches. This CD
is available free of charge from your local Bosch distributor.
The test data CD
Test data for Bosch common rail high pressure pumps,
common rail injectors and VP29/29/30/44 distributor-type
injection pumps (available as a subscription, available
through the ESI[tronic] service line).

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

Data and facts
Retrofit kit VPM 844
Designation Order no.VP 29/30 VP 44
Retrofit kit VPM 844 for solenoid valve controlled distributor-type injection pumps 29/30/44
Caution: Max. permissible coolant temperature during tests (VP 29/30/44) is 17 °C.
If temperature is exceeded, this may make additional on-site measures necessary
1 687 001 844 X X
Win2000 VP 44 multilingual processor unit without keyboard
Note: If WIN 2000 PC 1 687 022 958 available, order only VP-M upgrade kit
1 687 022 959 X X
Retrofit kit VP-M 1 687 001 556 X X
Transformer conversion kit 400–500V for EPS 815* (only necessary for VP 29/30/44) 1 687 001 800 X X
Transformer conversion kit 200–240V for EPS 815* (only necessary for VP 29/30/44) 1 687 001 801 X X
Reducing fitting L= 350 mm (Ford/Rover) 1 680 750 100 X
Reducing fitting L= 450 mm (Audi/BMW/Ford/Nissan/Opel) 1 680 750 101 X
Test pressure line L= 845 mm (Cummins/John Deere/MAN/Nissan/VM Motori/Volvo) 1 680 750 102 X
Test pressure line L= 450 mm (Opel VP 29/SISU, Perkins VP 30) 1 680 750 103 X
Adapter cable PSG2 (pump control unit type 2) 1 684 465 498 X
Test nozzle holder combination type IX car/comm.veh. (d= 0.5) 6 units recommended 1 688 901 116 X X
Test nozzle holder combination type X car (d= 0.4) 6 units recommended 1 680 901 032 X
Perforated plate for type X test nozzle/holder combination (d=0.5) 6 units required 1 680 103 110 (X)
Test nozzle holder combination type X comm.veh. (d= 0.5) 66 units recommended 1 688 901 035 X
Clamping stand, Audi, 2 units required 1 688 030 186 X
Heat exchanger Important! Required for CRS 845 and VPM 844 1 687 010 030 X X
Specifications test data CD for CR injectors (passenger car/commercial vehicle)
and CR/VP-M pumps. Note: Update subscription from ESI[tronic] service line
1 687 370 270 X X
Tools CATalogue 1 987 729 257
Retrofit kit CRS 845
Designation Order no.CP1 CP2 CP3
Retrofit kit CRS 845 for common rail high pressure pumps 1 687 001 845 X X X
Win2000 multilingual processor unit without keyboard
inc. standard (inline/dist. pumps) and common rail software
1 687 022 958 X X X
Alternatively: upgrade kit if EPS processor unit already has
Win Me
1 687 001 555 (X) (X) (X)
Riser retrofit kit (12-channel for old KMA up to approx. 3/2001) 1 687 001 544 (X) (X) (X)
Special accessory set CP1 (clamping sets for CP1 pumps) 1 687 010 133 X
Special accessory set CP2 (clamping sets for CP2 pumps) 1 687 010 134 X
Special accessory set CP3 (clamping sets for CP3 pumps) 1 687 010 135 X
A drive flange is also required if accessory set CP1 is not available 1 685 702 084 X
Heat exchanger Important! Required for CRS 845 and VPM 844 1 687 010 130 X X X
Upgrade kit for heat exchanger. Measurement set split from 6 to 12 channels
Note: required for testing of pumps with delivery rate >160 l/h
1 687 001 557 (X) (X) (X)
Specifications test data CD for CR injectors (passenger car/commercial vehicle)
and CR/VP-M pumps. Note: Update subscription from ESI[tronic] service line
1 687 370 270 X X X
Tools CATalogue 1 987 729 257
Retrofit kit CRI 846
Designation Order no.
Retrofit kit CRI 846 incl. special accessory set for passenger car common rail injectors (CRS 845 required)
Note: Before commissioning the test unit for the first time, it is necessary to calibrate the rail
pressure sensor on the EPS 815
1 687 001 846
Precision voltage stabiliser
Note: Only required if no test unit VPM 844 is available
1 687 022 873
Voltage stabiliser kit (only for new stabiliser purchase) 1 687 016 043
Transformer conversion kit 400–500V for EPS 815 (only necessary for VP 29/30/44) 1 687 001 800
Transformer conversion kit 200–240V for EPS 815 (only necessary for VP 29/30/44) 1 687 001 801
Special accessory set CRIN for commercial vehicle common rail injectors (CRI 846 required) 1 687 001 599
Specifications test data CD for CR injectors (passenger car/commercial vehicle) and CR/VP-M pumps
Note: Update subscription from ESI[tronic] service line
1 687 370 270
Tools CATalogue 1 987 729 257
X = required (X) = if required
* Transformer conversion kit required by production date 07/05 (estimated)
Subject to modifications and program changes.

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

AA/PDT2 WAW 3220 GB 04.05 The right to make changes of a technical nature and to alter the range on offer is reserved
Bosch – skilled partner for
workshop business
Developments from Bosch stand for innovative progress in automobile
manufacturing
Geared to the growing proportion of electronics in the vehicle, Bosch offers
workshops the suitable testing technology for all sizes of company and
service concepts. Sturdy, innovative, state-of-the-art automobile technology:
Computer-assisted diagnosis systems help in finding any fault more quickly
and more reliably. The modular layout - using future-oriented technologies
– enables broad networking and efficient use of comprehensive information
from the ESI[tronic] software. Mobility and user-friendly user guidance
support the workshop in reliable and timesaving diagnosis.
Where to find Original Bosch Quality:
Robert Bosch GmbH
Automotive Aftermarket
D-76227 Karlsruhe I www.bosch-diagnostics.com
ECU Diagnostics KTS
Engine System Testing FSA
Emissions Analysis BEA
Diesel System Testing EPS
Battery Service BAT
Brake Testing BSA
Wheel Alignment FWA
Air Conditioning Service ACS