Retrofit test kits for diesel systemsof the latest generation
Prüftechnik
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Fit for the future – diesel test equipmentfor passenger cars and commercial vehicles
Basic test bench
Retrofit kits
Special accessory kits
EPS 815 with KMA
VPM 844 CRS 845
CRI 846
CRINCP1 CP2 CP3
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Bosch – the leader in diesel technology and workshoptest equipmentSince its production of the first diesel truck in 1924 and the
first diesel automobile in 1936, Bosch has been the world
leader in the supply of diesel technology. Based on close
and continuous co-operation with engine designers and a
high degree of innovative power in development and pro-
duction, recent years have seen the emergence of modern
high-pressure systems which, with their high performance
and economy, have boosted the market share held by diesel
engines. Our expertise as an original equipment manufac-
turer also enabled us to develop innovative test equipment,
including the ESI[tronic] software product. The test equip-
ment enables us to diagnose our electronically controlled
diesel systems on the vehicle itself in order to identify and
replace faulty components. In this way Bosch offers service
centres everything they need to master state-of-the-art
diesel systems and open up new selling potentials.
The basis for component testing from Bosch isthe EPS 815 component test bench plus KMA testinstrument technology.Expanding this system to include the CRS 845 test kit
(3.1) for testing common rail high pressure pumps CP1,
CP2, CP3 and the VPM 844 test kit (3.2) for testing solenoid
valve controlled distributor pumps of type VP29/30/44
will safeguard the future of your testing operations. The
test equipment and programs simulate all necessary oper-
ating states as in normal running of the vehicle. During
testing, all process steps are displayed continuously on the
monitor. The information required for this is derived from
the test data CD.
Why Bosch?Component testing in accordance with manufacturer's
specifications is only possible with the use of CRS 845,
CRI 846 and VPM 844 retrofit kits.
This ensures that:
• Statutory emissions regulations are complied with
• Precise and repeatable measured values are determined
• A warranty evaluation in accordance with
manufacturers' specifications is possible
Diesel systems conquer the market
3.1 CRS 845 3.2 VPM 844
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4.1 Precision voltage stabiliser
4.2 Piston stroke measuring device Delta Phi
Automatic programming with VPM 844
Test data CD
All data for programming
pump control units and
testing components
4.4 Processor unit
The VPM 844 retrofit kit for testing solenoid valvecontrolled distributor pumps This test concept, too, is largely an automated process.
There are no more adjuster screws. All adjustment oper-
ations are effected by programming the control unit. This
test, defined on the basis of strict factory specifications,
incorporates all parameters such as engine speed, press-
ure, temperature, setting, waiting and measuring times.
By means of the precision voltage stabiliser (required for
VPM 844 and CRI 846) (4.1) the components are supplied
with exactly the right voltage. The processor unit (4.4) is
used for calibration and programming. Data communication
with the pump control unit is by way of specially developed
measurement and evaluation boards. Measurement of the
piston stroke Delta Phi (4.2) requires a special device.
4.3 Test nozzle holder combination type X
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The retrofit kit for testing common railpumps.The main externally visible feature is the splash guard
(3.1), which is essential at a continuous pressure of 1600
bar. The high pressure rail (5.1), including pressure sensors,
serves as a pressure accumulator with an integral regulator.
The distributor (5.2) splits the volumetric flow upstream of
the cooling and quantity measurement stages. The control
unit controls the sensors and valves of the test specimen
and of the rail. The control valve regulates the back pressure
of the pump under test and thereby simulates the vehicle
situation. The adapters for mounting of the various pumps
are available as accessories.
The heat exchanger (5.3) is required to cool the test oil
prior to measurement in both systems.
The high pressure route to success – CRS 845
5.1 High pressure rail 5.2 Distributor
5.3 Heat exchanger
Bosch Diagnostics Software
CD-TestData
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EPS 944 31.10.2003V1.0.0.8
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Special accessory setsThe special accessory sets CP1, CP2 and CP3 supplement
retrofit kit CRS 845 with regards to pump testing.
For testing common rail pumpsBosch offers diesel workshops the complete equipment
package for inspecting high pressure pumps:
• After connecting the removed diesel injection pump on
the test bench and to the retrofit kit, the individual test
steps are carried out almost entirely automatically.
• All steps of the test procedure are visualised on the
monitor (6.1)
• The CD test data provides all the information for
inspecting the pumps
Diesel Service opens up new opportunitiesfor the workshopHigh performance modern common rail systems are
becoming increasingly accepted in the market place.
Initially, the required high pressures were produced by
the CP1 high pressure pump. Today, the latest genera-
tions of high pressure pumps are used in the vehicles,
such as the quantity-regulated CP3 system which is
designed for pressures of 1600 bar or higher and the CP2
system which is used in the commercial vehicle sector.
Bosch test technology allows workshops to carry out
professional diagnosis and repairs of state-of-the-art
diesel systems. Bosch's know-how is also available to the
diesel specialist for complex component repairs.
CP3
Test equipment for common railhigh pressure pumps
CP2
6.1 equality test
CP1
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Common rail injector test
7.2 CRI 846 on EPS 815
7.3 CRIN
7.1 CRI 846
Retrofit kit CRI 846 including passenger car andcommercial vehicle accessory setsPowerful performance development and attractive engine
characteristics of state-of-the-art diesel engines mean that
the number of vehicles with diesel drive technology is rising.
The common rail technology thereby provides the basis.
In addition to the high pressure pump, the injector is a key
component of a modern common rail injection system.
With the common rail injector retrofit kit CRI 846 (7.1)
including special accessory set for passenger cars, up to 6
passenger car injectors (1st and 2nd generation) can be
set up for a test procedure (7.2).The tight manufacturing
tolerances and the associated high measuring accuracy will
allow the diesel specialist in future to readjust the injec-
tors after repair, as well as inspect injectors with IMA*
technology. Special accessory set CRIN (7.3) allows the
inspection of commercial vehicle injectors (1st and 2nd
generation). The prerequisite for special accessory set
CRIN is retrofit kit CRI 846.
*) „Injektor-Mengen-Abgleich” `= injector quantity adjustment
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Repairs made easy
8.3
8.1
8.2
Bosch Diagnostics Software
ToolsCATalogue
2004/1
Service Werkzeuge/Service Tools/
Diagnostic Equipment Bosch / Zexel
Deutsch, EnglishFrançais, Español
Italiano, Português,Svenska
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Well equipped for component replacement and repair
for diesel and electric thanks to easily understood repair
manuals and quick location of spare parts. This special
software (DVD with quarterly updates as subscription)
helps you save time and increase profit per order (8.1 – 8.2).
ESI[tronic]-K "Component repair instructions"Repair and test manuals, service information and service
telegrams for diesel and electrical system components
assist in fault analysis.
ESI[tronic]-D "Diesel spares" Comprehensive overview of diesel products, unique with
detailed exploded views.
ESI[tronic]-W "Diesel test values"For testing and setting inline and distributor fuel injection
pumps for diesel units.
ESI[tronic]-K/W "Archive"Each new customer receives one free copy of the archive
data of ESI[tronic]K and W with the ESI[tronic] subscription.
The ToolsCATalogue CD provides information about allcustomer service tools and special accessories (8.3).It contains around 2200 Bosch and Zexel tools for repairing
starters, alternators, and also diesel fuel injection systems,
including information on how to use them. It also contains
a special accessories catalogue for test benches. This CD
is available free of charge from your local Bosch distributor.
The test data CDTest data for Bosch common rail high pressure pumps,
common rail injectors and VP29/29/30/44 distributor-type
injection pumps (available as a subscription, available
through the ESI[tronic] service line).
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Training for success
Training at one of our training centres is essential before
successful diagnosis and servicing can be carried out.
The essential basic knowledge is taught in theory and
practise.
These training courses are offered among others:
EP 4 Common rail systemCourse content: Design, function and mode of operation
of common rail high pressure pumps. Special features to
be observed when servicing pumps. Testing on the EPS
815 component test bench with KMA test instrument techno-
logy.
EP 3.2 New generation distributor pumpsCourse content: Design, function and mode of operation
of solenoid valve controlled distributor pumps, types VE- M
and VR (VP 29, VP 30, VP 44). Servicing and testing with
service tools, test equipment and the EPS 815 pump test
bench with KMA test instrument technology.
EP vehicles, commercial vehicle EDCCourse content: Design and function of the various
commercial vehicle EDC systems
• with H pump MS 5 system and MS 6.1
• with PDE MS 6.2
• with CRS MS 6.3 in commercial vehicle and the
older M7 system with pump
Onboard testing of components on commercial vehicles
with engine testers. Fault finding with ESI[tronic] and
state-of-the-art diagnosis technology (9.2). Input and
output testing on a dynamometer.
EP vehicles, passenger car EDCCourse content: Distr. type EDC injection pumps, inline
EDC pumps, VR EDC injection pumps, common rail, UIS,
UPS. Function, design and mode of operation of individual
components. Interaction of components in overall system,
possible faults, testing components in situ using the engine
tester. Fault finding with ESI[tronic] and state-of-the-art
diagnosis technology (9.2).
9.1 The training coursesteach basic knowledge
9.2 KTS 650, the top-end devicefor control unit diagnosis
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Designation Order no. VP 29/30 VP 44
Retrofit kit VPM 844 for solenoid valve controlled distributor-type injection pumps 29/30/44 1 687 001 844 X XCaution: Max. permissible coolant temperature during tests (VP 29/30/44) is 17 °C. If temperature is exceeded, this may make additional on-site measures necessaryWin2000 VP 44 multilingual processor unit without keyboard 1 687 022 959 X XNote: If WIN 2000 PC 1 687 022 958 available, order only VP-M upgrade kitRetrofit kit VP-M 1 687 001 556 X XTransformer conversion kit 400–500V for EPS 815* (only necessary for VP 29/30/44) 1 687 001 800 X XTransformer conversion kit 200–240V for EPS 815* (only necessary for VP 29/30/44) 1 687 001 801 X XReducing fitting L= 350 mm (Ford/Rover) 1 680 750 100 XReducing fitting L= 450 mm (Audi/BMW/Ford/Nissan/Opel) 1 680 750 101 XTest pressure line L= 845 mm (Cummins/John Deere/MAN/Nissan/VM Motori/Volvo) 1 680 750 102 XTest pressure line L= 450 mm (Opel VP 29/SISU, Perkins VP 30) 1 680 750 103 XAdapter cable PSG2 (pump control unit type 2) 1 684 465 498 XTest nozzle holder combination type IX car/comm.veh. (d= 0.5) 6 units recommended 1 688 901 116 X XTest nozzle holder combination type X car (d= 0.4) 6 units recommended 1 680 901 032 XPerforated plate for type X test nozzle/holder combination (d=0.5) 6 units required 1 680 103 110 (X)Test nozzle holder combination type X comm.veh. (d= 0.5) 66 units recommended 1 688 901 035 XClamping stand, Audi, 2 units required 1 688 030 186 XHeat exchanger Important! Required for CRS 845 and VPM 844 1 687 010 030 X XSpecifications test data CD for CR injectors (passenger car/commercial vehicle) 1 687 370 270 X Xand CR/VP-M pumps. Note: Update subscription from ESI[tronic] service lineTools CATalogue 1 987 729 257
Retrofit kit CRS 845
X = required (X) = if required* Transformer conversion kit required by production date 07/05 (estimated)Subject to modifications and program changes.
Data and facts
Retrofit kit VPM 844
Designation Order no. CP1 CP2 CP3
Retrofit kit CRS 845 for common rail high pressure pumps 1 687 001 845 X X XWin2000 multilingual processor unit without keyboard 1 687 022 958 X X Xinc. standard (inline/dist. pumps) and common rail softwareAlternatively: upgrade kit if EPS processor unit already has 1 687 001 555 (X) (X) (X)Win MeRiser retrofit kit (12-channel for old KMA up to approx. 3/2001) 1 687 001 544 (X) (X) (X)Special accessory set CP1 (clamping sets for CP1 pumps) 1 687 010 133 XSpecial accessory set CP2 (clamping sets for CP2 pumps) 1 687 010 134 XSpecial accessory set CP3 (clamping sets for CP3 pumps) 1 687 010 135 XA drive flange is also required if accessory set CP1 is not available 1 685 702 084 XHeat exchanger Important! Required for CRS 845 and VPM 844 1 687 010 130 X X XUpgrade kit for heat exchanger. Measurement set split from 6 to 12 channels 1 687 001 557 (X) (X) (X)Note: required for testing of pumps with delivery rate >160 l/hSpecifications test data CD for CR injectors (passenger car/commercial vehicle) 1 687 370 270 X X Xand CR/VP-M pumps. Note: Update subscription from ESI[tronic] service lineTools CATalogue 1 987 729 257
Retrofit kit CRI 846
Designation Order no.
Retrofit kit CRI 846 incl. special accessory set for passenger car common rail injectors (CRS 845 required) 1 687 001 846Note: Before commissioning the test unit for the first time, it is necessary to calibrate the rail pressure sensor on the EPS 815Precision voltage stabiliser 1 687 022 873Note: Only required if no test unit VPM 844 is availableVoltage stabiliser kit (only for new stabiliser purchase) 1 687 016 043Transformer conversion kit 400–500V for EPS 815 (only necessary for VP 29/30/44) 1 687 001 800Transformer conversion kit 200–240V for EPS 815 (only necessary for VP 29/30/44) 1 687 001 801Special accessory set CRIN for commercial vehicle common rail injectors (CRI 846 required) 1 687 001 599Specifications test data CD for CR injectors (passenger car/commercial vehicle) and CR/VP-M pumps 1 687 370 270Note: Update subscription from ESI[tronic] service lineTools CATalogue 1 987 729 257
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Our knowledge, your success.Bosch Diagnostics
Diagnostics – the key to theautomotive workshop of thefuture Motor vehicle systems are
becoming increasingly complex;
the demands placed on qualified
diagnosis in workshops are rising.
For professional service on mod-
ern vehicles, Bosch provides
everything at one stop, perfectly
coordinated: testing technology,
software, technical training and
hotline, supplemented by parts
in initial equipment quality.
ESI[tronic] – Software for
diagnostics and service
• Simple operation
• Rapid access
• Modular structure
• Comprehensive market
coverage
• Continually updated
• Universal operation re-
gardless of manufacturer
Test technology – matched
to each workshop type
• Optimized combination of
hardware and software for
rapid troubleshooting,
qualified repair and high
time savings
• PC-based, testing techno-
logy of the latest generation
with extendable modules
Service training –
knowledge as a factor for
success
• Comprehensive training
program for automotive
workshops
• Practical training courses
• Highly qualified trainers
with a great deal of
practical experience
Technical hotline –
support from the system
developer
• Support in difficult
technical situations
• Skills covering all brands
and manufacturers
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Bosch – skilled partner forworkshop business
Developments from Bosch stand for innovative progress in automobilemanufacturing Geared to the growing proportion of electronics in the vehicle, Bosch offers
workshops the suitable testing technology for all sizes of company and
service concepts. Sturdy, innovative, state-of-the-art automobile technology:
Computer-assisted diagnosis systems help in finding any fault more quickly
and more reliably. The modular layout - using future-oriented technologies
– enables broad networking and efficient use of comprehensive information
from the ESI[tronic] software. Mobility and user-friendly user guidance
support the workshop in reliable and timesaving diagnosis.
ECU Diagnostics KTS
Engine System Testing FSA
Diesel System Testing EPS
Emissions Analysis BEA
Where to find Original Bosch Quality:
Robert Bosch GmbH
Automotive Aftermarket
D-76227 Karlsruhe I www.bosch-diagnostics.com
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Brake Testing BSA
Wheel Alignment FWA
Air Conditioning Service ACS
Battery Service BAT
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