Eps 205 Work Shop Managing

Bosch EPS205 Injection Tester
Bosch EPS205 Injector Tester

Using the Capabilities to Improve Revenue
Ilidio Serra, Manager Technical Service and Support

Robert Bosch, LLC
Automotive Aftermarket, AA Technical Service and
Support NA
Broadview, IL
ADS International Convention

August 5, 2016
Las Vegas, Nevada
Wynn Las Vegas
Automotive Aftermarket
1 AA/SNA9.2 | 6/3/2016 | © 2016 Robert Bosch LLC and affiliates. All rights reserved.
Description
 Multi-purpose Injector Testing
Device
 Conventional Nozzle Holder
Assemblies
 Unit Injector Nozzles
 Common Rail Injectors
Nozzle Holder
Assemblies
 Opening Pressure
 Capable to measure the two different
opening pressures for two spring

assemblies
 Internal leakage of the assembly
 Chatter Characteristics
 Seat Leakage
 Spray Pattern
Common Rail Injectors

 Solenoid and Piezo Injectors
 Pressure up to 1800 Bar
 Injectors up to 500 mm /st

3
(combined injected and backflow)
 Backflow up to 150 mm3/st
 Universal Clamping Arm
 Universal Collection Chamber
 Engine Family Specific Adapters
(Inlet and Backflow)
(Shared with CRI_CRIN 848H)
 Able to accommodate most manufacturers
 Bosch
 Delphi
 Denso
Improvements
 EPS200 Software Version
 V2.01
 Automatic rate of injection adjustment
 ISA Class detection improvement
 Backflow protection
 Piezo resistance improvement
 V2.02
 Pressure transition improvements
 Backflow only test points now possible
Only available through test

specification subscription
Improvements
 Windows 7 Update
 32 GB vs. 2 GB
 Improved peripheral support
 Provided no charge to all North American

EPS205 customers
NHA Testing vs Common Rail Testing

 NHA Testing  Common Rail Testing
 Increasing pressure causes nozzle needle to  Pressure to injector is constant
lift  Pressure regulated by test bench
 Lifting nozzle needle causes pressure to drop  Nozzle needle lifting controlled by activation of
and needle seats injector
 Non-quantified flow from nozzle  Continuous flow from nozzle while activated
 Rate that pressure is maintained affects:  Quantifiable flow from nozzle
 Spray Pattern
 Chatter
300 1002.0
250 1000.0
200 998.0
150 996.0
100 994.0
50 992.0
0 990.0
Pressure Pressure
VL
Injector Mapping
 During the development stage an injector is
run through a process called mapping.
TL/EM
 In this process, the injector is operated at a

VE LL fixed rail pressure and the actuation time is
increased from 0 μs to the maximum
actuation time in 10 μs increments.
 From this map, the test points and the engine

VE calibration values are determined as an
injector can be operated at any pressure and
actuation time combination.
ERPM Pressure Q1
500 598 2.23
Q2
95.40
Q3 Q4
6.29
Q5
6.29
Q6
6.29
Typical Full Load Curve
600
700
573
586
2.37
2.30
92.32
95.29
6.29
6.29
6.29
6.29
6.29
6.29
(with Regeneration)
800 613 2.17 96.72 6.29 6.29 6.29
900 698 2.18 100.77 6.29 6.29 6.29  Injected quantity can be varied based on rail
1000 749 1.97 101.51 6.29 6.29 6.29
1100 836 1.97 99.49 6.29 6.29 6.29 pressure and activation time i.e.:
1200 930 1.97 109.57 6.29 6.29 6.29
1300 1077 1.97 114.61 6.29 6.29 6.29
1400 1234 1.97 115.60 6.29 6.29 6.29
1500
1600
1413
1549
1.97
1.97
125.81
130.89
 80 mm3 @ 600 bar has a longer duration
1700
1800
1588
1618
1.97
1.97
131.61
131.60
than • 120 mm3 @ 1400 bar
1900 1669 1.97 131.01
2000 1720 1.97 130.42
2100 1760 1.97 132.31
2200 1800 1.97 134.20
2300 1800 1.97 134.03
2400 1800 1.97 133.85
2500 1800 1.97 133.43
2600 1800 1.97 133.01
2700 1800 1.93 132.81
2800 1800 1.90 132.62
2900 1800 0.95 142.67
3000 1800 133.86 6.29 6.29 6.29
3100 1795 129.85 6.29 6.29 6.29
3200 1771 0.73 117.04 6.29 6.29 6.29
3300 1772 1.79 96.12 6.29 6.29 6.29
3400 1576 1.13 87.30 6.29 6.29 6.29
3500 1441 0.71 83.42 6.29 6.29 6.29
Test Specifications
 Bosch Test Plans available via subscription
 Current release 2016/A
 1300 Solenoid Injector Plans

 300 Piezo Injector Plans
 Covers
 Leak test
 Injector start behavior (without return flow
counter-pressure)
 Full-load quantity (VL)
 Pilot injection quantity (VE)
 Idle quantity (LL)
 Emission quantity (EM)
 Actuator resistance
Test Specifications
 Non-Bosch Injectors
 Templates available to produce your own
test plan
 Typical actuation times and pressures
entered
 Customer defines quantity and
tolerance
 Easy to enter and save
Using the Capabilities to Improve Revenue
Why is the customer here?

 What made the customer remove the
injector(s)
 Fault Codes
 Electrical
 Hydraulic
 Mechanical
 After treatment
 Diagnostics
 OE
 Internet
 None
 One or multiple Injectors
 Multiple = End of Life or System
problem
Testing Tips
 Pre-checks
 Inspect injector for:
 Damaged electrical connections
 Stretched studs
 Pin fretting/arching
 Shorts/opens
 Corrosion induced shorts
Testing Tips
 Pre-checks
 Debris
 Combustion leakage
 Physical damage
Testing Tips
 Pre-checks
 Corrosion
 Fuel contamination
Testing Tips
 Normal defect rates for OE manufactured
injectors < 1 per every 10,000 produced.
(defect in material or workmanship)
 Odds of having multiple OE manufacturing

defects in one engine, Extremely unlikely!
 Multiple injector failure is usually caused by

outside influences
Testing Tips
 High backflow @ leak test
 Ball seat erosion
 High pressure seal failure
 Typically requires complete flushing of fuel

system due to hard particles overwhelming
the filtration
 Confirmation of fuel filter used – micron rating
 Inform customer flushing needs to be done

before installing replacement injectors
Testing Tips
 Leak tests pass – other points fail
 Fuel contamination
 Defective bio-fuel
 Water in fuel
 Excessive additive
 Need to assess the quality of fuel used
 Inform customer flushing needs to be done

before installing replacement injectors
Customer Pick-Up
 How many failed?
 None
 Interview customer and find out more

details
 What made them remove the injector(s)
 Up-sell your diagnostic services

 Your own shop
 Referral shop
Customer Pick-Up
 All/Multiple
 Discuss mileage/age
 End of life
 Contamination
 Water in Fuel
 Up-sell complete fuel system
flush
 Discuss other potential damage
 Lines
 Pump
 Rail
Customer Pick-Up
 All/Multiple
 Contamination
 Dirt/hard particles in fuel
 Up-sell complete fuel system
flush
 Fuel tank cleaning
 Fuel tank vent system up-grade
Customer Pick-Up
 Protect your shop
 Document multiple failed injectors if you

cannot work on vehicle
 Document recommendations on how to

repair the vehicle
 High full load delivery can cause
cylinder failures – Recommend cylinder

inspection.
 Produce your own limited liability release
Thank You for your attention!

Eps 205 Work Shop Managing

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Eps 205 Work Shop Managing

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Bosch EPS205 Injection Tester

Bosch EPS205 Injector Tester

Ilidio Serra, Manager Technical Service and Support

ADS International Convention

 Common Rail Injectors

opening pressures for two spring

Common Rail Injectors

 Injectors up to 500 mm /st

 ISA Class detection improvement

 Piezo resistance improvement

 Backflow only test points now possible

Only available through test

 Improved peripheral support

 Provided no charge to all North American

NHA Testing vs Common Rail Testing

 In this process, the injector is operated at a

 From this map, the test points and the engine

 1300 Solenoid Injector Plans

 Easy to enter and save

Using the Capabilities to Improve Revenue

Why is the customer here?

 One or multiple Injectors

 Multiple = End of Life or System

 Damaged electrical connections

 Odds of having multiple OE manufacturing

 Multiple injector failure is usually caused by

 High pressure seal failure

 Typically requires complete flushing of fuel

 Confirmation of fuel filter used – micron rating

 Inform customer flushing needs to be done

 Need to assess the quality of fuel used

 Inform customer flushing needs to be done

 Interview customer and find out more

 What made them remove the injector(s)

 Up-sell your diagnostic services

 Up-sell complete fuel system

 Dirt/hard particles in fuel

 Up-sell complete fuel system

 Fuel tank vent system up-grade

 Document multiple failed injectors if you

 Document recommendations on how to

cylinder failures – Recommend cylinder

 Produce your own limited liability release

Thank You for your attention!

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