bosch eps205 injector tester using the capabilities to improve

1 AA/SNA9.2 | 6/3/2016 | © 2016 Robert Bosch LLC and affiliates. All rights reserved.

Bosch EPS205 Injection Tester

Automotive Aftermarket

Bosch EPS205 Injector TesterUsing the Capabilities to Improve Revenue

Ilidio Serra, Manager Technical Service and SupportRobert Bosch, LLCAutomotive Aftermarket, AA Technical Service and Support NABroadview, IL

ADS International Convention August 5, 2016Las Vegas, NevadaWynn Las Vegas




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 mm3/st

(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 Increasing pressure causes nozzle needle to

lift Lifting nozzle needle causes pressure to drop

and needle seats Non-quantified flow from nozzle

Rate that pressure is maintained affects: Spray Pattern Chatter


NHA Testing vs Common Rail Testing Common Rail Testing

Pressure to injector is constant Pressure regulated by test bench

Nozzle needle lifting controlled by activation of injector Continuous flow from nozzle while activated Quantifiable flow from nozzle

0

50

100

150

200

250

300

Pressure

990.0

992.0

994.0

996.0

998.0

1000.0

1002.0

Pressure




Injector Mapping During the development stage an injector is

run through a process called mapping.

In this process, the injector is operated at a 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 calibration values are determined as an injector can be operated at any pressure and actuation time combination.

VL

VE LL

TL/EM

VE




Typical Full Load Curve (with Regeneration) Injected quantity can be varied based on rail

pressure and activation time i.e.:

80 mm3 @ 600 bar has a longer duration than • 120 mm3 @ 1400 bar

ERPM Pressure Q1 Q2 Q3 Q4 Q5 Q6500 598 2.23 95.40 6.29 6.29 6.29600 573 2.37 92.32 6.29 6.29 6.29700 586 2.30 95.29 6.29 6.29 6.29800 613 2.17 96.72 6.29 6.29 6.29900 698 2.18 100.77 6.29 6.29 6.29

1000 749 1.97 101.51 6.29 6.29 6.291100 836 1.97 99.49 6.29 6.29 6.291200 930 1.97 109.57 6.29 6.29 6.291300 1077 1.97 114.61 6.29 6.29 6.291400 1234 1.97 115.60 6.29 6.29 6.291500 1413 1.97 125.811600 1549 1.97 130.891700 1588 1.97 131.611800 1618 1.97 131.601900 1669 1.97 131.012000 1720 1.97 130.422100 1760 1.97 132.312200 1800 1.97 134.202300 1800 1.97 134.032400 1800 1.97 133.852500 1800 1.97 133.432600 1800 1.97 133.012700 1800 1.93 132.812800 1800 1.90 132.622900 1800 0.95 142.673000 1800 133.86 6.29 6.29 6.293100 1795 129.85 6.29 6.29 6.293200 1771 0.73 117.04 6.29 6.29 6.293300 1772 1.79 96.12 6.29 6.29 6.293400 1576 1.13 87.30 6.29 6.29 6.293500 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





Inspect injector for: Debris Combustion leakage Physical damage





Inspect injector for: 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





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





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!

bosch eps205 injector tester using the capabilities to improve

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