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
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 Bosch EPS205 Injection Tester

Description
Multi-purpose Injector Testing
Device
Conventional Nozzle Holder

Assemblies
Unit Injector Nozzles

Common Rail Injectors

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

Improvements
Windows 7 Update
32 GB vs. 2 GB

Improved peripheral support

Provided no charge to all North American

EPS205 customers

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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 s to the maximum
actuation time in 10 s 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.

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

Using the Capabilities to Improve Revenue

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

Testing Tips
Pre-checks
Inspect injector for:

Damaged electrical connections

Stretched studs

Pin fretting/arching

Shorts/opens
Corrosion induced shorts

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

Testing Tips
Pre-checks
Inspect injector for:

Debris

Combustion leakage

Physical damage

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

Testing Tips
Pre-checks
Inspect injector for:

Corrosion

Fuel contamination

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

Customer Pick-Up
How many failed?
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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

Customer Pick-Up
How many failed?
All/Multiple

Contamination

Dirt/hard particles in fuel

Up-sell complete fuel system

flush
Fuel tank cleaning

Fuel tank vent system up-grade

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

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

Automotive Aftermarket
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 Bosch EPS205 Injection Tester

Thank You for your attention!

Automotive Aftermarket
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