Eps 807

EPS 807 / 815
en Repair instructions
Injection pump test bench
en 2 | EPS 807 / 815 | 2EPS 807 / 815
Contents English
1. Symbols used 3 6. Repair works 16
1.1 In the documentation 3 6.1 Change Flywheel 16
1.1.1 Warning notices - 6.2 Replacing the drive motor 16
Structure and meaning 3 6.3 Change Test oil heating 17
1.1.2 Symbols – Designation and 6.3.1 Change Float switch 18
explanation 3 6.3.2 Change Temperature sensor 18
1.2 On the product 3 6.4 Readjusting the shut-off valve 19
1.3 Important notes 3 6.5 Change Heating exchanger 19
1.4 Safety instructions 4 6.6 Replacing the rotary encoder B1 20
1.4.1 Mains voltages and High voltages 4 6.6.1 Preparatory work 20
1.4.2 Rotation 4 6.6.2 Removing the rotary encoder B31 20
1.4.3 Dimensions and Weights 4 6.6.3 Removing the rotary encoder B4 20
1.4.4 Pressures 4 6.6.4 Removing the trigger wheel 20
1.4.5 Heat radiation 4 6.6.5 Removing the flange with
rotary encoder 21
2. Assembly and Disassembly 5 6.6.6 Removing the rotary encoder B1 21
2.1 Test-bench housing 5 6.6.7 Mounting the rotary encoder B1 21
2.2 Drive assembly 5 6.6.8 Mounting the flange with
2.3 Test oil heating 6 rotary encoder 22
2.4 Test oil circulation 6 6.6.9 Assembling the trigger wheel 22
2.4.1 Control valve Test Oil 7 6.6.10 Mounting the rotary encoder B4 22
2.4.2 Cut-off valve 7 6.6.11 Mounting the rotary encoder B31 23
2.5 Lubricating oil circulation 7
2.5.1 1. Generation 7 7. Adjustment and Functional Test 24
2.5.2 2. Generation 8 7.1 Test the operating unit 24
2.5.3 3. Generation 8 7.1.1 Test tip switch elements 24
2.5.4 Lubricating oil-Control valve 9 7.1.2 Test indicator lamps 24
2.6 Cabinet 9 7.1.3 Test emergency stop switch elements 24
2.6.1 Complete 9 7.2 Testing temperature sensors 24
2.6.2 Mounting panel 10 7.3 Testing cooling proportional valve 24
2.7 Economic transformer 11 7.4 Testing speed monitoring A5 (DZE) 25
2.8 Multiway tap with purge valve 11 7.4.1 Printed circuit board 1 688 400 009
(up to FD 12-2000) 25
3. Structure 12 7.4.2 Printed circuit board 1 688 400 251
3.1 Block diagram 12 (from FD 01-2001) 26
3.1.1 EPS 815 up to date of manufacture 7.5 Sensor compensation on AMKASYN-Converter
05-2002 12 (up to FD 05-2002) 27
3.1.2 EPS 815 from date of manufacture 7.5.1 Preparation 27
06-2002 12 7.5.2 Performing sensor compensation 27
3.2 Injection pump test bench 13 7.6 Sensor compensation on KU-Converter
3.3 Lubricating oil supply (Special accessories) 13 (from FD 06-2002) 28
3.4 Switch case 13 7.6.1 Preparation 28
7.6.2 Performing sensor compensation 28
4. Overview of possible fluctuations 14
8. Appendix 29
5. Troubleshooting 15
1 689 975 140 | 2013-07-01 Robert Bosch GmbH

Symbols used | EPS 807 / 815 | 3 en
1. Symbols used 1.3 Important notes

Installation and/or repair work may only be performed
1.1 In the documentation by trained and instructed Service personnel at Robert
1.1.1 Warning notices - Structure and meaning Bosch GmbH or by organizations appointed to do such
Warning notices warn of dangers to the user or people in work by Robert Bosch GmbH. If the devices are opened
the vicinity. Warning notices also indicate the consequenc- or modified by unauthorized persons, then all warranty
es of the hazard as well as preventive action. Warning no- claims will be rendered null and void.
tices have the following structure:
Electrical systems and resources may only be put into
Warning KEY WORD – Nature and source of hazard! operation when in proper operating condition (for more
symbol Consequences of hazard in the event of fail- information, refer to Inspection and testing information
ure to observe action and information given. 0108_084). This requirement is deemed to have been
¶¶ Hazard prevention action and information. fulfilled if after modification or repair (initial test) it has
been ascertained that requirements as specified by the
The key word indicates the likelihood of occurrence and electrotechnical rules have been adhered to. To this
the severity of the hazard in the event of non-observance: end, tests as under the type and scope of the measures
defined by the electrotechnical rules (e. in Germany BGV
Key word Probability of Severity of danger if in- A2) are to be conducted. The type and scope of tests are
occurrence structions not observed
specified in VDE 0701/0702 Section 1 within Germany.
DANGER Immediate impend- Death or severe injury
The relevant national specifications are to be adhered to.
ing danger
WARNING Possible impending Death or severe injury
danger !!Observe ESD handling instructions when working on
CAUTION Possible dangerous Minor injury the device when it is open. The instructions are avail-
situation able in EDIS at 'Bosch Test Equipment\Inspection &
Testing A-Z\General notes\Safety'.
1.1.2 Symbols in this documentation
Symbol Designation Explanation
! Attention Warns about possible property damage.

Information Practical hints and other
i
useful information.
1. Multi-step Instruction consisting of several steps.
2. operation
One-step Instruction consisting of one step.
e
operation
Intermediate An instruction produces a visible inter-

result mediate result.
Final result There is a visible final result on com-
"
pletion of the instruction.
1.2 On the product
!!Observe all warning notices on products and ensure

they remain legible.
Robert Bosch GmbH 1 689 975 140 | 2013-07-01

en 4 | EPS 807 / 815 | Symbols used
1.4 Safety instructions 1.4.4 Pressures

1.4.1 Mains voltages and High voltages
Damage under high pressure can cause
Hazardous voltages occur in both the leak of oil.
network and the electrical system. If con- High hydraulic pressures occur during the
tact is made with live parts, there is a risk operation of the injection pump test benches.
of electric shock from flashover voltages ¶¶ Wear eye protective ware.
caused by damaged insulation. That is why
the works on the electrical system or the 1.4.5 Heat radiation
operating materials may be performed only
by electric’s specialists or by authorised Danger of burns!
persons under guidance and supervision of The temperature on the surface of the brak-
an electric’s specialist in accordance with ing resistance can achieve >60°C.
electrical regulations. Open switch cabinet door can cause burn-
ing when touching the braking resistance on
1.4.2 Rotation the non-protected places.
¶¶ Avoid works in this area, in case they can
Danger of injury! not be evaded, allow the braking resis-
When working in the area with rotating tance to cool down first.
parts, there is a danger of injury caused by
inattention of the operator in that he can be
grasped on the clothing.
¶¶ Rotating parts must be masked off prop-
erly as far as possible.
1.4.3 Dimensions and Weights
If during the repair works bigger single

parts and assemblies are replaced, they
must be properly secured and attached on
the appropriate lifting devices so that they
can not cause any danger.
¶¶ Use only both technically faultless lifting
devices and load sensor with adequate
portability!
¶¶ Do not stay under suspended loads.
¶¶ Assign the check of loads only to experi-
enced persons.

Assembly and Disassembly | EPS 807 / 815 | 5 en
2. Assembly and Disassembly 2.2 Drive assembly
2.1 Test-bench housing
P
/2
22
/1
P 87
19 45
87
45
Fig. 1: Test-bench housing

Fig. 2: Drive assembly

en 6 | EPS 807 / 815 | Assembly and Disassembly
2.3 Test oil heating 2.4 Test oil circulation
1P
23
87
45
P
/3
20
87
45
Fig. 4: Test oil circulation

Fig. 3: Test oil heating

2.4.1 Control valve Test Oil 2.5 Lubricating oil circulation

2.5.1 1. Generation
458729
-14_P
al
Fig. 5: Control valve Test Oil
458729-16_Pal
2.4.2 Cut-off valve
Fig. 7: Lubricating oil circulation
45872
9-15_
Pal
Fig. 6: Cut-off valve
al
_P
-17
29
87
45
Fig. 8: Test Oil tank

2.5.2 2. Generation 2.5.3 3. Generation
al
_P
-18
29 al
87 _P
45 -20
29
87
45

al
_P
-19
29
87
45 al
_P
-21
29
87
45


2.5.4 Lubricating oil-Control valve 2.6 Cabinet

2.6.1 Complete
4587
29-22_
Pal
Fig. 13: Lubricating oil-Control valve
AZR
3 4
1 2
458
729
/6P
Fig. 14: Cabinet up to FD 05-2002
HAU
PTS
MAIN CHALTE
SWITC R
H
AMK
DANGER
_Pa
29-10
4587
Fig. 15: Cabinet from FD 06-2002

2.6.2 Mounting panel
2_Pal
29-1
4587
1_Pal
29-1
4587
Fig. 17: Mounting panel from FD 06-2002
Fig. 16: Mounting panel up to FD 05-2002

2.7 Economic transformer 2.8 Multiway tap with purge valve
4587
33P
P
/1
45
87
38 Fig. 19: Multiway tap up to FD 05-2000
Fig. 18: Economic transformer
l
3_Pa
29-1
4587
Fig. 20: Multiway tap 1 687 010 126 from FD 06-2000

en 12 | EPS 807 / 815 | Structure
3. Structure
3.1 Block diagram
3.1.1 EPS 815 up to date of manufacture 05-2002
458741-17_Pal
Fig. 21: Block diagram
3.1.2 EPS 815 from date of manufacture 06-2002
458741-17_Pal
Fig. 22: Block diagram

Structure | EPS 807 / 815 | 13 en
3.2 Injection pump test bench Code Designation Function

H2 Detecting lamp Drive motor "ON"
Code Designation Function H3 Detecting lamp Program Test oil heating "ON"
H4 Detecting lamp Lubricating oil engine "ON"
B1 Speed sensor Speed sensing
K1 Contactor Program Test oil heating
B2 Limit switch Limit switch test oil tank
K2 Contactor Heating protection
B3 Sensor Temperature sensor test oil tank
Q1 Main switch Mains switch-on
(long)
Q2 Engine circuit breaker Engine protector Test oil sup-
B4 Speed sensor Speed sensing (Speed monitoring)
ply
B5 Sensor Temperature sensor Inflow
S1 Emergency stop switch Emergency shutoff
E1 Heating element Test oil heating
S2 Pressure tip switch Converter "ON"
S3 Pressure tip switch Converter "OFF"
S4 Pressure tip switch Drive motor "ON"
M1 Three-phase motor Drive
S5 Pressure tip switch Drive motor "OFF"
M2 Three-phase motor Test oil supply
S6 Pressure tip switch Program Test oil heating "ON"
Y3 Control valve Cooling water regulation
S7 Pressure tip switch Program Test oil heating
"OFF"
S8 Pressure tip switch Lubricating oil engine "ON"
3.3 Lubricating oil supply (Special acces-
S9 Pressure tip switch Lubricating oil engine "OFF"
sories) T2 Control transformer Voltage supply MGT and KMA
T3 Control transformer Voltage supply 230V Socket
Code Designation Function T4 Control transformer Voltage supply. 100V in Japa-
nese version
M3 Three-phase motor Lubricating oil supply
V1 Si Rectifier Voltage supply for Stop / start
Q3 Engine protective Engine protection Lubricating oil
magnet
circuit supply
V2 Si Rectifier Voltage supply for Stop / start
S8 Pressure tip switch Lubricating oil engine ON
magnet
S9 Pressure tip switch Lubricating oil engine OFF
X2 Plug connection Measuring system MGT800 or
KMA 802
3.4 Switch case X3 Multi-pin socket Connection for PC, screen
and timing lamp
X4 Terminal Stop / Starting magnet -
Code Designation Function X5 Terminal Stop / Starting magnet +12V
A1 Electric module supply Mains module AN 10F X6 Terminal Stop / Starting magnet +24V
A2 Monitor unit Central module AZ 10 X7 Plug connection Computer interface drive
A3 Frequency converter Change straightening module
AW 14/24
A4 Populated PC board Computer card AZ R01
A5 Populated PC board Speed module DZE 800
F2 G-fusible link Safety fuse Secondary wind-
ing 24V/5AT on T2
F3 G-fusible link Safety fuse for secondary
winding +4V/5AT on T2
ing 20V/2,5AT on T2
ing 28V/2AT on T2
F6 Overload circuit breaker Safety fuse for Stop / Start
12V/7A
F7 Overload circuit breaker Safety fuse for Stop / Start
24V/7A
ing 230V/2,5AT on T3
F9 Overload circuit breaker Safety fuse for Test oil heat-
ing
F10 Overload circuit breaker Safety fuse for primary wind-
ing on T2
ing on T3
ing on T4
ing 100V/5AT on T4
H1 Detecting lamp Converter "ON"

en 14 | EPS 807 / 815 | Overview of possible fluctuations
4. Overview of possible
fluctuations
BOSCH MGT 824 min
EPS815
1 2 4 5 6 7 8 9 10 11 12
BOSCH KMA 802
EPS815
1 2 4 5 6 7 8 9 10 11 12 BOSCH
KMA 822
BOSCH KMA 802
EPS815
458726P
Fig. 23: Overview

Troubleshooting | EPS 807 / 815 | 15 en
5. Troubleshooting
Kurzzeichen Benennung Funktion Besondere Hinweise
Tip switch S2 (UE) 230 VAC supply is not available Checking transformer T3,
without efficiency (measuring on A1_X03 Terminals Safety fuse F11, F8
(Interruption LL0 and LL1) (measuring on Kl100/101)
drive-end circle)
Error A2 (AZ module) Using control unit of the measuring system
or AMK control unit Error diagnostics
Keep emergency tip switch Remove emergency stop switch S1
S1.17/18 depressed
DZE/A5 - Stop Interpret DZE error message
(PCB 1 688 400 009: LED V59 (Interface A5_X8 - A4_X77 is broken, inter-
lits and LED V78 blinks face A5_X10 - measuring system is bro-
or ken, speed recess is not switched on, po-
PCB 1 688 400 251: LED V29 lits sition recess is not kept, unequal running
and LED V23 blinks) direction)
A5 / Software is damaged Reinstall software for DZE/A5, if not suc-

(PCB 1 688 400 009: LED V59 cessful replace LP
lits and LED V78 is off
or
PCB 1 688 400 251: LED V29 lits
and LED V23 is off)
Hardware interruption in the Check the following cables: Precaution!
drive-end circle A2_X25 - A5_X11 (signals ES1 - ES2), If the main switch Q1 is on
A5_X11 (signals S1.21-S1.22, switch com- these cables lead 230V !
ponent S1.2 of control unit)
Interruption of the Transformer T2, Check F10 /engage, If transformer is in good condi-
emergency-off circle Safety fuse F2, F10 check F2 (F2 is mounted onto the terminal tion and safety fuses are secure
(there is 24 VAC be- strip Transformer T2) there is
tween A5_X1.3 and 24 VACbetween Kl160 and
A5_X1.2) Kl161
Emergency off S1.11-S1.12, Remove emergency switch-off S1 If the switch and cable are in
Cable Control unit good condition there is 24 VAC
between Kl160 and Kl165
Float switch, Fill up test oil or let temperature cool In order to correct the mistake
Tank temperature > 70°C down EPS must be switched-on dead
during shutoff on account of
tank >70°C .
There is 24 VAC between Kl160
and 166!
Engine circuit breaker Q2 Engage Q2, check the set release current
has activated (Secondary switch (1.8A), if necessary check test engine
1.13-1.14)
DZE / Connecting Cable A5_X2 - A2_X30/31 is dam- Check cable / After printing of S2 (UE) there
cable is damaged aged see Item 7.1 is approx. 24 VDC on A2_X31
(UE and 0V)!
If cable is in good condition.: see Item 7.2
Check A5 (LP DZE)

en 16 | EPS 807 / 815 | Repair works
6. Repair works 6.2 Replacing the drive motor
6.1 Change Flywheel 4
!!Bosch does not operate the lifting and removal tool. 3 5
1 2
2
3
1
4
8 6
9
458741/5
7
Fig. 24: Lifting and removal tool for the flywheel
1 Eye bolt DIN 580-M12
2 Hexagon nut M12
3 Hexagon screw M10 x 35-8.8
4 Hexagon screw M16 x 50-8.8 458741-06_Pal
Fig. 26: Overview of drive motor
Disassembly:
1
1. Remove the flywheel (see section 6.1).
2 2. Remove storage sheets from oil tray.
3. Put the wooden strip under the clamping rail (for
1/
4 support).
874
45 4. Remove inner hexagon screw (Fig. 26, Pos. 1) (4x)
between brackets (console) and engine flange.
Fig. 25: Overview of flywheel with drive motor
1 Centering piece 1
2 Intermediate flange
Disassembly Flywheel:
1. Remove the inner hexagon screw from adapter (Fig.
25, Pos. 1).
2. Remove the adapter (Fig. 25, Pos. 1).
3. Remove the inner hexagon screw (7x) from interme-
diate flange (Fig. 25, Pos. 2).
4. Deactivate intermediate flange (Fig. 25, Pos. 2) or
unseat using two hexagon screws M10 or M12 from
flywheel.
5. Fix flywheel (weight 62 Kg) using the applicable lift-
ing gear (see Fig. 24).
458741-07_Pal
6. Release flywheel from the cone by beating slightly 2
with a rubber hammer and lift it off. 3
Fig. 27: Securing the clamping rail
Montage:
¶¶ The assembly is carried out in reciprocal succession 5. Loosen hexagon screw (Fig. 27, Pos. 1) (2x) between
and comply with Instructions in Item 6.2. supporting frame and rubber-bonded metal.

Repair works | EPS 807 / 815 | 17 en
6. Unscrew the hexagon nut (Fig. 3, Pos. 7) (2x) to the 6.3 Change Test oil heating
end of the threaded bolt.
7. Remove the hexagon nut (Fig. 3, Pos. 6) (2x).
8. Tip the control cabinet.
9. Remove the oval head screw securing the front panel
6 3
(Fig. 3, Pos. 2) (4x) on the mounting frame (Fig. 3,
2
Pos. 4).
5 7
10. Dump front mask (Fig. 26, Pos. 2).
11. Remove hexagon screws (Fig. 26, Pos. 9) (4x). 4
12. Lift up supporting frame (Fig. 26, Pos. 4).
13. Remove hexagon screws (Fig. 26, Pos. 8) (8x) on
motor base.
14. Attach the drive motor (Fig. 3, Pos. 3) to the eye
bolts.
15. Lift the drive motor (weight 350 kg) from the sup-
port frame using the hoist.
1
Assembly:
¶¶ Reciprocal succession in relation to disassembly
!!When performing assembly of the brackets (console)

on the three-phase motor the brackets (console)
must be picked up onto the aligning pin Pos. 9 and
lay on the both cylindrical pins Pos. 10. The inner 4587
41/8
hexagon screws Pos. 7 must be tightened with one Fig. 28: Test oil heater with connecting cable
tightening torque of 80Nm.
!!During the assembly of the flywheel and the inter- !!When lifting the fastening panel (Fig. 28, Pos. 7) and
mediate flange the tightening torque for the inner demounting or mounting the heating elements
hexagon screws amounts to 70+5Nm (Fig. 28, Pos. 1) ensure that the float switch (Fig. 28,
Pos. 6) and the temperature sensor (Fig. 28, Pos. 3)
!!The assembly of the adapter is carried out with are not damaged for it can cause faulty measurement
70+5Nm. or failure of heater controls.
!!After the assembly of the flywheel it must be tested Disassembly:

for true running and face strike, in which here is only 1. Disconnect electrical connecting cable from the
max 0,05 mm permitted. damaged heating element (Fig. 28, Pos. 1) in the
switch cabinet.
!!Align the drive motor and clamping rail unit centrally 2. Pull connecting cable through the cable screwing.
on the support frame. 3. Remove hexagon screw (Fig. 28, Pos. 4).
4. Lift off fastening panel (Fig. 28, Pos. 7).
5. Remove inner hexagon screw (Fig. 28, Pos. 5).
6. Pull down heating elements.
Assembly:
¶¶ The assembly is carried out in reciprocal succession.

6.3.1 Change Float switch 6.3.2 Change Temperature sensor
0
/1
1/9 87
41
8 74 45
45
Fig. 30: Temperature sensor with connecting cable
!!When lifting the fastening panel (Fig. 28, Pos. 7) and

demounting or mounting of the temperature sensor
Fig. 29: Float switch with connecting cable ensure that the temperature sensor is not damaged,
otherwise it can cause faulty measurements or the
failure of heater controls.
!!It is not necessary to remove the fastening panel
while demouning the float switch. During the disas- Disassembly:
sembly ensure that the brass sleeve is not concealed 1. Pull off electric connecting cable of the damaged
or damaged, otherwise it can cause the failure of the temperature sensor (BNC plug).
float switch. 2. Remove hexagon screws (Fig. 28, Pos. 4).
3. Lift off fastening panel (Fig. 28, Pos. 7).
Disassembly: 4. Remove hexagon nuts.
1. Pull plug from float switch. 5. Pull up temperature sensor.
2. Remove inner hexagon screws (4x).
3. Pull up float switch. Assembly:
¶¶ The assembly is carried out in reciprocal succession.
Assembly:
1. Launch float switch in fastening panel.
2. Align float switch with cable port to the back.
3. Attach float switch with inner hexagon screw (4x).
4. Slip on plug.

6.4 Readjusting the shut-off valve 6.5 Change Heating exchanger
!!When mounting the shut-off valve ensure that the 3 4

2 1
pressure lines are not mistaken for pressure testers
(Danger of pressure testers destruction. See also
section 2.4).
Aligning the shut-off valve: 458741-11_Pal
1. Release counter nut. Fig. 31: Heat exchanger with valve

2. Screw in threaded pin to half. 1 Cooling water outlet
3. Tighten counter nuts. 2 Cooling water inlet
3 Test oil inlet
4. Switch on injection pump test bench.
4 Test oil outlet
5. Turn test oil control valve slowly to the left until the
shut-off closing.
6. Observe the lock point. !!When connecting the cool water and test oil cables
7. Release counter nuts. ensure that they are joint in the counter current.
8. If the indicated pressure is over 6 bars screw out Should this regulation stayed unnoticed it can cause
threaded pin. If the indicated pressure is lower than decreased cooling result.
6 bars screw in threaded pin.
9. Tighten counter nuts. Disassembly:
1. Demount cool water hose lines
2. Demount test oil hose lines
3. Screw out heating exchanger with fastening panel
completely
Assembly:
¶¶ Reciprocal succession in relation to disassembly

6.6 Replacing the rotary encoder B1

1
iiThe following description only applies to the drive
motor 1 687 220 905.
2 3
6.6.1 Preparatory work 4
1. Turn off the EPS 815 at the master switch.
2. Disconnect the EPS 815 from unit from the mains
and secure to prevent renewed switch-on.
3. Remove the component connected to the flywheel.
4. Remove the side cover (Fig. 32, Pos. 1) on both
5
sides.
1
4587
41-1
9_Pa
l
HAUPTS
Fig. 33: Drive motor with rotary encoder B31
CHALTE
MAIN SWITCH R
6.6.4 Removing the trigger wheel

1. Remove the hexagon socket head bolt (Fig. 34,
45877
2-1
Pos. 4).
2. Remove the housing flange (Fig. 34, Pos. 1).
Fig. 32: Removing the side panel 3. Remove the retaining ring (Fig. 34, Pos. 3) with
retaining ring pliers.
6.6.2 Removing the rotary encoder B31 4. Remove the trigger wheel (Fig. 34, Pos. 2) from the
shaft. Do not lose the feather key in the shaft.
iiThe rotary encoder B31 is not contained as standard
in the EPS 815 and is retrofitted in conjunction with
the test sets VPM 844 and CAM 847. In it's as-deliv-
ered condition, the EPS 815 has a cover in place of
1 2 3 4
the rotary encoder B31.
1. Loosen the collet chuck. To do so, unscrew the hexa-

gon socket head bolt (Fig. 33, Pos. 5).
Pos. 4).
3. Remove the rotary encoder B31 (Fig. 33, Pos. 3) or
the cover (Fig. 33, Pos. 2).
4587
41-2
0_Pa
l
6.6.3 Removing the rotary encoder B4

1. Remove the connecting cable from rotary encoder Fig. 34: Removing the trigger wheel
B4 (Fig. 33, Pos. 1).
2. Remove the rotary encoder B4 (Fig. 33, Pos. 1). To
do so, loosen the lock nut and then unscrew the
rotary encoder B4.

6.6.5 Removing the flange with rotary encoder 4. Remove the hexagon socket head bolt (Fig. 37,
1. Carefully loosen all clamping bolts (Fig. 35, Pos. 2) Pos. 1).
counterclockwise by half a rotation. 5. Remove the rotary encoder B1 (Fig. 37, Pos. 2) from
2. Remove the hexagon socket head bolt (Fig. 35, the flange.
Pos. 3).
3. Carefully pull the flange with the rotary encoder
(Fig. 35, Pos. 1) from the shaft.
2
2
1
4587
41-2
1_Pa
l
Fig. 35: Removing the flange with rotary encoder
6.6.6 Removing the rotary encoder B1 Fig. 37: Removing the rotary encoder B1
Pos. 1) for the cable clamp. 6.6.7 Mounting the rotary encoder B1
2. Remove the cable clamp (Fig. 36, Pos. 2). 1. Place the new rotary encoder B1 in the flange.
2. Loosely screw in the hexagon socket head bolt
!!When pushing out the plug insert (Fig. 36, Pos. 3), (Fig. 37, Pos. 1). Do not tighten!
make sure the pins do not bend. 3. Attach the connecting cable.
3. Carefully push the plug insert (Fig. 36, Pos. 3) of the

12-pole connector out of the plug housing using a
screwdriver (Fig. 36, Pos. 4).
2
4
3
458741-22_Pal
Fig. 36: Removing the plug insert

4. Push the plug insert (Fig. 38, Pos. 3) into the plug 6.6.8 Mounting the flange with rotary encoder
housing, with consideration for the plug coding. The 1. Carefully push the flange with the rotary encoder
plug housing must click in audibly. If the plug insert (Fig. 40, Pos. 1) onto the shaft.
does not click in, remove the plug housing then push 2. Secure the flange with the hexagon socket head bolt
in the plug insert and place on a surface. Using a (Fig. 40, Pos. 3).
plastic-headed hammer, carefully tap the plug insert 3. Tighten all three clamping bolts (Fig. 40, Pos. 2)
into the plug housing (see Fig. 39). clockwise with a torque wrench.
5. Fasten the connecting cable with a cable clamp Tightening torque: 2.5 +0.5 Nm
(Fig. 15, Pos. 2) and a hexagon socket head bolt 4. Use a torque wrench to tighten the hexagon socket
(Fig. 15, Pos. 1). head bolt (Fig. 40, Pos. 4).
Tightening torque: 2 ±0.2 Nm
1
5. Secure the hexagon socket head bolt using screw
2 locking agent (Fig. 40, Pos. 4).
3
4
2
1
458741-25_Pal
3
4587
41-2
6_Pa
l
Fig. 38: Mounting the plug insert
Fig. 40: Removing the flange with rotary encoder
6.6.9 Assembling the trigger wheel

¶¶ Assemble the trigger wheel in the opposite order to
when you removed it (see Section 6.6.4).
6.6.10 Mounting the rotary encoder B4

1. Screw the rotary encoder B4 (Fig. 33, Pos. 1) into
the housing flange.
2. Adjust the gap between the rotary encoder and the
trigger wheel with a feeler gage.
Set dimension: 0.3 mm
3. Fasten the rotary encoder B4 with lock nuts.
4. Check the gap between the rotary encoder and the
41-2
4_Pa
l
trigger wheel with a feeler gage.
4587
5. Attach the connecting cable to the injector.
Fig. 39: Plug housing with plug insert

6.6.11 Mounting the rotary encoder B31
iiThe rotary encoder B31 is not contained as standard

in the EPS 815 and is retrofitted in conjunction with
the test sets VPM 844 and CAM 847. In it's as-deliv-
ered condition, the EPS 815 has a cover in place of
the rotary encoder B31.
1. Push the rotary encoder B31 (Fig. 41, Pos. 3) onto

the coupling shaft or attach the cover (Fig. 33,
Pos. 2) and secure with hexagon socket head bolts
(Fig. 41, Pos. 4).
2. Tighten the hexagon socket head bolt (Fig. 41,
Pos. 5) with a torque wrench.
Tightening torque: 1.2 Nm
3. Attach the connecting cable.
2 3
4
4587
41-1
9_Pa
l
Fig. 41: Drive motor with rotary encoder B31
4. Attach the side covers of the EPS 815.

en 24 | EPS 807 / 815 | Adjustment and Functional Test
7. Adjustment and Functional 7.2 Testing temperature sensors

Test ¶¶ Resistance measurement on X2 (connection measur-
ing system) with switched on EPS:
$$ Between Pin 16/17: tank temperature sensor
7.1 Test the operating unit $$ Between Pin 18/19: inlet temperature sensor
""At temperature of 25°C these sockets have
!!Precaution: switch off main switch before the test !! 1005 ±5 Ohm.
7.1.1 Test tip switch elements 7.3 Testing cooling proportional valve
1. Disconnect plugs X3 and X5 on the printed board A5. 1. Connect and open water inlet.
2. Test the following pins compared with pin 9 with 2. Attach 24Vdc onto X2 (connection measuring sys-
continuity tester on plug X3: tem), onto Pin 12 and 13 (possibly take away from
$$ Pin 1 – Lubricating oil OFF X4 and X6)
$$ Pin 2 – Lubricating oil ON ?? Cooling valve must be open.
$$ Pin 3 – Heating OFF
$$ Pin 4 – Heating ON !!When exchanging instrument and return leads the
$$ Pin 5 – Regulator release OFF valve must be always open.
$$ Pin 6 – Regulator release ON
$$ Pin 7 – Converter OFF
$$ Pin 8 – Converter ON
""Through-way is available each time by pressing the
orresponding key
7.1.2 Test indicator lamps

1. Disconnect terminal X5 from the printed board A5.
2. Test compared with pin 3 with continuity tester:
$$ Pin 1 - H2 (Lamp Regulator release)
$$ Pin 4 - H1 (Lamp Converter ON)
$$ Pin 5 - H3 (Lamp Heating)
$$ Pin 6 - H4 (Lamp Lubricating oil)
""If through-way is available the corresponding lamp is
in good condition
7.1.3 Test emergency stop switch elements

¶¶ Test for through-way between terminals 161 and 165
as well as on printed board A5 between X11_1 and
X11_3 .
""Interruption by pressing emergency stop

Adjustment and Functional Test | EPS 807 / 815 | 25 en
7.4 Testing speed monitoring A5 (DZE)

7.4.1 Printed circuit board 1 688 400 009 (up to
FD 12-2000)
If main switch Q1 is on the following LED’s must lit on

A5 (DZE) (in the left down corner):
$$ V63 - 24V-Supply (control signal on converter)
$$ V62 - 12V- Supply (tip switch evaluation and
speed measurement)
$$ V60 - 5V- Supply (computer, logic, interface etc.)
If not, test the supply of the LP (transformer T2, safety
fuses F10, F5).
Further LED V78 should blink (watchdog). This identifies

a proper performance of the program. Should it be off
the operating program must be reinstalled (download).
LED V59 identifies the stop command of the speed
measurement on the driver. Blinking indicates error
(interface to the control unit / indicating instrument or
converter is interrupted, maximal speed is exceeded,
false running direction etc.) – comply with error mes-
sage of the BAG.
The following LED’s are analogue to the lamps of the

EPS control unit/:
$$ V70 – Acknowledgement Converter ON
(corresponds to H1)
$$ V72 – Acknowledgement Regulator release
(corresponds to H2)
$$ V74 – Program Heating (corresponds to H3)
$$ V23 – Lubricating oil pump (corresponds to H4)
Herewith damaged lamps or cables can be possibly

detected.
Fig. 42: Printed circuit board 1 688 400 009

7.4.2 Printed circuit board 1 688 400 251 (from FD

01-2001)
If main switch Q1 is on the following LED’s must lit on

A5 (DZE):
$$ V55 - 24V-Supply (control signal on converter)
$$ V68 - 5V- Supply (computer, logic, interface etc.)
If not, test the supply of the LP (transformer T2, safety
fuses F10, F5).
Further LED V23 should blink (watchdog). This identifies

a proper performance of the program. Should it be off
the operating program must be reinstalled (download).
LED V29 identifies the stop command of the speed
measurement on the driver. Blinking indicates error
(interface to the control unit / indicating instrument or
converter is interrupted, maximal speed is exceeded,
false running direction etc.) – comply with error mes-
sage of the BAG.
Fig. 44: Printed circuit board 1 688 400 251 (from 07-2004)
Fig. 43: Printed circuit board 1 688 400 251 (from 01-2001 till
06-2004)

Adjustment and Functional Test | EPS 807 / 815 | 27 en
7.5 Sensor compensation on AMKASYN- 7.5.2 Performing sensor compensation

Converter (up to FD 05-2002) 1. Press the key .
?? The following message appears:
Tools required: ENC.ADJUST. SERVICE
RR AZ-Terminal (AZB) 1 687 023 427 ERR.RESET SYSTEM
7.5.1 Preparation 2. To select the "ENC.ADJUST." function press the keys

1. Connect the control panel (AZB) to the connector <Shift> + <F1/F3>.
X35 (Pos.1) on the AZ module. ?? A password is then requested
3. Use the numeric keyboard on your control panel to
enter the password "12345".
4. Confirm your entry by pressing the key: <CR>.
5. Enter the AW number "1'.
7. Switch "Converter and calibration-fluid supply" and
"Drive motor" (Controller enable) ON.
8. Select the "JOG MODE" function, to do so press the
<F4/F2> key
X35 ?? A speed request appears in the control panel display.
1 9. Use the numeric keyboard on your control panel to
entrer a low speed value (100 - 150 [rpm]), e.g. "521".
10. Confirm your entry by pressing the key: <CR>
ABORT
CW-rot. CCW-rot.
!!For hazardous-free operation the drive motor should be

capable of rotating freely (clutch must be disassembled)
11. For the purpose of sensor compensation the drive

motor has to be turned in both directions. To this end
start the speed control using the <F1/F3> key (CW
red) or <F2/F4> (CCW red.). Keep pressing the keys.
The drive motor then turns in the specified direction.
458784-5 ?? The drive motor then turns in the specified direction.
12. Change direction occassionally using the <F1/F3>
keys (CW red) or <F2/F4> (CCW red.) until the fol-
Fig. 45: AMKASYN-Converter lowing message appears on the control panel display:
Encoder data in ser. EEPROM
2. Switch on the EPS using the main switch. 13. The following message appears after the data has
?? After switching on the EPS the following message been accepted: Succesful enc. adjaust.
is displayed in the control panel: System Ini- 14. Use the mains switch to switch off the EPS.
tialization 15. Disconnect the control panel from the AZ module.
?? Following successful initialization the following 16. Use the main switch to switch on the EPS again
message appears: System ready. and perform a functional test.
3. On the control panel press the F4/F2 key
?? The following message appears: !!The drive must be running in order to perform a func-
ERR.RESET SYSTEM tional test. To this end neither a pump nor a clutch
DIAGNOSIS START-UP may be clamped onto the flywheel on the EPS.

"Drive motor" (Controller enable) ON.
18. Start the drive at a speed of approx. 1000 rpm.
19. After successfully performing sensor compensation
no speed fluctuations (surging) or loud drive noise
may occur duirng operation.

7.6 Sensor compensation on KU-Convert- 11. Change direction occassionally using the
er (from FD 06-2002) <Shift> + <F1> (Drehen +) key or <Shift> + <F2>
(Drehen -) until the following message appears on
Tools required: the control panel display:
RR KU-Terminal (KUB) 1 687 023 426 Geberabgleich erfolgreich!
12. Use the mains switch to switch off the EPS.
7.6.1 Preparation 13. Disconnect the control panel from the KU module.
1. Remove cable from DZE board at inverter terminal 14. Connect cable from DZE board at inverter termi-
X35 and connect data terminal with adapter cable. nal X35.
2. Switch on the EPS using the main switch. 15. Use the main switch to switch on the EPS again
?? Following successful initialization the following and perform a functional test.
message appears: System bereit!.
!!The drive must be running in order to perform a func-
7.6.2 Performing sensor compensation tional test. To this end neither a pump nor a clutch
1. Press the key < >. may be clamped onto the flywheel on the EPS.
2. Press the key <o> (2x).
?? The following message appears: 16. Switch "Converter and calibration-fluid supply" and
AKTUELLE WERTE "Drive motor" (Controller enable) ON.
GEBERABGLEICH 17. Start the drive at a speed of approx. 1000 U/min.
18. After successfully performing sensor compensation
3. Confirm your entry by pressing the key: <CR>. no speed fluctuations (surging) or loud drive noise
?? A password is then requested. may occur duirng operation.
4. Use the numeric keyboard on your control panel to
enter the password "12345".
"Drive motor" (Controller enable) ON. Keep pressing
the keys.
7. Select the "Tippen" function, to do so press the <F2>
key
?? A speed request appears in the control panel dis-
play. Drehzahl ....... U/min
8. Use the numeric keyboard on your control panel
to enter a low speed value (100 - 150 U/min), e.g.
"521".
9. Confirm your entry by pressing the key: <CR>
Drehen + Drehen -
!!For hazardous-free operation the drive motor should

be capable of rotating freely (clutch must be disas-
sembled)
10. For the purpose of sensor compensation the

drive motor has to be turned in both directions.
To this end start the speed control using the
<Shift> + <F1> (Drehen +) or <Shift> + <F2>
(Drehen -). Keep pressing the keys.
?? The drive motor then turns in the specified
direction.

Appendix | EPS 807 / 815 | 29 en
8. Appendix
RR Hydraulic diagram
RR Circuit diagram

0 1 2 3 4 5 6 7 8 9
L1 /4.0
L2 /4.0
L3 /4.0
SL /4.0
-F10 -F10
10A 1 3 6A 1 3
2 4 2 4
+20V
-20V
400V
440V
460V
480V
500V
+20V
-20V
400V
0V
0V
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4
-T3 -T3 -T3
2 kVA 2 kVA 736 VA
. 400 400 400
SL
-T1
SL 15 16 SL 15 16 SL 15 16
230V
230V
230V
0V
0V
0V
-F10
1 1 1 102
1 * 3
-X1.6 1 2 3 SL -F8 -F8 -F8 -X1.2
102 10A
2 102 10A
2 102 3A
2
2 4 3.5 3.2 3.8
3.7
102
101 101 101 3.8

100 3.6 100 3.4 100 3.8 101
3.5 3.2 3.8
3.7
Alternativ: Alternativ: 100
T3= 1 687 224 280 oder ...281 T3= 1 687 224 281 T3= 1 687 224 271
-Q1
U V W
Anschluss bei 200-240V bzw.440-500V Anschluss bei 400V Anschluss bei
(mit T1) (ohne T1) Standard-Bestckung
L1 L2 L3
PE
-X1.2 100 SL 101 SL
T3-Bestell-Nr. Klemmen- Nr. (Spg. in Volt) F10
1 2 3 4 5 6 7 8 *
1 687 224 280 +10 0 -10 200 220 230 240 --- 16A
1 687 224 281 +20 0 -20 400 440 460 480 500 10A
Bauseitige
Absicherung: N SL L' N L1
fr 200 - 240V = 50A

-X3
M
fr 400 - 500V = 35A 1
230Vac
~ -M4
Steckdosen- Lfter
Leiste
Option:
T1 = 1 687 224 253 (200,220,230,240V)
T1 = 1 687 224 256 (440,460,480,500V)
2 4
Datum 06.10.04 =
68Y2370-04 05.10.04 Ge. Robert Bosch GmbH Hauptstrom EPS 815 R 017
68Y3133-02 24.06.02 Ge. Bearb. EHW3-Ge. +
EPS815R 3
Stromlaufplan 1 689 911 376
1680S00052 29.08.11 Ge. Gepr. 19.09.11 Bl.
nderung Datum Name Norm Urspr.088/FVB10 Ers.f. Ers.d. DIN A3 7 Bl.

0 1 2 3 4 5 6 7 8 9
3.9/ L1 L1 /5.0
3.9/ L2 L2 /5.0
3.9/ L3 L3 /5.0
3.9/ SL SL /5.0
Q2 Q3
1 3 5 1 3 5
1.8A 0.7A
-F9.1 -F9.2 -F9.3
6A . 6A . 6A .
. . .
1 3 5
-Q2 -Q3 -K2
7.1 7.2 7.1
2 4 6 2 4 6 2 4 6
1 3 5
-K3
5.5
2 4 6
-X1.1 1 2 3
W1 V1 U1 W1 V1 U1 -E1 SL -E2 SL -E3 SL

1 1 1
-M2
M -M3
M 2 2 2
3 3
~ ~
-X1.1 4 5 6
Option:
Prf”l- Schmier”l- Prf”l-
Pumpe Pumpe Heizung
3 5
Datum 06.10.04 =
68Y2370-04 05.10.04 Ge. Robert Bosch GmbH Steuertrafo,Pumpen,Heizung EPS 815 R 017
68Y3133-02 24.06.02 Ge. Bearb. EHW3-Ge. +
EPS815R 4
1680S00052 29.08.11 Ge. Gepr. 19.09.11 Bl.
nderung Datum Name Norm Urspr.088/FVB10 Ers.f. Ers.d. DIN A3 7 Bl.

0 1 2 3 4 5 6 7 8 9
4.9/ L1 L1 /6.0
4.9/ L2 L2 /6.0
4.9/ L3 L3 /6.0
4.9/ SL SL /6.0
1 3
-F11
2 4
6A
+20V 0V -20V 400V

1 2 3 4
-T2
14
-K2
7.1
13
SL 15 16 17 18 19 20 21 22 23 24 25
0V 20V 0V 24V 0V 14V 0V 14V 0V 24V 28V
Khlventil Tank Zulauf
-K3 -B3 -B5

1 1
Z1
24V~ A1 sw SSS SSS
-F4 -F5 -F6 -F7 -F2 -F3 -Y3

2 2 A2 bl SIG SIG
2.5AT 2AT 7A 7A 5AT 5AT
13
Brcke
-Q2 14
7.1
-V1 -V2
-X1.2 160 161 162 163 1 2 3 4 5 6 7 8 9 10 11 12
-X1.3 1 2 3 4 5 6 7 8 9 10 11 12
X1.3 1 2 3 4 5 6 7 8 9 10 11 12
gn/ge
gn/ge
gn/ge
gn/ge
gn/ge
2 5 7 8 9 12 13 16 17 18 19
32 33 34 35 36 2 5 7 8 9 12 13 16 17 18 19
161 /7.0
X4 X5 X6 -X2
160 /7.0
0V 12V= 24V=
28VAC1
28VAC0
BED-SL /7.6
1 2 4.7
Signal- & Spannungsversorgung Meásystem
3 4 4.7
5 6 4.7
4 6
Datum 06.10.04 =
68Y2370-04 05.10.04 Ge. Robert Bosch GmbH Steuertrafo/Klemmleiste EPS 815 R 017
68Y3133-02 24.06.02 Ge. Bearb. EHW3-Ge +
EPS815R 5
STROMLAUFPLAN 1 689 911 376
1680S00052 29.08.11 Ge. Gepr. 19.09.11 Bl.
nderung Datum Name Norm Urspr. 088/FVB10 Ers.f. Ers.d. DIN A3 7 Bl.
0 1 2 3 4 5 6 7 8 9
5.9/ L1
5.9/ L2
5.9/ L3
5.9/ SL
SBUS-RX /7.6
SBUS-TX /7.6
SBUS-GND /7.6
SCHIRM-X35 /7.6
GN G0I 10
9
B1
YE G0N
AMK-Geber
BK G1I 4
VI G1N 3
BU G2I 2
RD G2N 1
BN 5V 11
OR GND 6
5
7
8
-A1
KU10, -14
X35
PE 2 3 5 Schirm X31 1 2 3 4 5 6 7 8 9
X01 L1
L1 nur bei A1=KU14 X01 L2
X01 L3 2 3 5 Schirm 1 2 3 4 5 6 7 8 9
-L1 X35 X31
1 3 1 X08/1 SL
2 X08/2 X02 W
2 4 3 X08/3 X02 V
4 X08/4 X02 U
PE
-A2
KU-R01/AG1
-R2 bn X03 UZP -M1
X04 RBN U V W
20R SL
X03 UZN
M
3
40R 40R
bl
~ SL
X04 RBP TH R1 TH
Schirm
X33
RT2
RTB2
RTB1
X05 RT1
X33 1 2 3 4 5 6 7 8 9 10
X06 X07
1 2 3 4 5
QRF /7.0
WBA/EF /7.0
0V /7.0
RF /7.0
WEF /7.0
SCHIRM-X07 /7.0
5 7
Datum 06.10.04 =
68Y2370-04 05.10.04 Ge. Robert Bosch GmbH Kompakt-Umrichter, Motor EPS 815 R 017 +
68Y3133-02 24.06.02 Ge. Bearb. EHW3-Ge
EPS815R 6
1680S00052 29.08.11 Ge. Gepr. 19.09.11 Bl.
0 1 2 3 4 5 6 7 8 9
X7
-B4 -X2 16
1 6 2 7 3 8 4 9 5
VDO-Geber 3 20 11 10 14 15 6 1 15
10
6.4/WBA/EF
14
6.4/ QRF
+ -
6.4/ 0V 2 2 2 2
6.4/ RF 3 20 11 10 14 15 6 1 H1 H2 H3 H4
6.4/ WEF 24V
1
24V
1
24V
1
24V
1
.4/ SCHIRM-X07 13
UE RF HZG SMOL
1 2 3 4 5 6 7 1 2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6
X10
X2 X6 -X4 1 2 3 4 5 6 7 8 9 10 X5
1
X3/1
2
X3/2
3
X3/3
4
X3/4
5
X3/5
-A5 6
DZE 800 X3/6
7
X3/7
8
X3/8
9
X3/9 S2 4 S4 4 S6 4 S8 4
4 4 4 4
3 3 3 3
S3 3 S5 3 S7 3 S9 3
X1
UE1 RF1 HZG1 SMOL1

7 6 5 4 3 2 1 X8
1 2 3 4 5 6 7 8 9 UE0 RF0 HZG0 SMOL0
7 6 5 4 3 2 B2
6.4/ SCHIRM-X35
1 T>70øC
28Vac1 SBUS-RX
6.4/
11 21
6.4/ SBUS-TX
28Vac0 1.53
bn bl 6.4/ SBUS-GND
Q2 -S1 12 22
1.54 -X1.2 170 165 164 X1.4/5 18
X1.4/4 17
X1.4/3 12
X1.4/2 11
5.4/ 161
X1.4/1 GN/YE
5.4/ BED-SL SL
Notaustaster
A1 A1 A1
-K2 -Q2 -Q3

A2 A2 A2
5.4/ 160
Bedienger„t
Sonderzubeh”r
Schmier”l-Versorgung
1 2 4.7 2 4.3 2 4.5

3 4 4.7 4 4.3 4 4.5
5 6 4.7 6 4.3 6 4.5
13 14 5.5 13 14 5.7
6
68Y3133-02 24.06.02 Datum 06.10.04 =
Ge. Robert Bosch GmbH DZE und EPS-Bedienger„t EPS 815 R 017
68Y3019-01 31.01.01 Ge. Bearb. EHW3-Ge +
EPS815R 7
1680S00052 29.08.11 Ge. Gepr. 19.09.11 Bl.
Historie
2013-07-01 Pal Kapitel 2 Montage / Demontage erweitert mit Varianten Schmierölversorgung
Kapitel 3.1 Blockschaltbild hinzugefügt.
Kapitel 6.6 Drehgeber B1 wechseln neu hinzugefügt
Kapitel 7.4 erweitert mit DZE LP Versionen
Robert Bosch GmbH
Diagnostics
Franz-Oechsle-Straße 4
73207 Plochingen
DEUTSCHLAND
www.bosch.com
bosch.prueftechnik@bosch.com
1 689 975 140 | 2013-07-01

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EPS 807 / 815

1 689 975 140 | 2013-07-01 Robert Bosch GmbH

1. Symbols used 1.3 Important notes

Symbol Designation Explanation

! Attention Warns about possible property damage.

1.2 On the product

!!Observe all warning notices on products and ensure

Robert Bosch GmbH 1 689 975 140 | 2013-07-01

1.4 Safety instructions 1.4.4 Pressures

1.4.3 Dimensions and Weights

If during the repair works bigger single

1 689 975 140 | 2013-07-01 Robert Bosch GmbH

2. Assembly and Disassembly 2.2 Drive assembly

2.1 Test-bench housing

Fig. 1: Test-bench housing

Robert Bosch GmbH 1 689 975 140 | 2013-07-01

2.3 Test oil heating 2.4 Test oil circulation

Fig. 4: Test oil circulation

1 689 975 140 | 2013-07-01 Robert Bosch GmbH

2.4.1 Control valve Test Oil 2.5 Lubricating oil circulation

Fig. 5: Control valve Test Oil

Fig. 7: Lubricating oil circulation

Fig. 6: Cut-off valve

Fig. 8: Test Oil tank

Robert Bosch GmbH 1 689 975 140 | 2013-07-01

2.5.2 2. Generation 2.5.3 3. Generation

Fig. 9: Lubricating oil circulation

Fig. 10: Test Oil tank

1 689 975 140 | 2013-07-01 Robert Bosch GmbH

2.5.4 Lubricating oil-Control valve 2.6 Cabinet

Fig. 13: Lubricating oil-Control valve

Fig. 14: Cabinet up to FD 05-2002

Fig. 15: Cabinet from FD 06-2002

Robert Bosch GmbH 1 689 975 140 | 2013-07-01

2.6.2 Mounting panel

Fig. 17: Mounting panel from FD 06-2002

Fig. 16: Mounting panel up to FD 05-2002

1 689 975 140 | 2013-07-01 Robert Bosch GmbH

2.7 Economic transformer 2.8 Multiway tap with purge valve

Fig. 18: Economic transformer

Fig. 20: Multiway tap 1 687 010 126 from FD 06-2000

Robert Bosch GmbH 1 689 975 140 | 2013-07-01

3.1.2 EPS 815 from date of manufacture 06-2002

Fig. 22: Block diagram

1 689 975 140 | 2013-07-01 Robert Bosch GmbH

3.2 Injection pump test bench Code Designation Function

Robert Bosch GmbH 1 689 975 140 | 2013-07-01

BOSCH KMA 802

BOSCH KMA 802

Fig. 23: Overview

1 689 975 140 | 2013-07-01 Robert Bosch GmbH

A5 / Software is damaged Reinstall software for DZE/A5, if not suc-

Robert Bosch GmbH 1 689 975 140 | 2013-07-01

6. Repair works 6.2 Replacing the drive motor

6.1 Change Flywheel 4

!!Bosch does not operate the lifting and removal tool. 3 5

Fig. 26: Overview of drive motor