Operating Instructions Emissions Analysis Measuring Instrument
Contents
1. Endtest 3 5 Display measurement results Result Display Y rn AVERAGE VALUE gt Al MEASURE gt gt lt MEASURE gt lt MEASURE N k m weess k 1 54m M k agri ta SS en k 1 39 m ENT ENT ENT ENT SHIFT ENT Y Y Y Y AVERAGE VALUE gt 9 MEASURE 1 gt t gt lt MEASURE2 gt lt MEASURE N IDLE 780 rpm M IDLE 780 rpm IDLE 780 pm 77777 IDLE 780 rpm H ENT ENT ENT ENT SHIFT ENT Y Y Y Y AVERAGE VALUE gt lt MEASURE 1 gt L 3 MEASURE 2 gt lt MEASURE N gt MAX 5560 rpm Wi MAX 5570 rpm MAX 5560 rpm MAX 5560 rpm 4 4 ENT ENT ENT ENT SHIFT ENT Y Y Y Y AVERAGE VALUE gt lt MEASURE 1 gt gt lt MEASURE 2 gt lt MEASURE N Tacc 1 125 IK Tacc 1 21s Tace 09s 777 77 Tacc 0 96s kk ENT ENT ENT ENT SHIFT ENT Y Y Y Y AVERAGE VALUE gt lt MEASURE 1 gt gt lt MEASURE 2 gt lt MEASURE N gt Thold 2 45s Thold 3 03s Thold 276s 77 7 7 Thold 2 45 s ENT The function is quit at any place by pressing the ESC key ESC END In the menu Result Display the mean values and all measurements of the following parameters can be displayed Turbidity value Idle speed Cutoff speed Acceleration time Hold time You can toggle between the average value and the mea2. H CUTOFF SPEED 5050 rpm SHIFTAENT ENT Y A CUTOFF SPEED L 4 CUTOFF SPEED OK gt 3 NOTOK A EGA NOT PASSED ENT M A for measurement Tev ups for Result Menu After the message COMPLY WITH TEST CONDITIONS and acknowledgement with ENT you will see a prompt in the display requiring you to enter the oil temperature Enter the oil temperature and confirm it by pressing ENT With category A and oil temperature more than 60 C itis possible to skip oil temperature input by pressing ENT Bringing the engine up to normal operating temperature H If the engine is not brought up to the specified operating temperature there is a danger of it being damaged by carrying out the exhaust gas analysis test Apart from that all the measured values subsequently gained may possibly be incorrect To check that the engine temperature has reached the specified value use the oil temperature sensor to measure the oil temperature prescribed only for category A vehicles Connect the oil temperature sensor to plug in socket 5 of the VSM Adjust the immersion depth of the oil temperature sensor to match that of the oil dipstick see figure Insert the oil temperature sensor instead of the oil dipstick The engine oil temperature is displayed Remove the oil temperature sensor ENT only possible with category A and oil temperatur
3. v TEST PIN IN CALIBRATION SLOT ENT CALIBRA CRC C ENT v CRC CHECK 4 numbers input v CRC CHECK 7895 gt BC 0E27 ENT No ENT OK No Y LINEARITY OK ENT ENT ROUTINE CHECK DEFECTIVE E FILTER CLEAN Save meas value with the key max 10 Y Unit as in configuration RESULT SHOW gt RESULT lt PRINT gt RESULT lt QUIT ENT Meas value T ENT RESULT N2 0 0 gt ENT 21 8 2 Calibration date The Calibration date submenu gives the choice between DISPLAY SET and DELETE In the first case the last calibration date is displayed and cannot be changed The other two options are only for authorised staff e g the staff of the calibration agency In both cases an error message is displayed RTM error 2020 Command presently not available Adjustment switch ENT returns you to the submenu The calibration date is stored in the RTM To calibrate the system the calibration seal must be broken and the calibration switch in the RTM must be pressed After calibration has been completed the calibration switch must be reset and anew seal attached After the RTM opacimeter has been calibrated the procedure must be concluded with the menu item Set calibration date 8 3 Calib
4. 20 6 5 Print A test print containing the date time and all printable characters is printed 7 The Service Menu The submenu accessible from the SERVICE can only be reached by entering a code Only authorised After Sales Service staff can access this submenu 8 The Calibration Menu 8 1 Overview The CALIBRATION menu allows you to read information such as the calibration date and to check and change settings such as the CRC check You can choose from the following submenu items see also figure entitled CALIBRATION MENU CALIBRATION DATE CALIBRATION MEASUREMENT CHECK linearity check CRC CHECK SELECTION EGA DIESEL gt SELECTION lt DIAGNOSIS gt SELECTION lt CONFIGURATION gt SELECTION lt TEST FUNKTIONS gt SELECTION lt SERVICE gt SELECTION lt CALIBRATION CALIBRA lt CALIB CALIB DATE SHOW gt CALIB DATE lt SET gt CALIB DATE lt DELETE ENT y CALIB DATE 13 12 98 EN RTM FEHLER 2020 JUSTIERSCHALTER T ENT J CALIBRATION lt CALIB MEASURE gt ENT CALIBRATION lt LINEARITY gt v PLEASE WAIT ZERO ADJUSTMENT ENT Y 0 ARE STORED N 0 0 1 ARE STORED N 0 0 ESC v PLEASE WAIT ZERO ADJUSTMENT
5. These are used correspondingly to evaluate the EGA By pressing ENT you confirm the engine type selected and move on to the next input field 3 2 3 Selecting the probe to be used The emission probe used must be selected with the arrow keys and gt Probe 1 with a 10mm diameter or probe 2 with a 16mm diameter By pressing ENT you confirm the probe type selected and move on to the next input field 3 3 Engine preconditioning and prechecks from rated value input and measured parameters Program sequence depends on system configuration Engine conditioning Idle speed Cutoff speed measurement COMPLY WITH TEST CONDITIONS T ENT D OILTEMPERATURE 60 90 88 0 C T ENT only possible with category A and ENT oil temperature more than 60 REMOVE OILTEMP ROBE i ENT only possible with category A and ENT gi oil temperature less than 60 SPEED 788 rem _ SPEED 788 rpm SPEED 788 rpm SPEED t drm PULSES 1 f M PULSES 2 pl lt PULSES 25 5 amp e ENT PULSES 25 5 ENT ENT is possible if no speed is measured then triggering in RTM to follow SHIFT ENT SPEED 788 rpm RESTZEIT 105 Y IDLE SPEED T 780 rpm ENT vi Y ACCELERATE STEP BY STEP wl HOLD CUTOFF SPEED IFOR 3 s SHIFTSENT ENT or accelerate SPEED 5050 rpm SHIFT ENT MAK Re SCH
6. gas analysis test requires setpoints and measuring parameters This data must be input into the exhaust gas measuring system as reference values so that the measured values can be compared and evaluated This data can be procured either direct from the vehicle manufacturer or importer or purchased from institutes or publishing houses that compile the data from various vehicle manufacturers This data can be entered manually into the relevant input fields from vehicle and customer identification Rated value input and measured parameters VEHICLE I VEHICLE CATEGORY A gt lt CATEGORY B ENT ENT ENGINE ASPIRATED gt ENGINE lt TURBOCHARGED PROBE 1 10 mm PROBE 2 16 mm v M for idle speed and cutoff speed measurement 12 3 2 1 Selecting vehicle category Using the arrow keys and select vehicle category A or category B 3 to 6 measurement rev ups are performed for category A vehicles 4 to 10 measurement rev ups are performed for category B vehicles By pressing ENT you confirm an input and move on to the next input field 3 2 2 Selecting engine type In this input field you must select the engine type ASPIRATED or TURBOCHARGED using the arrow keys 4 and gt There are different limit values in the standard at this point for the respective categories
7. identification in configuration PRINTER ON OFF IDENTIFICATION ke IDENTIFICATION MM y IDENTIFICATION NEW gt LD VEH LIC PLATE CH T ENT few veh lic plate Yes delete old data SHIFT ENT VEHICLE MAKE CH SHIFT ENT ENT x VEHICLE MODEL CH SHIFT ENT ENT A VEHICLE TYPE e SHIFT ENT ENT ENT MILEAGE ENT be Customer IDENTIFICATION Yes CUSTOMER 6 24 CHARACTERS 1 LINE There are three options for vehicle customer identification None The report printout contains no details about the vehicle and customer New The report printout contains the data that you input during the following procedures Old customer data is not deleted it is displayed and can be altered see section 2 3 2 Input or Edit mode By pressing ENT you confirm an input and move on to the next input field By pressing SHIFT ENT you can return to the previous input field pressing repeatedly brings you back to the main menu However if you change the registration number the program assumes that you are dealing with a new customer and automatically deletes all previous data The report printout contains the data last entered It is not possible to make any changes 11 3 2 Setpoint input and measuring parameters Each exhaust
8. the breakaway speed displayed is plausible and stable the engine speed RPM measured by means of the alternator s residual ripple is correct If not you must choose a different method of measuring the engine speed RPM 2 5 Program and menu overview When you switch on the Emission Analysis Measuring Instrument EAM the software first of all carries out a self test Afterwards the main menu appears containing 6 menu items selection options that are selected using the cursor keys and and confirmed by pressing the ENT key EGA Diesel Diesel exhaust gas analysis test Diagnosis Configuration Test functions Service Calibration Self test VSM T AUTOM v Download TDM firmware T AUTOM v RTM and TDM self tests In case of malfunction show cause AUTOM SELECTION EGA DIESEL DIAGNOSIS CONFIGURATION TEST FUNCTIONS SERVICE CALIBRATION EGA DIESEL DIAGNOSIS CONFIGURATION TEST FUNCTIONS CONT MEASURE SW VERSIONS RPM REV UPS LANGUAGE OIL TEMPERATURE DATE TIME VOLT BATTERY REPORT HEADING PRINT PRINTER UNITS CODE xxxx v SERVICE CALIBRATION IFACE PC HOST CALIB DATE IFACE TDM CALIB MEASURE FACE RTM LINEARITY CRC CHECK DISK PRINTER INTERN PRINTER EXTERN DTL KEYS DTL DISPLAY SYSTEM e VSD Each of these menu items is described in a separate section Most of the menu items offe
9. the installed tape printer or the connected external printer PDR 203 or PDR 212 will print The serial printer interface SST can also be configured for communication with a PC host PRINT DEALER YES or NO The 7 x 24 characters described in section 5 5 Report header which contain the test station dealer s address can either be printed or not PRINT CUSTOMER YES or NO The 6 x 24 characters of customer identification usually the name and address can either be printed in the test report or not If you select YES you can enter this information during the test procedure but at no other time PRINT VEHICLE YES or NO The vehicle data registration number manufacturer model etc can either be printed in the test report or not If you select YES you can enter this information during the test procedure but at no other time 5 7 Units In the UNITS submenu you can choose between two units of measurement for the opacity values K value in m Opacity value in 96 or This setting only affects what is displayed in the TEST FUNCTION OPACITY menu 19 6 The Test Functions Menu 6 1 Overview The TEST FUNCTIONS menu enables you to use the system like a simple measuring unit i e without test procedures The following measurements are possible RPM OIL TEMPERATURE BATTERY VOLTAGE PRINT Pressing ENT always returns you to the menu SELECTION lt EGA DIESEL gt SELE
10. to vehicle earth Connect the clip on sensor to the connecting cable blade receptacle Only ever connect one engine speed sensor The system automatically selects the engine speed sensor connected Connect the black clamp of the connecting cable to vehicle earth Ho Set the number of pulses and cylinders in accordance with the source used for picking up the engine speed RPM Only use a clip on sensor that matches the diameter of the injection tubing 2 4 1 The clip on sensor Measuring point Clip on sensors are wearing parts eum 0 The points listed below must always be observed when handling clip on sensors so that damage to the foil in the clip on sensor and therefore failures can be avoided and the service life of the pickup can be extended The clamping point must be perfectly smooth The clip on sensor must not be rotated after being clamped with the securing clip Only use a clip on sensor that matches the diameter of the injection tubing If the diameter of the clip on sensor is too large it is not possible to measure the engine speed RPM If the diameter of the clip on is too small the pickup may be If the injection tubing is too thin clamp the clip to the irreparably damaged next metal part available Never use emery paper or other tools to clean the clip on The clip on sensor must not be rotated around the sensor injection tubing after being clamped The clip on sensor must be clamp
11. 1 09 95 18 53 11 09 95 18 53 T ENT M ENT ENT ENT DATE TIME 11 09 95 18 53 I ENT 18 5 2 Software versions By pressing ENT you can display three pieces of information containing a number and date one after the other VSM Power supply control module with national code MTM Motor Test Module contained in the VSM RTM Opacimeter 5 3 Language In the LANGUAGE submenu you can select the language you want to work with using the lt and gt cursor keys and then confirm your selection by pressing ENT This setting is stored permanently i e it is not lost when the Measuring Instrument is switched off 5 4 Date and time In the DATE TIME submenu you can choose between DIS PLAY and SET In the first case you cannot make any changes in the latter you are switched to Edit mode see section 2 3 2 Input or Edit mode and you can re enter or change the date and or time The field that can be changed flashes pressing ENT moves you to the next field Pressing ESC either exits the menu or displays the old setting if changes have been made 5 5 Report heading The REPORT HEADING submenu contains 7 lines in which enter the address of the test station The details of the test station are then printed out automatically on the report printouts 5 6 Printer In the PRINTER submenu you can set the printer type and the form of the report printout PRINTER INTERNAL or PDR203 PDR212 IFACE PC HOST Either
12. CTION lt DIAGNOSIS gt SELECTION lt CONFIGURATION gt SELECTION lt TEST FUNKTIONS gt SELECTION lt SERVICE gt SELECTION I CALIBRATION Test menu TEST FUNCTION lt RPM gt ENT TEST FUNCTION TEST FUNKTION TEST FUNCTION v ENT dependend on the last setting Y Speed 4000 rpm IMPULSE 1 gt 4 Speed 1000 min IMPULSE 4 gt OIL TEMPERATURE lt VOLT BATTERY gt lt PRINT ENT ENT ENT Y Y v OIL TEMPERATURE VOLT BATTERY PRINTER 25 1 C 12 4 V PLEASE WAIT c ENT EMI S or after printout ENT 1 Speed 250 rpm Speed rpm lt IMPULSE 56 2 9 IMPULSE 56 ATTENTION pressing the key an input field is opened for additional impulse numbers only entry of class1 6 2 Engine speed RPM The engine speed RPM is displayed continuously Using the With the ES C key back to the Main Menu 6 4 Battery voltage The battery voltage is displayed continuously in volts V cursor keys and gt you can select the number of pulses of the engine speed sensor depending upon the engine to be tested 6 3 Oil temperature The temperature is displayed continuously in C
13. F blinks Meas value is displayed Meas value is stored Throt off Yes Yes RESULT RESULT RESULT RESULT PRINT lt SHOW lt CURVE lt QUIT ENT ENT S i ji e y back to Main Menu Y Yy m min KURVE Curves SELECTION m lt 4 0 34 870 gt lt k1 Kn gt only if rev ups are available EI ENT ENT Yy C hPa lt 4 120 1020 gt ENT Curve is printed out ESC 16 In the DIAGNOSIS menu you have the choice of two types of measurement CONTINUOUS MEASUREMENT and FREE ACCELERATION Use the cursor keys lt and gt to make your selection and confirm it by pressing ENT 4 1 Continuous measurement Procedure Connect the engine speed sensor to the vehicle Start the engine and if necessary warm it up Insert the exhaust gas probe into the exhaust pipe and make sure it is seated securely Caution Hot probe A The exhaust gas probe may still be very hot from being used beforehand for testing a different vehicle You then select the number of pulses and cylinders proceed as described in the passage Selecting the number of pulses and cylinders in section 3 3 Engine preconditioning and prechecks The current engine speed RPM is also displayed at the same time After selecting confirm the inputs by pressing ENT You can now carry out up to 25 measurement rev ups at different engine speeds RPM Once the engi
14. Make sure that all test connections are properly plugged in and secure Never open the casing of the screen Danger of acid burning in the respiratory system gt When exhaust gas measurements are taken the sam pling hoses which are used release a highly caustic gas hydrogen fluoride that can cause acid burning in the respiratory system when heated to temperatures in excess of 250 C 482 F or in the event of fire Safety precautions Consult a doctor immediately after inhaling Always wear gloves made of neoprene or PVC when removing combustion residues Neutralize any residues left after a fire with a calcium hydroxide solution This produces non toxic calcium fluoride which can be washed away Danger of acid burning Ty Acids and alkalis can cause severe burning on unprotected skin Hydrogen fluoride forms hydrofluoric acid in combination with moisture water The condensate which accumulates in the sampling hose and in the condensate container likewise contains acid When replacing the O sensor it should be remembered that it contains alkali Safety precautions Rinse any affected parts of the skin immediately in water then consult a doctor The O sensor is a hazardous waste and must be disposed accordingly Bosch technical equipment suppliers are able to dispose of the sensors O in the appropriate manner If liquid crystal escapes from a damaged liquid crystal display it is imp
15. OT PASSED appears in the display 13 3 4 Rev up measurement next measurement from engine conditioning and pre check Measurement rev ups INSERT PROBE T ENT F MEASUREMENT REV Gal UPS TO FOLLOW Ca T ENT Y PLEASE WAIT ZERO ADJUSTMENT v IDLE 5s v Accelerate ENT M t D tegory A 3 6 rev ups tegory B 4 10 rev ups FULL THROT 60s Text FULL THROT blinks riggering over the Russ does not function press the ENT key at the same time FULL THROT Acceleration detected text FULL THROT does not blink TROT OFF After 3 s cutoff speed text THROT OFF blinks k1 10 175m Meas value is displayed Idle speed further Evaluation routine decides whether the further rev up rev up is necessary NO A PLEASE WAIT DRIFT ERROR measurement in the purging phase PURGE DRIFT FAULT rift ok No DRIFT 0 30 m t Yes valuation o k Yes i EGA PASSED ENT Result Menu 14 RESULT RESULT RESULT RESULT lt SHOW gt lt Quit ENT ENT ENT ei Report is SURVE printed out Result display ki gt Back to the main menu dc ESC ENT s A Curve is printed out The prompt INSERT PROBE will be displayed before the measurement rev ups Caution Hot probe The exhaust gas probe may still be very hot
16. Operating Instructions Emissions Analysis Measuring Instrument EAM 3 011 S20 Program description BOSCH Bosch Test Technology Certified Ouality Management Systems according to DIN EN ISO 9001 by Kraftfahrt DIN EN ISO 9001 Bundes Sy Zertifizierungsstelle Ch 47 AS SUMAN AGEN Reg Nr 4066 01 Reg Nr Z 1037 17 UK MOT approved for vehicles category AandB For your nearest UK Service point please contact Robert Bosch Ltd P O Box 98 Broadwater Park North Orbital Road Denham Uxbridge Middlesex UB9 5HJ Tel 01895 838 888 Fax 01895 838 349 Before starting up and operating the unit al ways read through the operating instructions and particularly the safety instructions thoroug hly In this way you can avoid any uncertainties with respect to use of the unit thus ensuring your own safety and preventing damage occur ring to the unit All work on the engine as well as the con nection of testers in the engine area and on the ignition system must be performed only when the engine is not running and the ignition is switched off Licencing agreements By using this program you agree to be bound by the following terms and conditions 1 Copyright This software and data is the property of Robert Bosch GmbH or her suppliers and is protected with respect to duplication by copyright laws international agreements and other national legal provisions No part of this dat
17. Program and menu overview The sequence charts Overview of the exhaust gas test The EGA Diesel Diesel exhaust gas analysis test Vehicle and customer identification Setpoint input and measuring parameters Engine preconditioning and prechecks Rev up measurement Display measurement results The Diagnosis Menu Continuous measurement Free acceleration The Configuration Menu Overview Software versions Language Date and time Report heading Printer Units The Test Functions Menu Overview Engine speed RPM Oil temperature Battery voltage Print The Service Menu The Calibration Menu Overview Calibration date Calibration measurement Check CRC check Error Messages Maintenance 10 1 Checking display accuracy 10 2 Maintaining the calibrating pen Page 000000 A 0 gt On 16 17 17 18 18 19 19 19 19 19 19 20 20 20 20 20 20 21 21 21 22 22 22 22 22 23 23 23 Instructions for your personal safety and for the protection of equipment vehicle components High voltage G Mains voltages Hazardous voltages occur in both the lighting system and the electrical system of a motor vehicle If contact is made with live parts e g with the ignition coil there is a risk of electric shock from flashover voltages caused by damaged insulation e g ignition cables which have been attacked by martens This applies to both the primary side and the secondary side of th
18. The display The display consists of a 2 line LCD with 16 characters per line This means that a number of words must be abbreviated Long instructions are displayed as moving letter displays that repeatedly run across the screen The display is backlit and this function can be switched on and off by means of the key combination SHIFT I 2 2 What the keys mean The cursor keys are used for selecting options in menus Standard mode or for moving the cursor Edit mode gt Menu selection or move cursor one character to the right Menu selection or move cursor one character to the left Confirmation key ENT Confirming menu selection or input or pro gressing through the test program Cancel key ESC Cancel the current program step and return to the main menu Delete key DEL Menu selection to the right like gt Standard or deletes the character to the left of the cursor Edit mode Shift key SHIFT Switches over to the second level of key assignments input of the yellow characters Shift only applies to the next character Space bar SPACE Inserts a blank Number keys 0 9 Keys for entering numbers Decimal point Letters keys A Z Keys for entering letters SHIFT lt Key with yellow lettering gt Key combination for entering the special yellow character Special function keys For storing measured values for continuous measurement and checking only SHIFT I Key combination for
19. a and software may be duplicated or sold and such action is a punishable offence should these conditions be contravened Robert Bosch GmbH shall reserve the right to prosecute and to claim damages 2 Liability All data in this program are based as far as possible on manufac turers and importers specifications Robert Bosch GmbH shall accept no liability for the accuracy and completeness of this software and data nor for any damage caused by faulty software and data In all cases the extent of liability of Robert Bosch GmbH shall be limited to the actual amount the customer has paid for this product This disclaimer of liability shall not apply to damage caused willfully or through gross negligence on the part of Robert Bosch GmbH C Copyright 1994 Robert Bosch GmbH All rights reserved Contents Instructions for your personal safety and for the protection of equipment vehicle components ao oo ch ch ch OO P oO 1 7 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 3 3 1 3 2 3 3 3 4 3 5 4 4 1 4 2 5 5 1 5 2 5 8 5 4 5 5 5 6 5 7 6 6 1 6 2 6 3 6 4 6 5 7 8 8 1 8 2 8 3 8 4 8 5 9 10 General Information Application Who it is made for Guarantee Description of the unit Operating the RTM 430 Opacimeter Publication entitled Connecting Test Systems to the Vehicle Definitions of terms The Basics The display What the keys mean Program control RPM measurement
20. asuring Instrument see Description of the unit and to the vehicle Number of marks The number of pulses used for RPM measurement engine speed measurement using a TDC sensor depends upon the type of TDC sensor system You must know how many pins or notches there per 360 rotation of the crankshaft 2 4 3 The RIV sensor Measuring point Connect the RIV sensor to the injection pump Connect the connecting cable of the RIV sensor to plug in socket 2 of the Emission Analysis Measuring Instrument instead of the clip on sensor connecting cable see Description of the unit Number of pulses The number of pulses used for RPM measurement engine speed measurement using an RIV sensor depends upon the type of engine The number of pulses must be set accordingly for 4 stroke engines pulse number 1 for 2 stroke engines pulse number 2 2 4 4 RPM measurement engine speed measurement by means of alternator residual ripple battery connecting cable B B The battery connecting cable B B is used to measure the engine speed RPM of compression ignition diesel engines by means of the vehicle electrical system Functional description The engine speed RPM is measured by evaluating the residual ripple of the alternator output voltage This signal is however superimposed by interference To be able to detect the useful signal amongst this interference an adaptation phase of approx 15 to 30 seconds is requi
21. brating plug in socket of the receiver end on the underside of the unit The display displays the following text example OPACITY 50 8x 1 63x m The measured opacity value must be between 45 and 55 or 1 40 m and 1 80 m If a measured value is displayed that is not within this tolerance the RTM opacimeter must be serviced in house see Operating Instructions RTM 430 AT PR UBF 956 1 Part Number 1 689 979 651 After servicing the check using the calibrating pen must be repeated If servicing does not lead to the desired effect contact your Bosch After Sales Service representative 10 2 Maintaining the calibrating pen Remove any dust deposits on the calibrating pen using a bellows type lens brush as used for cleaning camera lens Under NO circumstances use compressed air because this would damage the calibrating pen 23 Emissions Analyse MeBgerat EAM 3 011 S20 O 684 103 120 BOSCH Robert Bosch GmbH Gesch ftsbereich KH Produktbereich Pr ftechnik Postfach 1129 D 73201 Plochingen 1689 981 666 KH PR UBF 957 2 En 08 12 98 Printed in the Federal Republic of Germany Imprim en R publique F d rale d Allemagne par Robert Bosch GmbH
22. cters can be added As soonas the cursor is visible you are in Input or Edit mode and are Preparing the measuring point able to move the cursor by means of the cursor keys in order to change individual characters The keys have the following meaning The clearance between the clip on sensor and the next bend in the tubing must be at least 10 mm Move cursor one character to the left gt Move cursor one character to the right Clean the clamping point in a straight section of the injection DEL Deletes the character to the left of the cursor and tubing using sandpaper the remaining characters are shifted to the left ESC Rejects the changes and displays the old content The metal at the clamping point must be bare and must be again as a flashing display The cursor disappears totally smooth no dents etc Remove the insulation from around insulated injection tubing 2 4 RPM measurement Connecting to the vehicle The engine and ignition must always be switched off Determine the diameter of the injection tubing and select an N before any work is carried out on the ignition system appropriate clip on sensor The standard clip on sensor KG6 6 mm is enclosed If the car in question has injection Before performing RPM measurement engine speed tubes with a different diameter your can order appropriate AX measurement always connect the B clamp of the clip on sensors available as special accessories battery connecting cable B B
23. down first this also applies to auxiliary heating systems Keep the tester connecting cables well away from all hot parts Do not leave the engine running any longer than necessary for the test or setting Noise Noise levels in excess of 70 dB A can occur when measurements are carried out on a vehicle especially at high engine speeds Damage to hearing may result if human beings are exposed to noise at such levels over an extended period of time Safety precautions If necessary noise protection facilities must be provided by the owner at all workplaces in the vicinity of the testing area If necessary suitable personal noise protection facilities must be used by the operator 1 General Information 1 1 Application The Emissions Analysis Measuring Instrument EAM is used for measuring the emissions of smoke from diesel engined vehicles 1 2 Who it is made for The Emissions Analysis Measuring Instrument has been built for trained expert personnel in the automotive sector In order to ensure your own safety and to prevent damage to the equipment as a result of improper use please read the information in these Operating Instructions carefully 1 3 Guarantee Never carry out any modifications to our products Furthermore KH PR products must only be used in conjunction with genuine accessories Non compliance shall render all terms of the guarantee void Despite having taken the utmost of care while programm
24. e ignition system to the cable harness and the plug connections to the lighting systems Litronic and to the tester connections Safety precautions All testers must be connected to properly grounded shock proof sockets Testers must always be connected using the power cables supplied with them All extension cables must be fitted with shock proof contacts Any cables with damaged insulation must be replaced e g power or ignition cables Connect testers to the lighting system and switch them on before connecting them to the vehicle Connect testers to the engine ground or to the battery B before switching on the ignition Always switch off the ignition before performing any work on the electrical system of the vehicle The term work includes connecting testers replacing parts of the ignition system removing assemblies e g generators connecting assemblies to a test bench etc Wherever possible tests and settings should always be carried out with the ignition switched off and the engine stationary If tests or settings are carried out with the ignition switched on or the engine running care must be taken not to touch any live parts This applies to all the connecting cables of the testers as well as to the connections of any assemblies at the test bench Test connections must always be made using suitable connec tors e g Set of Test Cables 1 687 011 208 or vehicle specific adapter cables
25. e less than 60 C Selecting the number of pulses and cylinders To measure the engine speed RPM you must select the correct number of pulses and cylinders to match the engine being tested This enables the rotational speed of the engine speed sensor connected to be identified For details see section 2 4 RPM measurement engine speed measurement Before performing RPM measurement engine speed measurement always connect the B clamp of the battery connecting cable B B to vehicle earth Use the arrow keys gt to select the number of pulses or cylinders 1 2 3 4 5 6 8 10 12 16 288 You can freely edit the number of pulses by pressing the key Confirm the number of pulses by pressing ENT Measuring the breakaway speed This measuring step is not obligatory and can be skipped by pressing ENT Starting from idle speed accelerate the engine carefully up to breakaway speed To avoid damaging the engine accelerate the engine e ging g g slowly up to breakaway speed If the max tolerance is exceeded abort the procedure immediately The breakaway speed is now measured over a period of 3 seconds and a mean value is calculated If the breakaway speed is o k confirm it by pressing ENT The rev up measurement is then started automatically If the breakaway speed is not o k confirm this by pressing the cursor keys lt and gt and then press ENT The message EXHAUST GAS ANALYSIS TEST N
26. ed onto the injection tubing in such a way Connecting to the Emission Analysis Measuring Instrument that it does not make contact with any other components wires hoses engine etc Connect the clip on sensor connecting cable to plug in socket 2 of the Emission Analysis Measuring Instrument see Clamp the clip on sensor onto the cleaned section of Description of the unit injection tubing as shown in the figure When making the connection injection tubing level A must Connect the Emission Analysis Measuring Instrument plug flush with the the switching surface level B of the clip on in socket 1 see Description of the unit to vehicle earth using sensor clamp B of the battery connecting cable B B in order to achieve equipotential bonding during RPM measurement engine speed measurement Number of pulses The number of pulses used for RPM measurement engine speed measurement using a clip on sensor depends upon the type of engine The number of pulses must be set accordingly with a 4 stroke engine 1 pulse with a 2 stroke engine 2 pulses 2 4 2 The TDC sensor Measuring point If the vehicle manufacturer has installed a TDC sensor in the vehicle or there is a hole provided for fixing the workshop TDC sensor to be used RPM measurement engine speed measu rement can be carried out using this sensor Connect the vehicle specific TDC sensor connecting cable to plug in socket 3 of the Emission Analysis Me
27. erative to avoid direct contact between the liquid and the skin as well as inhalation or swallowing Safety precautions Wash the skin and clothing thoroughly with soap and water if it comes into contact with liquid crystal Consulta doctor immediately after inhaling or swallowing liquid crystal Danger of asphyxiation Car exhaust fumes contain carbon monoxide CO a colorless odorless gas If inhaled carbon monoxide causes an oxygen deficiency in the body Extreme caution is therefore essential when working in a pit as some of the components of the exhaust gas are heavier than air and settle at the bottom of the pit Caution is also necessary when working on LPG driven vehicles Safety precautions Always ensure effective ventilation and suction especially when working in a pit Always switch on and connect the suction plant in a closed area Danger of injury OY Danger of crushing If the vehicle is not prevented from rolling away there is a danger of people being crushed against a workbench for example Both running and stationary engines have rotating and moving parts e g belt drives which may cause injuries to fingers and arms A special hazard is presented by electrically driven fans in that they may be switched on without warning while the engine is stationary and the ignition is switched off There is a danger of tripping over the protruding rollers the connecting cables and the power cable of t
28. from being used beforehand for testing a different vehicle Insert the exhaust gas probe into the exhaust pipe and make sure that it is seated securely Then confirm the prompt by pressing ENT The following information is displayed PURGING AND MEASUREMENT REV UPS WILL FOLLOW Press ENT If necessary zero adjustment will be carried out After waiting for 5 seconds Idle you will receive the prompt FULL THROT Push the accelerator pedal to the floor quickly and without jolting and hold it there until the prompt RELEASE appears After a short evaluation period the result of the first measurement appears The evaluation is different for category A vehicles and category B vehicles Category A vehicles At least 3 measurement rev ups are carried out If all measured values are lt 2 00 m then no further evaluation is carried out and the measurement is deemed passed If not all measured values are 2 00 m the mean value of the last 3 measurements is calculated The lowest turbidity factor of these 3 measured values must be greater than or equal to 7596 of the mean value If the measurement is not valid another measurement rev up is carried out The new mean value of the last 3 measurements is then calculated Up to a maximum of 6 measurement rev ups are carried out If the maximum number of measurement rev ups is reached the following rule applies If a turbidity value is 75 of the mean val
29. he test system Do not place heavy objects on or lean on the sensor holder because there is a danger of it breaking and falling on your feet Safety precautions Take steps to prevent the vehicle from rolling away while it is being tested Select the park position if the vehicle has an automatic trans mission and apply the handbrake or lock the wheels with chocks wedges Keep well away from rotating moving parts while the engine is running When working on or in the vicinity of electrically driven fans allow the engine to cool down first then disconnect the plug of the fan motor Keep the tester connecting cables well away from all rotating parts Lock the brakes on the test system trolley so that it cannot roll away Lay the connecting cables in such a way that no one can trip over them Do not place heavy objects on or lean on the sensor holder e Danger of burning When working on a hot engine there is a risk of injury from burning if such components as the exhaust gas manifold the turbocharger the Lambda sensor etc are touched or if parts of the body come too close to them These components may be heated to temperatures of several hundred degrees Celsius Depending on the duration of the exhaust gas measurements the sampling probe of the exhaust gas measuring instrument may also become extremely hot Safety precautions Always wear protective clothing e g gloves Allow the engine to cool
30. ing compiling and checking we cannot guarantee for the accuracy of the operating software SystemSoft 1 4 Description of the unit The design operation and method of connecting the unit to the vehicle can be found in the separate Operating Instructions Emissions Analysis Measuring Instrument Description of the Unit IA4 UBF 957 1 1 689 981 664 1 5 Operating the RTM 430 Opacimeter A basic description of the RTM 430 opacimeter covering its design operating instructions maintenance technical data and scope of delivery is contained in the RTM 430 Operating Instructions manual supplied Opacimeter RTM 430 IA4 UBF 956 1 1 689 979 651 1 6 Publication entitled Connecting Test Systems to the Vehicle Useful information concerning the connecting of test systems and their sensors can be found in the following publication Connecting Test Systems to the Vehicle KH PR UBF 550 1 En 1 689 979 625 1 7 Definitions of terms Effective measuring length The effective measuring length is the light segment through which the smoke passes It has a length of 430 mm The determined measured values are converted as a function of the length of the measuring chamber Absorption coefficient k factor m Theabsorption coefficient is a measure of the amount of light absorbed by the soot white smoke and blue smoke related to 1 m light segment Therefore this coefficient is indepen dent of the used unit 2 The Basics 2 1
31. ne has reached the desired speed press the key to store the measured value The measurement is then stopped by pressing ESC Using the cursor keys and gt you can then display or print out the measured values or end continuous measurement completely Confirm your selection by pressing ENT 4 2 Free acceleration This procedure is used to measure the exhaust gas values e g when adjusting the engine The k values are not evaluated and no purging rev ups are carried out A maximum of 16 measurement rev ups can be carried out If you want to stop carrying out measurement rev ups before you reach 10 times press ESC or ignore the FULL THROTTLE prompt i e do notrev up the engine the program will then detect time out after a specified delay has elapsed At the end of the measurements you can use the cursor keys 4 and gt to display or print out the measured values print out curves which show the opacity and engine speed values plotted against time or end this type of measurement completely Confirm your selection by pressing ENT 17 5 The Configuration Menu 5 1 Overview The CONFIGURATION menu allows you to read out information such as the software version and to enter or change settings such as the date time You have the choice of the following submenu items see figure SW VERSION LANGUAGE DATE TIME REPORT HEADER PRINTER UNITS Pressing ENT always returns you to the menu Importa
32. nt Only when leaving the configuration by pressing the ESC key the changes are accepted SELECTION SELECTION SELECTION SELECTION SELECTION SELECTION EGA DIESEL gt lt DIAGNOSIS gt lt CONFIGURATION gt lt TEST FUNKTIONS gt lt SERVICE gt lt CALIBRATION ESC ENT CONFIGURATION CONFIGURATION CONFIGURATION CONFIGURATION CONFIGURATION CONFIGURATION SW VERSIONS gt lt LANGUAGE gt DATE TIME gt REPORT HEADING lt PRINTER gt lt UNITS ENT ENT ENT EMI ENT i A A PRINTER Y VSM ESP LANGUAGE lt INTERN PDR203 UNIT OPACITY V1 00 15 04 98 GERMAN sx ENER PDR212 lt NM gt T lt ENGLISH XXxxx IFACE PC HOST ENT T ENT MTM LC R 128 ENT D V1g08 18 03 97 i SST PC HOST T 1200 BAUD ET REPORT HEADING 2400 BAUD 7 24 CHARACTERS 4800 BAUD RTM 9600 BAUD V1a0 12 09 95 1 ENT En Y D REPORT HEADING DEALER PRINT 7 24 CHARACTERS WITHOUT WITH T ENT ENT Y Y 1 LINE CUSTOMER PRINT XXXXX lt WITHOUT WITH gt d x T s ENT EN ENT 3 Y 7 LINE VEHICLE PRINT DATE TIME gt DATE TIME XXXXX lt WITHOUT WITH gt SHOW gt Je SET ENT i ENT ENT Y Y DATE TIME DATE TIME 1
33. r a submenu that contains further selection options The test procedures and setting selection options are described below in detail with the aid of sequence charts 10 2 6 The sequence charts The sequence charts illustrated below show you the respective texts displayed on the hand held control unit in rectangular boxes with two lines of text single lined boxes as they are displayed in uppercase letters on the display The keys you need to press to move forwards and backwards in the sequence or to change or make inputs are marked by arrows in the text Lozenges branching symbols etc indicate program internal sequences and decisions as specified either by the user or by statutory regulations 2 7 Overview of the exhaust gas test The basic test sequence is shown in the following figure ain Menu SELECTION EGA DIESEL Vehicle Identification Rated value input and measured parameters Key ESC before measuring block Abortion after Main Menu Key ESC after 1 measurement Abortion after Result Menu Vehicle conditioning CUTOFF SPEED measurement Measurement rev ups Result Display 3 The EGA Diesel Diesel exhaust gas analysis test 3 1 Vehicle and customer identification This menu is where you enter data for identifying the vehicle and customer This data is then printed out together with the test result Old from Main Menu EGA Diesel Vehicle and customer
34. ration measurement The RTM is balanced zero adjusted etc and then continuously displays the opacity in and m This measurement is performed with the measuring chamber closed and without exhaust gas temperature compensation 8 4 Check The RTM is balanced zero adjusted etc first The user then sees the following prompt Please insert test pen into calibrating plug in socket Confirm by pressing ENT If an error is found during the linearity check the following message and question to the user are displayed Routine check fault Filter been cleaned If the linearity check is run through successfully OK is displayed In both cases pressing ENT returns you to the Calibration check menu 8 5 CRC check This function is solely for use by the staff of the calibration agency when checking the integrity of the system The user reaches an input field in which the cursor is visible As soon as the user has entered 4 digits the associated checksum appears ENT returns you to the submenu 22 9 Error Messages If an error arises when switching on during a test procedure or for some other reason e g calibration is necessary it is displayed by means of 2 pieces of information Error number Error text 4 digit number in the 1st line normally moving letter display The following table lists the individual errors with number error text and remedy if it can be performed by the user In all other ca
35. red before the measurement phase Measuring procedure Switch off the engine Using the battery connecting cable B B connect the VSM plug in socket 1 see Description of the unit to the vehicle battery The battery connecting cable is protected against polarity reversal When working on a 24 V vehicle electrical system connect to 24V Do not connect the VSM just to one of the 2 batteries The voltage range is from 9 to 32 V When working on a vehicle with a number of independent batteries e g a camping bus connect the battery connecting cable B B to the battery that is charged directly by the vehicle alternator Ho Set the number of cylinders accordingly Start the engine and accelerate briefly so that the charge indicator lamp in the vehicle goes out TI Switch on the vehicle lights and if fitted the rear heated window Switch off the blower and other consumers Leave the engine running at idle speed The engine speed RPM measured can be checked in the Engine preconditioning and prechecks test step The engine speed RPM measured is displayed after approx 15 to 30 seconds T If RPM measurement engine speed measurement does not result in a value being displayed first check whether the polarity of the connections is correct You can now perform a test rev up i 1 J The engine must be at normal operating temperature When performing the test rev up watch the breakaway speed If
36. ses please contact After Sales Service This also applies to error numbers that are not listed in the table 2000 Transmitter receiver Clean transmitter and dirty receiver Clean trasmitter and receiver 2001 Measured value rise is too small 2002 Supply voltage fault Check power supply cables 2003 Purging air curtain error After Sales Service 2004 Check required Inform calibrating agency 2005 EPROM checksum wrong After Sales Service 2006 EPROM checksum wrong After Sales Service 2009 Too much light on receiver After Sales Service 2010 Valve faulty After Sales Service 2011 Exhaust gas temperature After Sales Service sensor faulty 2012 Measuring chamber After Sales Service Temperature sensor faulty 2013 D A converter faulty After Sales Service 2020 Command presently not After Sales Service available Switch unit off and back on again 2030 Transmission fault 10 Maintenance 10 1 Checking display accuracy Starting from the Start mask SELECTION EGA DIESEL gt Press the gt key 5 times The display displays SELECTION CALIBRATION Press ENT Press the gt key 2 times The display displays Calibration CALIBRATION MEASUREMENT Press ENT The display displays PLEASE WAIT ZERO ADJUSTMENT After approx 1 minute the display displays 0 STORED N 0 0 Insert the calibrating pen into the cali
37. sured values using the arrow keys and ENT can be used to move from one parameter to the next ESC cancels the display of measured results 15 4 The Diagnosis Menu SELECTION SELECTION SELECTION SELECTION SELECTION SELECTION EGA DIESEL gt lt DIAGNOSIS gt lt CONFIGURATION gt lt TEST FUNCTIONS gt lt SERVICE gt lt CALIBRATION ENT Program sequence depends on DIAGNOSIS DIAGNOSIS t fi ti CONT MEASURE REV UPS System contiguration ENT ENT v OILTEMPERATURE 80 0 C ENT v v SPEED 788 rpm SPEED 788 rpm PULSES 1 16 gt PULSES 1 16 gt ENT v r CUTOFF SPEED START UP SLOWLY T ENT or accelerate ENE SHIFT E Nm i SPEED 5050 rpm automatic connection MAX 5050 rpm if max value 2 s stable Key ESC before meas block i Abortion after Main Menu CUTOFF n m T ENT Key ESC after 1 measurement is DLE m Remaining time runs Abortion after Result Menu only if idle speed is available L mt rpm v 4 0 34 870 FULL THROT 60s Text FULL THROT blinks Accelerate Acceleration detected SR SH T Text FULL THROT not No No FULL THROT blinking C hPa Y 4 120 1020 THROT OFF after meas time k1 16 1 75m 1 Text THROT OF
38. switching the back lighting on and off SHIFT ENT Key combination for one step back 2 3 Program control 2 3 1 The Program or Operation mode For the most part control of the program consists simply of confirming the test steps specified This is done using the top keys on the hand held control unit If there are several menu items or selection options to choose from this is indicated by means of selection arrows lt and gt in the 2nd line In such cases the left menu can be selected using the lt and gt cursor key sand the right menu or another setting option using the or DEL key 2 3 2 Input or Edit mode Values or texts that can be changed can be changed in Input mode There are 2 possibilities The field is empty no input has been made so far The type of input is identified by the flashing cursor on the left of the input field Characters can be entered directly The content of the field flashes inputs have already been made Inthis case the entry can be overwritten directly When the first character is entered the old entry is deleted completely and the new character you have entered appears together with the cursor You want to delete add to or change the old entry The cursor is not yet visible DEL Deletes the entry and the cursor appears on the left lt 4 Thecursor appears under the 1st character and this can be overwritten gt The cursor appears after the least character and chara
39. ue this value is rejected and the new mean value is calculated from the remaining measured values This will be repeated until no turbidity value is 75 of the mean value If the measurements are within the prescribed tolerance range EGA PASSED appears on the display Confirm this by pressing ENT Category B vehicles At least 4 measurement rev ups are carried out If all measured values are 2 00 m the mean value of the last 4 measurements is calculated The lowest turbidity value of these 4 measured values must be greater than or equal to 7596 of the mean value If the measurement is not valid another measurement rev up is carried out The new mean value of the last 4 measurements is then calculated Up to a maximum of 10 measurement rev ups are carried out If the maximum number of measurement rev ups is reached the following rule applies If a turbidity value is 75 of the mean value this value is rejected and the new mean value is calculated from the remaining measured values This is repeated until no turbidity value is 7596 of the mean value If the measurements are within the prescribed tolerance range EGA PASSED appears on the display Confirm this by pressing ENT The following options are then displayed Print out measurement result Display measurement result Print out curve
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