Service Training Center Robert Bosch GmbH Automotive Aftermarket Diagnostics www.bosch-diagnostics.de
ESI[tronic] User training Course documentation Name :... Date : from... to... Location :... This training document is intended to provide information for training purposes. It must not be used for carrying out repairs on vehicles. Repair work must be carried out in accordance with valid workshop documentation. All values listed here are application-dependant and are therefore not generally applicable.
ESI[tronic] 2.0 Trainer Basics 1. Description of unit - KTS 560 / KTS 350 / KTS 590 / KTS 525 / KTS 530 / KTS 540 / KTS 570 / KTS 940 / KTS 970 / DCU 100 / DCU 220...... 4 - KTS Truck..... 8 - TPA 200.... 10 - Connection diagram.... 11 2. Installation/Licensing - ESI[tronic] 2.0 network installation... 13 - Licensing...... 14 - Online.... 15 - Offline... 18 - Activate/Configure KTS used. 22 - Bluetooth... 23 3. Introduction to ESI[tronic] 2.0 - Screen layout....... 24 - Help system..... 26 - ESI Ticket.. 27 - Online update... 29 4. Informationsarten - Diagnosis and repair.. 30 - Spare parts. 31 - Order and costing 32 - Component... 33 - Known faults (experienced-based repair) 34
KTS 560 / KTS 590 / KTS 350 / DCU 100 / DCU 220 Diagnostic systems from Bosch reliable, convenient and quick KTS 560 / KTS 590 cutting-edge control unit diagnosis for maximum efficiency The new, robust KTS modules KTS 560 and KTS 590 are perfectly tailored to the diagnostic software ESI[tronic] 2.0. Besides widely used diagnostic connectors, all future interfaces based on Ethernet are supported. Also, it is possible to use several diagnostic connectors in parallel and take full advantage of the vehicle manufacturer's diagnosis portals and reprogramming procedures according to Euro 5/6. For continued support in the future, parallel communication via different diagnostic connectors (including Ethernet) is essential for competitive workshops. Just like the KTS 560 and KTS 590, which are already fully compatible. Beside vehicle communication, voltage, resistance and current measurements can be carried out easily and quickly. The KTS 590 is also equipped with a 2-channel oscilloscope that not only indicates voltage and current curves but also allows for their immediate evaluation. All signals from sensors and actuators in the vehicle can be measured using the KTS 560 and KTS 590. An overview of the benefits of the KTS 560 and 590: All relevant current and future Ethernet-based diagnostic connectors supported, including parallel operation of several BUS systems Improved PassThru interface for reprogramming control units for Euro 5 using vehicle manufacturer's portals Works with any Windows PC with an installation and active license of the Bosch diagnosis application ESI[tronic] 2.0 Mobile and stable operation thanks to powerful Bluetooth interface Up to three CAN and K-Line interfaces can be used in parallel Long-range Bluetooth radio connection to the workshop PC allows for mobile use throughout the workshop Extra sturdy construction for demanding workshop use and many years of service 4
KTS 350: innovative diagnostic technology in a compact device Every workshop needs a multi-function diagnostic device comprising all the tools necessary for troubleshooting to make every-day work simpler and more efficient. The solution: the Bosch KTS 350. Besides widely used diagnostic connectors, it also supports all future interfaces based on Ethernet and is ready for all future demands of the automotive sector. Its significantly more powerful processor compared to its predecessor, along with the current Windows 10 operating system, allows for starting and working faster. Also, the KTS 350 comes with the Bosch diagnostic application ESI[tronic] 2.0 pre-installed on the device. It is versatile and ideal as an all-in-one diagnostic device, e.g. for independent workshops, fast fitters or as a secondary device for mobile use. With its complete range of functions, the KTS 350 is an efficient package deal for control unit diagnosis, maintenance, troubleshooting and repair. An overview of the benefits of the KTS 350: Mobile all-round solution for the full range of control unit diagnosis, troubleshooting, repair and maintenance tasks All relevant current and future Ethernet-based diagnostic connectors supported, including parallel operation of several BUS systems PassThru interface for reprogramming control units for Euro 5/6 using vehicle manufacturer's portals Plug and play thanks to pre-installed and pre-configured ESI[tronic] 2.0 application for optimum usability Faster system start-up due to an improved processor and cutting-edge SSD technology Regular online updates available Windows 10 operating system allows for easy installation of additional applications 5
DCU 100 - Robustly optimized for use with ESI[tronic] 2.0 The DCU 100 is a portable tablet computer that was developed for use in automotive workshops. Many years of experience in developing diagnostic tools as well as the needs of our customers were considered in developing the DCU 100 as alternative to existing Bosch diagnostic devices. The DCU 100 was developed specially for ESI[tronic] 2.0 and comes with Windows POSReady 7 as the operating system. Familiarization was therefore made easy for users. The device is small and easy to use but still comes with a 10" touchscreen. The lithium-ion battery installed in the back makes it possible to use the device independently. By means of the integrated, powerful Bluetooth module, the products of the KTS 5xx series can be operated in conjunction with ESI[tronic] 2.0 information types (A, C, P, M, Bike and Truck) as well as the TPA Startcenter / TPA 200. The DCU 100 has 2 controls: Power key Function key A central printer can be connected via USB or WLAN. On both the right and left side, the DCU 100 has ergonomic grips. 6
Convertible-PC DCU 220 Workshop tester and diagnostics centre Developed especially for workshop implementation, the robust DCU 220 (Diagnostic Control Unit) controls the testing and diagnostics systems of Bosch whether it be FSA 500 or the module of the KTS-row. Being a convertible PC, it is a notebook and a tablet PC in one und thus enables flexible and comfortable operation specifically under workshop conditions. Comprehensive details facilitate operation Simple switching between tablet and notebook operation Easy handling and integrated grip with stand function Robust housing with 11.6" touchscreen monitor Integrated camera: abnormalities on vehicles can be documented and required parts can be photographed Sustained mobile operation Has two identical lithium-ion batteries One battery is sufficient to carry out operations in the workshop If required, the batteries can be exchanged without interruption during operation (hot-swap function) Modular concept with the Diagnostic Control Unit For qualified diagnostics, professional repair and maintenance, Bosch offers the modular system components Convertible-PC DCU 220 and KTS 570, KTS 540, KTS Truck or FSA 500. Its strongpoint: For every workshop, a suitable solution can be achieved through combination. 7
KTS Truck The modular solution for commercial vehicles. KTS Truck Optimized and mobile diagnostics solution KTS Truck is the ideal entry-level solution for commercial vehicle workshops that already have a PC. KTS Truck module for light commercial vehicles, trucks, trailers, and buses Can be connected to DCU 130, PC or laptop Integrated Bluetooth connection with large range, up to 100 m Bluetooth USB adapter included in equipment supply Sturdy housing KTS Truck The following operating systems are supported: MS Win XP, Win Vista, Win 7 and Win 8 The USB interface means KTS Truck can be connected to all common laptops / PCs 8
KTS 900 Truck - complete mobile solution for truck-, van-, bus- and trailer diagnostics Mobile complete system for commercial vehicle diagnostics Robust, mobile, workshop Diagnostic Control Unit (DCU 220) for control of the KTS Truck module Can be operated simply and comfortably via both touchscreen as well as keyboard for combined implementation in the workshop as well as in the office Sustained mobile operation Has two identical lithium-ion batteries One battery is sufficient to carry out operations in the workshop If required, the batteries can be exchanged without interruption during operation (hot-swap function) With the KTS 900 Truck and the ESI[tronic] 2.0 Truck, the commercial vehicle workshop has the complete solution for the diagnostics of trucks, vans, buses and trailers. Mobility through integrated efficient wireless technology DCU 220 with robust housing and 11.6" touchscreen High flexibility thanks to operability as tablet-pc or notebook Vehicle abnormalities can be documented with the integrated camera and the required replacement parts 9
TPA 200 The professional addition for ESI[tronic] and KTS in the tyre service TPA 200 The ideal addition to your existing ESI[tronic] and KTS diagnostics solution. For diagnostics and maintenance service of RDKS tyre valves, Bosch has developed the TPA 200 diagnostics device. The TPA 200 offers the possibility to check RDKS sensors reliably and program RDKS universal valves. In addition to the implementation for professional tyre services, the TPA 200 can also be used for vehicle acceptance and, in addition to ESI[tronic] and KTS control devices, can be used directly. The functions of TPA 200 are: Activation of Schrader sensors Activation/checking of RDKS sensors (incl. display of the RDKS sensor information) Programming of universal sensors (Schrader EZ-sensor, Alligator Sens.it and others) Specific RDKS sensor measurement method (1 to max. 100 vehicles) Workshop-specific work procedures (e.g. by means of job number, indicator) Wireless transfer of data (Bluetooth) Functions of the TPA Startcenter (contained within the delivery contents of the TPA 200) are: Vehicle databank for direct RDKS systems Sensor information (e.g. torque values) TPA 200 Update function Recording function Upload / processing of TPA 200 vehicle data Client data management Support for all ESI[tronic] 2.0 languages 10
Connection diagram KTS 590 OBD interface in vehicle OBD connecting cable Test cables Test cables(kts 590) KTS 590 USB connecting cable Bluetooth USB adapter for USB 3.0 PC Power Supply 11
KTS Truck Connecting tip from test cable set OBD interface in vehicle Vehicle-specific adapter cable (special accessory) OBD connecting cable Universal adapter cable KTS Truck Adapter cable with battery clips Connecting cable for cigarette lighter socket USB connecting cable Bluetooth USB adapter (only needed for PC/Laptop without internal Bluetooth hardware) PC/Laptop (z. B. DCU 220) 12
ESI[tronic] 2.0 network installation With network installation, all ESI[tronic] 2.0 data are installed at a specified storage location within a network. With network installation, all ESI[tronic] 2.0 data are installed at a specified storage location within a network. The storage location (referred to in the following as the server) may be a file server, a PC or NAS (Network Attached Storage). All other workstations (PC/Laptop) connected to this network obtain the required ESI[tronic] 2.0 data from this server. The advantage of this procedure is that no DVDs are required for installation at these workstations, thus considerably shortening the installation time involved. In addition, Information types not required for a vehicle can be left on the server and do not have to be installed at the workstations. 13
Licensing To be able to use ESI[tronic] 2.0 (e.g. performance of control unit diagnosis), ESI[tronic] 2.0 must be licensed. Licensing can be performed online or with a license file. ESI[tronic] 2.0 licensing KTS Truck: Connect KTS to a PC/Laptop via the USB connecting cable. Start ESI[tronic] 2.0. Licensing The licensing status, period of validity and contract scope are displayed under: Main menu >> System Information >> Software Information. Main menu >> Licensing. lect <Online> (recommended) or <Offline>. Online licensing is performed directly in ESI[tronic] 2.0 via the licensing server. Online licensing can only be executed if ESI[tronic] 2.0 is installed on a PC/laptop with Internet access. Offline licensing : After creating a license request file, it must be transferred to a PC/laptop with Internet access (e.g. using a USB stick). A license file must then be requested on this PC/laptop via the "ESI[tronic] 2.0 licensing portal". The license file must then be transferred to the PC/laptop on which ESI[tronic] 2.0 is installed (e.g. using a USB stick). ESI[tronic] 2.0 must then be licensed using the license file. We recommend that offline licensing only be performed when ESI[tronic] 2.0 is installed on a PC/laptop without Internet access. Licensing must be performed if one of the following fault messages is displayed: No valid license available. Certain functions are therefore deactivated. Please request a license to be able to use all the ESI[tronic] functions. Your license expired on MM/DD/YYYY. You can continue to use ESI[tronic] without restrictions until MM/DD/YYYY. After this date, some functions will be deactivated. Please renew your license. Your license expired on DD.MM.YYYY Certain functions are therefore deactivated. Please renew your license to be able to use all the ESI[tronic] functions again. 14
Licensing online Online licensing can only be executed if ESI[tronic] 2.0 is installed on a PC/laptop with Internet access. Licensing online Main menu >> Licensing >> <Online>. Enter customer number and password. Online enabling is initiated with Continue. Link with the Bosch server is established. Dialog box "Online licensing" is displayed with the contract overview. Change password can be used to change the password in the ESI[tronic] 2.0 licensing portal.after the password has been changed, the password must be re-entered in ESI[tronic] 2.0. 15
If no link can be established with the Bosch server: Check proxy settings under "(Main menu) >> User settings >> Proxy settings" (contact your administrator for more information). Click the button to display contractual information, and click the button to hide it. Select available or assigned contract. Initial licensing: Mark available contract. Relicensing (in case of contract extension or amendment): Mark assigned contract. Select <Generate>. License key is created. Dialog box "Online licensing" is displayed with license information. In some countries (e.g. Mexico) the E-mail and Repeat e-mail boxes are displayed. An e-mail address to which the wholesaler can send the license file must be entered here. 16
Select <Execute>. Licensing is implemented. Re-start ESI[tronic] 2.0 with <OK>. ESI[tronic] 2.0 is licensed. 17
Licensing Offline If internet access is not available, a license request file can be created with Offline licensing. The license request file can then be transferred to a PC/Laptop with internet access (e.g. with USB stick) and a license file requested from this using the ESI[tronic] online licensing procedure. Licensing by file Main menu >> Licensing >> <Offline> >> <Create license request file>. Select the storage location of the license request file "licenserequest.blr", e.g. USB stick. Select <Save>. Select OK Transfer license request file and URL file to a PC/Laptop with internet access. Open URL file "licenserequest" with browser, e.g. Internet Explorer. "ESI[tronic] 2.0 licensing portal" is opened. 18
Enter customer number and password. The customer number and password can be found on the delivery slip. Select <Log in>. 19
Contract overview is displayed. Select <Browse...>. The "Choose File to Upload" dialog box opens. Select license request file "licenserequest.blr", e.g. on USB stick. Select available or assigned contract. Select <Open>. Initial licensing: Select available contract. Relicensing (in case of contract extension or amendment): Select assigned contract. Select <Continue>. Contract data are displayed. Select <Licensing> / <New licensing>. <Licensing> is displayed in the case of initial licensing, while <New licensing> is displayed in the case of relicensing. Select storage location of license file "licencenep_name of PC/Laptops.blr", e.g. USB stick. Select <Save>. License file was created and saved to the relevant storage location. 20
Apply license file Main menu >> Licensing >> <Apply license file>. Select Search. Select license file "licencenep_name of PC/Laptops.blr" from storage location, e.g. USB stick. Select <Open>. Select Execute. Licensing is being carried out. Re-start ESI[tronic] 2.0 with <OK>. ESI[tronic] 2.0 is licensed. 21
Activate/Configure KTS used Main menu >> Hardware settings. Select KTS 5xx, KTS 6xx or KTS Truck. Only configured KTS 5xx, KTS 6xx or KTS Truck can be activated. Use menu items KTS 5xx, KTS 6xx or KTS Truck for configuration. The KTS activated is used for control unit diagnosis. Only one KTS can be activated. Advanced mode (KTS Truck) Authorized users can activate or deactivate advanced functions for commercial vehicles and trailers, e.g. deleting the secure memory of an ECU. 22
Bluetooth The Bluetooth connection must first be set up before a Bluetooth link can be established between KTS and the PC/Laptop, e.g. DCU 130. All important information on Bluetooth operation is described in this Section. To obtain the best possible Bluetooth link we recommend using KTS 5xx / KTS Truck with PC/laptop and the Bluetooth-USB adapter provided. The Bluetooth settings for KTS 5xx are made in DDC, the Bluetooth settings for KTS Truck directly in ESI[tronic] 2.0. 23
Screen layout Simple menu structure with self-explanatory symbols. Screen layout Main menu bar KTS xxx Name of activated diagnostic unit, e.g. KTS 590. e.g. Connection symbol, Type and status of the connection of the activated diagnostic unit is displayed. Simulationsmodus ist aktiv. Advanced mode active for commercial vehicles (#_CV) and expanded mode for trailers (#_TR) (only with KTS Truck activated). Help: Context-sensitive Online Help. Print menu: The print dialog can be opened or the current protocol for the selected vehicle can be displayed or printed. Main menu: Multimeter (Only with activated KTS 5xx / KTS 6xx, not for KTS 525), Oscilloscope (Only with activated KTS 570 / KTS 590 / KTS 6xx) Protocol management, Altering user settings, KTS module configuration, KTS Truck licensing, ESI Ticket creation, Show system information, Show instructors, Show ESI[tronic] News, End ESI[tronic]. The following main menus can be selected: - Vehicle info - Diagnosis - Trouble-shooting - Maintenance - Circuit diagrams - Equipment Input/output field Box with variable content for selection/input of data and for information display. Sub-menu items are displayed in certain windows (e. g. start screen). 24
The width of the scroll bar can be altered: WIN 8 / WIN 10: The width of the scroll bar can only be changed in the registry (ScrollWidth) of the operating system. Further information can be obtained from your administrator. WIN 7: "Start >> Control panel >> Appearance and Personalization >> Personalization >> Window color >> Advanced view preferences >> Element scroll bar". 25
Help system ESI[tronic] 2.0 includes a comprehensive help system. Online help Select. The main aim of the navigation concept for this Online Help is to provide simple, user-friendly guidance within a uniform navigation system. The navigation information is given on the left of the screen. The navigation menu contains the tabs "Contents", "Index" and "Search". The navigation bar appears in the header of the Help pages. Another type of navigation is provided by the so-called hyperlinks (links). "Contents" tab The Help pages are listed according to topic. The main Help pages are marked with a book symbol. The books can be opened and closed by clicking onto " ". Only one book of the same hierarchy level is ever opened at the same time. If another book of this hierarchy level is opened, the one already open is closed. Help pages with no further sub-items are represented by " ". "Index" tab The Help pages are listed in alphabetical order. A gray box containing all the letters of the alphabet is presented under the heading "Index". Clicking onto a blue letter with the left mouse key selects the Help pages starting with this letter in the "Index" tab. Letters for which there are no index entries are shown in light gray. "Search" tab The term required must be entered in the <Search for> input box; the Online Help can then be searched for this term with <Search>. On completion, the results of the search are listed under the input box. On the Help page the search terms are highlighted in color and a search legend appears in the header. Highlighting can be cancelled and the legend hidden with the links in the legend. Navigation bar Breadcrumb: Path of current Help page is displayed, e.g. "Help on Help >> Help navigation". : Return to last Online Help view (press key: <Backspace>). : Go to Online Help view previously exited (press keys: <Shift > + <Backspace>). : The selected Help page is printed (press keys: <Ctrl> + <p>). 26
ESI Ticket ESI Ticket is your direct link to Bosch (ESI[tronic] Hotline). Create ESI Ticket Main menu >> ESI Ticket. ESI Ticket can be used: - To submit suggestions or requests. - To describe faults/errors. - To propose solutions. - For the attachment of files to be sent by e-mail to give further details of e. g. suggestions, solutions or faults/errors or for illustration purposes (e. g. a screen shot, a file or a protocol). For sending a ticket, an internet connection but no e-mail application is required. 27
Perform the following work steps in the order indicated: Enter the sender. Your company data will be automatically entered in the Sender box if these have already been entered under " Main menu >> User settings >> Company data". Select error type, e.g. "Data content". Select info type, e. g. "Vehicle info". Enter the data in the Data, Program and System tabs. File attachment (optional). Attachments are not to be printed out but should be sent to the Technical Hotline using Send ticket. Describe the reason for the ESI Ticket in the Fault/problem box. If possible: Describe a proposed solution in the Solution/proposal box. Send ESI Ticket: Select Send e-mail or Print. Select Send ticket (recommended), Save or Print. The Send ticket, Save, Print and Print preview buttons will only be activated after all mandatory fields "*" have been filled out. Save: ESI Ticket is saved to the directory to be selected as a ZIP file with the selected attachments. 28
Online update For installation of ESI[tronic] 2.0 software updates available on the download server. The "DDM" software was automatically installed during the installation of ESI[tronic] 2.0. The DDM (Bosch Diagnostics Download Manager) is always running in the background and is required to download and install software updates for Bosch diagnostic applications. DDM Double-click on the DDM icon in the taskbar with the left mouse button or select Main menu >> Online update. "Bosch Diagnostics Download Manager" is opened. For further information, see: "DDM" online help. DDM icons in the taskbar DDM ready for operation. No connection with the Bosch server. Downloads are downloaded. "Automatic Updates" function deactivated ("DDM >> My Contracts >> Automatic Updates"). 29
ESI[tronic] Information categories - Diagnosis and repair Made possible by the modular design: Each workshop can be specifically adapted to meet its individual requirements, which combine ESI[tronic] information. C Vehicle diagnosis World's most extensive cross-manufacturer combination of SIS troubleshooting instructions and control unit diagnosis For engine management systems for gasoline, diesel and passenger car brake systems for Bosch and other manufacturers Troubleshooting instructions suited to workshops, can be applied on any PC, can be linked to optimize vehicle diagnosis with Bosch test equipment Modular concept suitable for individual workshop requirements TSB Technical Service Bulletins Quick access to known vehicle faults Clear description of cause Assignment of symptoms Tested repair tips M Motor vehicle mechanical systems Inspection data and maintenance plans Technical vehicle data Wheel alignment data and inflation pressure tables Removal and installation instructions for toothed belts P Convenient circuit diagrams for motor vehicles Cross-manufacturer circuit diagrams for motor-vehicle electrical systems and comfort and convenience electrics represented in a standardized format 866,000 circuit diagram assignments and 24,000 complete circuit diagrams With zoom and printout functions Truck Diagnosis, maintenance plans and information for trucks, trailers, buses and vans When servicing and repair are required, the workshop has all the key data it needs at its disposal Bike Diagnostic package for motorcycles and scooters 30
ESI[tronic] Information categories - Spare parts Made possible by the modular design: Each workshop can be specifically adapted to meet its individual requirements, which combine ESI[tronic] information. A Applications and functions including automotive equipment Access to around 32,000 passenger cars, 19,000 commercial vehicles, 6,000 motorcycles, 8,000 trucks, tractors and special vehicles Identification by country-specific key numbers, work cards and interfaces 73,000 vehicles and engines are identifiable ZF Spare parts of ZF Services Comprehensive spare parts catalog for the brands SACHS, LEMFÖRDER, BOGE and ZF Parts Comprehensive linking to vehicle-specific information for installation and removal of shock absorbers, clutches, vehicle and steering parts with the corresponding specifications regarding tightening torques, wheel geometry values, setting values and tool information D Diesel spare parts Most comprehensive catalog for Bosch diesel products Around 51,000 spare-parts lists with over 380,000 individual parts Exploded view drawings in highest quality Stepless zoom function E Electrical system spare parts With 18,000 spare part lists and over 383,000 catalogued spare parts, this is the most extensive catalog for Bosch electrical systems Detailed exploded view drawings in highest quality Stepless zoom function F Spare parts archive 1,600 spare part lists are archived for older vehicles Spare part lists for electrical systems, diesel engines and pneumatics ZD Diesel spare parts from Zexel Zexel program software Catalog for Zexel diesel products Detailed exploded view drawings and spare parts lists 31
ESI[tronic] Information categories - Order and costing Made possible by the modular design: Each workshop can be specifically adapted to meet its individual requirements, which combine ESI[tronic] information. B Flat-rate units Over 10 million flat-rate units, over 21 million supplementary texts for 16,000 of the most common cars and vans Straightforward and standardized representation of flat-rate units of the various motor vehicle manufacturers in hours: minutes Display in euro S Vehicle service costing Complete functions of service work and inspections, wearing part repairs Default content for routine service with number of parts and labor times Fixed price calculation and transfer of all content to existing merchandise information systems 32
ESI[tronic] Information categories - Component Made possible by the modular design: Each workshop can be specifically adapted to meet its individual requirements, which combine ESI[tronic] information. K Component repair instructions Repair instructions, service information and telegrams for diesel and electrical system components Direct interaction of information from ESI[tronic]-D and ESI[tronic]-E (e.g. spare parts), and ESI[tronic]-W W Injection pump test data Test data for around 12,000 in-line fuel-injection pump combinations and for approx. 2,000 VE pumps Complete testing from data acquisition to log printout All test steps are displayed in optimized order ZW Zexel diesel test data Test data for Zexel diesel units Complete testing from data acquisition to log printout 33
ESI[tronic] Information categories - Known faults (experienced-based repair) Benefitting from the repair experience of other users Experience gained from the Bosch diagnosis hotline and internet forums indicates that certain issues with automotive technology occur again an again with specific vehicle models. Experienced Bosch authors will review every case and approve it. That way, they continually create new descriptions of known repair scenarios based on actual practice and provide new solutions in ESI[tronic] 2.0. 34