Bosch EPS 807 Einrichtungshandbuch

EPS 807 / 815

Repair instructions

Injection pump test bench

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

2 | EPS 807 / 815 |en

Contents English

1. Symbols used 3

1.1 In the documentation 3

1.1.1 Warning notices -

Structure and meaning 3

1.1.2 Symbols – Designation and

explanation 3

1.2 On the product 3

1.3 Important notes 3

1.4 Safety instructions 4

1.4.1 Mains voltages and High voltages 4

1.4.2 Rotation 4

1.4.3 Dimensions and Weights 4

1.4.4 Pressures 4

1.4.5 Heat radiation 4

2. Assembly and Disassembly 5

2.1 Test-bench housing 5

2.2 Drive assembly 5

2.3 Test oil heating 6

2.4 Test oil circulation 6

2.4.1 Control valve Test Oil 7

2.4.2 Cut-oﬀ valve 7

2.5 Lubricating oil circulation 7

2.5.1 1. Generation 7

2.5.2 2. Generation 8

2.5.3 3. Generation 8

2.5.4 Lubricating oil-Control valve 9

2.6 Cabinet 9

2.6.1 Complete 9

2.6.2 Mounting panel 10

2.7 Economic transformer 11

2.8 Multiway tap with purge valve 11

3. Structure 12

3.1 Block diagram 12

3.1.1 EPS 815 up to date of manufacture

05-2002 12

3.1.2 EPS 815 from date of manufacture

06-2002 12

3.2 Injection pump test bench 13

3.3 Lubricating oil supply (Special accessories) 13

3.4 Switch case 13

4. Overview of possible ﬂuctuations 14

5. Troubleshooting 15

6. Repair works 16

6.1 Change Flywheel 16

6.2 Replacing the drive motor 16

6.3 Change Test oil heating 17

6.3.1 Change Float switch 18

6.3.2 Change Temperature sensor 18

6.4 Readjusting the shut-oﬀ valve 19

6.5 Change Heating exchanger 19

6.6 Replacing the rotary encoder B1 20

6.6.1 Preparatory work 20

6.6.2 Removing the rotary encoder B31 20

6.6.3 Removing the rotary encoder B4 20

6.6.4 Removing the trigger wheel 20

6.6.5 Removing the ﬂange with

rotary encoder 21

6.6.6 Removing the rotary encoder B1 21

6.6.7 Mounting the rotary encoder B1 21

6.6.8 Mounting the ﬂange with

rotary encoder 22

6.6.9 Assembling the trigger wheel 22

6.6.10 Mounting the rotary encoder B4 22

6.6.11 Mounting the rotary encoder B31 23

7. Adjustment and Functional Test 24

7.1 Test the operating unit 24

7.1.1 Test tip switch elements 24

7.1.2 Test indicator lamps 24

7.1.3 Test emergency stop switch elements 24

7.2 Testing temperature sensors 24

7.3 Testing cooling proportional valve 24

7.4 Testing speed monitoring A5 (DZE) 25

7.4.1 Printed circuit board 1 688 400 009

(up to FD 12-2000) 25

7.4.2 Printed circuit board 1 688 400 251

(from FD 01-2001) 26

7.5 Sensor compensation on AMKASYN-Converter

(up to FD 05-2002) 27

7.5.1 Preparation 27

7.5.2 Performing sensor compensation 27

7.6 Sensor compensation on KU-Converter

(from FD 06-2002) 28

7.6.1 Preparation 28

7.6.2 Performing sensor compensation 28

8. Appendix 29

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

Symbols used | EPS 807 / 815 | 3 en

1. Symbols used

1.1 In the documentation

1.1.1 Warning notices - Structure and meaning

Warning notices warn of dangers to the user or people in

the vicinity. Warning notices also indicate the consequenc-

es of the hazard as well as preventive action. Warning no-

tices have the following structure:

Warning

symbol

KEY WORD – Nature and source of hazard!

Consequences of hazard in the event of fail-

ure to observe action and information given.

¶Hazard prevention action and information.

The key word indicates the likelihood of occurrence and

the severity of the hazard in the event of non-observance:

Key word Probability of

occurrence

Severity of danger if in-

structions not observed

DANGER Immediate impend-

ing danger

Death or severe injury

WARNING Possible impending

danger

Death or severe injury

CAUTION Possible dangerous

situation

Minor injury

1.1.2 Symbols in this documentation

Symbol Designation Explanation

!Attention Warns about possible property damage.

iInformation Practical hints and other

useful information.

Multi-step

operation

Instruction consisting of several steps.

eOne-step

operation

Instruction consisting of one step.

 Intermediate

result

An instruction produces a visible inter-

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.

1.3 Important notes

Installation and/or repair work may only be performed

by trained and instructed Service personnel at Robert

Bosch GmbH or by organizations appointed to do such

work by Robert Bosch GmbH. If the devices are opened

or modified by unauthorized persons, then all warranty

claims will be rendered null and void.

Electrical systems and resources may only be put into

operation when in proper operating condition (for more

information, refer to Inspection and testing information

0108_084). This requirement is deemed to have been

fulfilled if after modification or repair (initial test) it has

been ascertained that requirements as specified by the

electrotechnical rules have been adhered to. To this

end, tests as under the type and scope of the measures

defined by the electrotechnical rules (e. in Germany BGV

A2) are to be conducted. The type and scope of tests are

specified in VDE 0701/0702 Section 1 within Germany.

The relevant national specifications are to be adhered to.

!Observe ESD handling instructions when working on

the device when it is open. The instructions are avail-

able in EDIS at 'Bosch Test Equipment\Inspection &

Testing A-Z\General notes\Safety'.

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1.4 Safety instructions

1.4.1 Mains voltages and High voltages

Hazardous voltages occur in both the

network and the electrical system. If con-

tact is made with live parts, there is a risk

of electric shock from flashover voltages

caused by damaged insulation. That is why

the works on the electrical system or the

operating materials may be performed only

by electric’s specialists or by authorised

persons under guidance and supervision of

an electric’s specialist in accordance with

electrical regulations.

1.4.2 Rotation

Danger of injury!

When working in the area with rotating

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.

1.4.4 Pressures

Damage under high pressure can cause

leak of oil.

High hydraulic pressures occur during the

operation of the injection pump test benches.

¶Wear eye protective ware.

1.4.5 Heat radiation

Danger of burns!

The temperature on the surface of the brak-

ing resistance can achieve >60°C.

Open switch cabinet door can cause burn-

ing when touching the braking resistance on

the non-protected places.

¶Avoid works in this area, in case they can

not be evaded, allow the braking resis-

tance to cool down first.

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Assembly and Disassembly | EPS 807 / 815 | 5 en

2. Assembly and Disassembly

2.1 Test-bench housing

458719/1P

Fig. 1: Test-bench housing

2.2 Drive assembly

458722/2P

Fig. 2: Drive assembly

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6 | EPS 807 / 815 | Assembly and Disassemblyen

2.3 Test oil heating

4587231P

Fig. 3: Test oil heating

2.4 Test oil circulation

458720/3P

Fig. 4: Test oil circulation

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Assembly and Disassembly | EPS 807 / 815 | 7 en

2.4.1 Control valve Test Oil

458729-14_Pal

Fig. 5: Control valve Test Oil

2.4.2 Cut-off valve

458729-15_P

Fig. 6: Cut-oﬀ valve

2.5 Lubricating oil circulation

2.5.1 1. Generation

458729-16_Pal

Fig. 7: Lubricating oil circulation

458729-17_Pal

Fig. 8: Test Oil tank

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8 | EPS 807 / 815 | Assembly and Disassemblyen

2.5.2 2. Generation

458729-18_Pal

Fig. 9: Lubricating oil circulation

458729-19_Pal

Fig. 10: Test Oil tank

2.5.3 3. Generation

458729-20_Pal

Fig. 11: Lubricating oil circulation

458729-21_Pal

Fig. 12: Test Oil tank

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

Assembly and Disassembly | EPS 807 / 815 | 9 en

2.5.4 Lubricating oil-Control valve

458729-22_Pal

Fig. 13: Lubricating oil-Control valve

2.6 Cabinet

2.6.1 Complete

458729/6P

2 3 4 AZR

Fig. 14: Cabinet up to FD 05-2002

HAUPTSCHALTER

MAIN SWITCH

458729-10_Pa

AMK

DANGER

Fig. 15: Cabinet from FD 06-2002

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

10 | EPS 807 / 815 | Assembly and Disassemblyen

2.6.2 Mounting panel

458729-11_Pal

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

458729-12_Pal

Fig. 17: Mounting panel from FD 06-2002

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