Bosch Pre-Tech Diesel Service Training

Introduction

Welcome to the Bosch Pre-Tech Diesel Service Training CD-ROM. This program is an informational diesel fuel injection course designed for technicians and students, covering basic diesel theory, pump and governor operation, nozzle and nozzle holder (injector) operation and repair, parts identification, and the use of metrics in the shop.

The document provides context on the origin of Bosch products and their relation to the diesel engine. It details Robert Bosch's history, starting with his precision mechanics workshop in Stuttgart, Germany in 1886. Early innovations included the first low voltage magneto for gasoline engines and the first high-tension ignition system for automobiles. Bosch collaborated with Rudolf Diesel around 1920 on high-pressure fuel injection systems, introducing the first successful pumps in 1927. The company grew significantly, becoming a leader in automotive electrical systems and diesel fuel injection. The US branch separated in 1942 to become American Bosch, and Robert Bosch Corporation began manufacturing diesel fuel injection equipment in South Carolina in 1973.

Pre-Tech Diesel Service Training Program

The Bosch Pre-Tech Diesel Fuel Injection Service Training Program aims to bring all technicians to a common level of competency and understanding. It can also enhance product knowledge for experienced technicians and serve as support material for vocational/technical institutions. While it contains substantial service information, it does not replace factory service schools or qualify individuals as service technicians.

Prerequisites: Users are expected to have a basic knowledge of automotive and diesel theory, including:

• Two and four-stroke engine cycles
• Ignition and electrical systems
• Shop practices
• Fuel systems
• Lubrication and cooling
• Shop safety

Pre-Tech delivers essential information from an on-the-job perspective. The self-paced format is designed for maximum training in minimum time, allowing users to focus on difficult areas for direct, one-on-one learning.

The program comprises seven Modules, including eleven Audio-Visual Program Review Guides and three Programmed Instruction Text booklets. Review Guides contain visuals and narration, module introductions, objectives, required equipment, special instructions, and review exercises. Programmed Instruction Texts present information in place of visuals and narration, with exercises instead of review exercises. Answers for exercises are provided within each module or text.

Audio-visual programs and microfiche are not supplied with the CD-ROM but can be ordered separately via the Bosch Internet Website: www.boschservice.com or by contacting Bosch Training Materials at 1-800-937-2672. Older formats like Film/Tape Cartridge and Filmstrip/Cassette Tape are no longer available.

Pre-Tech Objectives

The primary objectives of Pre-Tech are to establish a common level of competency and understanding for prospective diesel fuel system technicians and to improve the product knowledge of experienced technicians. While specific criteria are not mandated, students are encouraged to achieve a minimum passing score of 70% on exercises when taken as open-book tests.

Pre-Tech Training Module Overview

Module 1: Diesel Basics

This module covers the introduction to Diesels and Diesel Injection and Governing, explaining differences between gasoline and diesel engines, diesel fuel properties, and advantages of diesel engines. It also briefly explains diesel engine operation, injection pumps, governors, and injectors.

Module 2: Product Identification

This module focuses on identifying various Bosch injection pumps (PF, PFR, A, MW, M, P inline; VA, VE distributor) and governors (RSV, RQV, RQV-K, RW, RWV). It also introduces original equipment manufacturers using these components and the Bosch Microfiche System.

Module 3: Nameplate Identification

This module teaches how to identify and interpret various numbers found on product nameplates, including Product Designations, Bosch Order Numbers, Serial Numbers, Date Codes, and Factory Codes, for purposes like parts ordering and form completion.

Module 4: Pump and Governor Operation

This module details the operating principles and basic adjustments for various pumps (A-Pump, P-Pump, MW-Pump, VE-Pump) and governors (RQV, RQV-K, RSV, RW).

Module 5: Metrics in the Shop

This module introduces the metric system and metric measuring tools essential for servicing diesel injection equipment. It includes workbook exercises requiring hands-on tasks with metric measuring tools and shims.

Module 6: Injector Operation, Service, and Testing

This module covers the operation, servicing, reconditioning, and testing of pintle and hole type injectors (nozzles). It guides users on troubleshooting, reconditioning, and testing injectors, enabling them to find opening pressure specifications and perform disassembly, cleaning, reassembly, and retesting of a KCA injector assembly.

Module 7: Diesel Service Microfiche

This module provides an overview of the Bosch Diesel Microfiche Service Information System (SIS) and Electronic Service Information (ESI). These systems offer access to service bulletins, equipment lists, part number cross-references, and repair information, primarily for Bosch Authorized Diesel Service Dealers and Central Distributors.

Special Instructions

Pre-Tech is a self-paced training program designed for individual study but can also be adapted for instructor-mediated, group-paced classroom instruction. While no exact time frame is set for completion, 1-2 hours per lesson is recommended. For classroom settings, ensure all participants can see and hear the presentation and have access to equipment for hands-on exercises. Teams of two or three can be formed to reduce equipment needs, but this may impact training effectiveness if individual participation is limited. Planned stops in audio-visual programs are opportunities for discussion and review.

For self-paced learning, users are responsible for timely completion. Instructors or supervisors should be available for questions and assistance. Exercises and Review Exercises are included, with answers provided. It is recommended to complete these as open-book tests. Scores below 70% suggest reviewing the lesson and retaking the exercise. Scores of 70% or higher should be followed by a review of missed questions.

A User Progress Sheet is included at the end of the document to track individual progress through the Pre-Tech Modules.

Tips For Using Pre-Tech Audio-Visual Programs

To maximize learning from the compact and rapidly paced audio-visual programs:

1. View the audio-visual program before completing Review Exercises.
2. In a classroom, encourage participants to respond to questions asked in the program.
3. Use chapter stops to encourage users to think through presented information before proceeding; use these stops for discussion and review in classroom settings.
4. While Review Exercises are open-book tests, encourage users to answer as many questions as possible without referring to the program information.
5. Utilize the audio-visual programs as an introduction or review for related subjects.

Special Equipment

The following equipment is required for Pre-Tech but is not included with the CD-ROM:

Required For all Modules:

• A Videotape Player or Slide Projector and Audiocassette Player (depending on audio-visual format).
• A Microfiche Reader is required if the optional Diesel Training Microfiche and Exercise Supplement is utilized (Bosch Microfiche is not included with this CD-ROM).

Required For Module 5:

• Shim-Set (provided by supervisor/instructor).
• 0-25 mm metric micrometer (capable of measuring 0.01 mm).
• Metric vernier caliper (capable of measuring 0.1 mm).
• Metric feeler gauge.

Required For Module 6:

• KCA Nozzle Holder Assembly (non-GM application).
• Common Metric Hand Tools (for disassembly and assembly).
• 0-25 mm Metric Micrometer.
• Bench Vise.
• Torque Wrench (to 80 Nm).
• Nozzle Tester (Bosch EFEP60H or equivalent).
• Test Line (Bosch EF8040/24 or equivalent).
• Nozzle Cleaning Kit (Bosch KDEP 2900 or equivalent).
• Commercial parts cleaning solvent.
• Calibration Oil.

Required For Module 7:

• Diesel Training Microfiche and Exercise Supplement: Part # PRE-FICHE.

Bosch Training and Reference Material

Additional Automotive and Diesel Training, Reference, and Study materials are available from Bosch. For more information or to order, contact your nearest Bosch Diesel Service Dealer (DSD), Central Distributor (CD), or visit www.boschservice.com. A listing of Bosch DSDs and CDs is also available on the Bosch Website.

The audio-visual programs and microfiche can be ordered separately via the Bosch Internet Website (www.boschservice.com) or by contacting Bosch Training Materials at 1-800-937-2672. Programs are available in 1/2" NTSC VHS Videotape and 35mm Slide/Audio Cassette formats. Older formats are no longer available.

The following table lists available materials by module:

Additional Reference Materials

Many excellent reference and study materials are available in public and school libraries, and from other diesel users and manufacturers. In addition to the references listed here, shop and service manuals from manufacturers such as Mack, J.I. Case, and International Harvester provide further reference and study material.

Additional reference sources:

• Exploring Power Technology (with workbook): Walker, Goodheart Wilcox, South Holland, MI
• Diesel Fundamentals, Service and Repair: Tobolt, Goodheart Wilcox, South Holland, MI
• Diesel Mechanics (with workbook): Schulz, McGraw Hill, New York, NY
• Diesel and High Compression Gas Engines: Kabes and Luck, American Technical Society, Chicago, IL
• Diesel Engineering Handbook: Karl Stinson, Diesel Publications, Inc., Stanford, CN
• Internal Combustion Engines: Edward Obert, International Textbook Co., Scranton, PA
• Apprentice Training Recommendations, #985623, Cummins Engine Co., Columbus, IN
• John Deere FOS, FMO, and Technical Service Manuals: Deere and Co., Moline, IL
• Metrics for Mechanics - A Self-Study Course (42-00-2815-1): Volkswagen of America, Englewood Hills, NJ
• Diesel Engine Repair: Dagel, John Wiley and Son, New York, NY

For questions or comments regarding this CD-ROM program, please contact:

Robert Bosch Corporation
Automotive and Diesel Service
Training and Information Development
P.O. Box 4601
Carol Stream, IL 60197-4601

Pre-Tech Progress Sheet

This section provides a template for tracking progress through the Pre-Tech program. Users should enter the date assigned and date completed for each module and workbook. Supervisors or instructors can then check work and provide comments.