Bosch KMA 802 User manual

en Original instructions
Quantity measurement technology
fr Notice originale
Technique de mesure des quantités
es Manual original
Técnica de medición de cantidad
zh 原始的指南
量测量技术
KMA 802/822

1 689 989 349 2017-07-01|Robert Bosch GmbH
| KMA 802/822 | 3
Contents English 4
Sommaire français 23
Índice español 42
目录（中文） 61

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4 | KMA 802/822 |
1. Symbols used 5
1.1 In the documentation 5
1.1.1 Warning notices -
Structure and meaning 5
1.1.2 Symbols in this documentation 5
1.2 On the product 5
2. User information 5
2.1 Important notes 5
2.2 Safety instructions 5
2.3 Electromagnetic compatibility (EMC) 5
3. Product Description 6
3.1 Intended use 6
3.2 Comparison of the “KMA” and “Glass” measuring
technology 6
3.2.1 Wetting 6
3.2.2 Temperature differences 6
3.2.3 Fluctuations in the injection-pump flow
rate 6
3.3 Scope of delivery 6
3.4 Special accessories 6
3.5 KMA 800 (PC and operator display unit mounted
on the injection pump test bench) 7
3.5.1 PC unit 7
3.5.2 Operator display unit 7
3.6 KMA 822 (trolley with PC and operator display
unit) 7
3.7 KMA 802 (measuring device) 8
4. Initial Commissioning 8
4.1 KMA 800 (PC and operator display unit mounted
on the injection pump test bench) 8
4.1.1 Fitting PC unit 8
4.1.2 Fitting the operator display unit 9
4.1.3 Fitting monitor 9
4.1.4 Connecting the connecting cables 10
4.2 KMA 822 (trolley with PC and operator display
unit) 10
4.2.1 Setting up trolley 10
4.2.2 Fitting keyboard 10
4.2.3 Fitting the PC 10
4.2.4 Connecting the connecting cables 10
4.3 KMA 802 (measuring device) 11
4.4 Electrical connection 11
4.4.1 KMA 800/822 11
4.4.2 KMA 802 (measuring device) 11
4.4.3 Overflow temperature 11
4.4.4 Cable routing 12
4.5 Commissioning 12
4.5.1 KMA 800/822 12
4.5.2 KMA 802 (measuring device) 12
4.5.3 Software settings 13
4.6 Test run 13
4.7 Measuring the overflow rate 13
5. Prevention of
contamination 14
6. Faults 15
6.1 fault memory 15
6.2 Troubleshooting 15
6.3 Cleaning the volume meter 15
6.3.1 Cleaning the volume meter 15
6.3.2 Venting the volume meter 17
7. Maintenance 18
7.1 Maintenance 18
7.2 Maintenance intervals 18
7.3 Cleaning monitor 19
7.4 Spare and wearing parts 19
8. Decommissioning 20
8.1 Temporary shutdown 20
8.2 Change of location 20
8.3 Disposal and scrapping 20
8.3.1 Substances hazardous to water 20
8.3.2 KMA 802/822 and accessories 20
9. Technical data 21
9.1 General data 21
9.2 Dimensions and weights 21
10. Range of adjustment limits
(guaranteed measurement range) 22
en
Contents English

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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 con-
sequences of the hazard as well as preventive action.
Warning notices have the following structure:
Warning
symbol
KEY WORD – Nature and source of hazard!
Consequences of hazard in the event of failu-
re 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-observan-
ce:
Key word Probability of
occurrence
Severity of danger if inst-
ructions not observed
DANGER Immediate impen-
ding 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.
1.
2.
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.
2. User information
2.1 Important notes
Important information on copyright, liability and warran-
ty provisions, as well as on equipment users and com-
pany obligations, can be found in the separate manual
"Important notes on and safety instructions for Bosch
Diesel Test Equipment". These instructions must be care-
fully studied prior to start-up, connection and operation
of the KMA 802/822 and must always be heeded.
2.2 Safety instructions
All the pertinent safety instructions can be found in
the separate manual "Important notes on and safety
instructions for Bosch Diesel Test Equipment". These
instructions must be carefully studied prior to start-
up, connection and operation of the KMA 802/822 and
must always be heeded.
2.3 Electromagnetic compatibility (EMC)
The KMA 802/822 satisfies the requirements of the
EMC directive 2014/30/EU, EN 61800-3.
Warning! This product may cause high-frequency
household interference so that interference suppressi-
on may be necessary.
enSymbols used | KMA 802/822 | 5

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6 | KMA 802/822 | Product Descriptionen
3. Product Description
Please comply with the instructions in the operating
manual for the injection-pump test bench.
3.1 Intended use
KMA (CMA) stands for Continuous Measuring Analysis.
It is designed to test and adjust diesel-fuel injection
pumps up to 12 cylinders in conjunction with an injec-
tion-pump test bench.
3.2 Comparison of the “KMA” and
“Glass” measuring technology
3.2.1 Wetting
The "glass measuring technology" involves determining
the volume of test oil sprayed in a graduated measuring
glass. When the measuring glasses are emptied, a test
oil residue remains in the measuring glass. This residue
is known as the measuring-glass wetting.
The "KMA measuring technology" involves continuously
measuring the sprayed-off test oil, i.e. the measure-
ments determined by the KMA are reduced by the quan-
tity of the measuring-glass wetting without the correc-
tion factor.
3.2.2 Temperature differences
In the case of the KMA measuring system, the test oil
to be measured is supplied to the measuring system
much more quickly. In contrast to the “glass measu-
ring technology”, the temperature may differ when the
measurements are read. This would result in quantitati-
ve differences.
However, in order to be able to use the same test va-
lues and adjustment values as in the "glass measuring
technology" system, the computer takes account of the
measuring-glass wetting and temperature difference. As
a result, the measurements displayed on the monitor
are comparable with the “glass measurements”.
3.2.3 Fluctuations in the injection-pump flow rate
In a continuous measuring system such as KMA measure-
ments are performed very quickly. As a result, the flow rate
may fluctuate for several "critical" injection pumps.
In the "glass measuring technology" system this fluctuation
effect is averaged over a long measurement period (e.g.
1000 strokes).
In the case of the KMA, some critical injection pumps
should preferably be measured on a long-term basis,
otherwise the flow rate cannot always be adjusted pre-
cisely (display constantly changes).
3.3 Scope of delivery
Designation KMA1)
802 822
Measuring device ● ●
PC protective casing ●—
Trolley — ●
Console with fitting accessories ● —
Retaining strip for monitor ● ●2)
Carrier plate ● —
Monitor with accessories ● ●2)
Power supply cable ● —
RS-232 connecting lead (8 m) — ●
RS 232 connecting lead (3 m) ● —
RS 232 connecting lead (0.75 m) ● —
Multi-socket outlet ● —
Connection accessories ● ●
1) Order number:
KMA 802 = 0 683 802 001
KMA 822 = 0 683 822 001
2) Pre-assembled. in trolley.
iFor operations on the KMA 802 or the KMA 822, a
PC is also required. This PC is an optional accessory
and contains the EP software package.
3.4 Special accessories
Designation Ordering number
Printer On request1)
USB connecting cable (1 m) for printer 1684465491
PC with EP software package On request1)
Connection set
(4 item quick coupling connection)
for additional PDHK (test nozzle-holder as-
sembly) with
thread M 20 x 1.5
(Type I, II, III, IV, VII, VIII, IX)
1 item per additional PDHK
required.
1687010089
Connection set
(4 item quick coupling connection)
for PDHK with thread M 22 x 1
(Type T- nozzles)
1 item per PDHK required.
1687010088
In-line filter insert (6 item)
(Damping unit – valve block)
1687001509
1) Information on special accessories can be obtained from your
authorized Bosch dealer.

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enProduct Description | KMA 802/822 | 7
3.5 KMA 800 (PC and operator display
unit mounted on the injection pump
test bench)
3.5.1 PC unit
1
2
3
458737/15
Fig. 1: PC unit mounted on the switch cabinet
The PC unit consists of a PC (fig. 1, item 2) and a com-
puter housing (fig. 1, item 1) which is attached to the
electrical cabinet (fig. 1, item 3) of the EPS.
3.5.2 Operator display unit
1
2
3
458737-18
Fig. 2: The operator display unit is mounted on the cover
The monitor (fig. 2, item 1) provides a display of: user
prompts, REQUIRED-ACTUAL data, measurement re-
sults, error messages, Help information etc. To operate
the KMA and the injection pump test bench, a keyboard
(fig. 2, item 2) is used.
Keyboard (fig. 2, item 2) and monitor (fig. 2, item1) are
pivoted on the EPS cover (fig. 2, item 3).
3.6 KMA 822 (trolley with PC and opera-
tor display unit)
458737-20
KMA 822
1
2
3
4
5
Fig. 3: Trolley with PC, monitor and printer
In this version, the PC (fig. 3, item 5) and the operator-
display unit (monitor (fig. 3, item 1), keyboard (fig. 3,
item 3)) are mounted in a trolley (fig. 3, item 2) which
can also accommodate a printer (fig. 3, item 4) as an
optional accessory.
The trolley (fig. 3, item 2) is positioned at the side of
the EPS.

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8 | KMA 802/822 | Product Descriptionen
3.7 KMA 802 (measuring device)
21 2 3
B2 B1
458737/4
Fig. 4: Electronics area of measuring device
The measuring device is situated in a partitioned sheet
steel housing (fig. 4, item 1) on the swivel arm.
The electronics for the two measuring cells (fig. 4,
item 2) are situated in the electronics compartment
(pointing towards the clamping bed). The data required
to determine the injected quantity is transmitted to the
PC via the printed circuit board (fig. 4, item 3).
26
5
4
62
B1 B2
458737/5
Fig. 5: Hydraulic area for measuring device
To damp the spraying-off procedure, twelve damping
units (fig. 5, item 5) have been installed in the hydrau-
lics compartment (pointing away from the clamping
bed). These damping units are connected to the test
nozzle holder combinations by twelve external quick-
release couplings (fig. 5, item 4). The test oil which
is to be measured is supplied alternately (multiplex
technology) to two volumetric displacement measuring
cells (fig. 5, item 2) via two valve blocks (fig. 5, item 6).
When the measurement is complete, the test oil flows
back to the test-oil tank.
4. Initial Commissioning
4.1 KMA 800 (PC and operator display
unit mounted on the injection pump
test bench)
4.1.1 Fitting PC unit
1
2
3
4
576
458737/17
Fig. 6: PC unit
1. Remove rear panel (fig. 6, item 1) from computer
housing (fig. 5, item 2).
2. Secure computer housing (fig. 6, item 2) to EPS
electrical cabinet (fig. 6, item 4). For this, fit four M6
screws (fig. 6, item 3) through the corner boreholes
in the base of the computer housing and screw them
into the threaded bushings in the cover of the EPS
control cabinet.
3. Install PC (fig.. 6, item 5) from the back.
iPC (fig. 6, item 5) must be situated on the left side
in the recess behind the control flap.
4. Secure mounting bracket (fig. 6, item 7) on back of
PC with two screws (fig. 6, item 6) to base of com-
puter housing.

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enInitial Commissioning | KMA 802/822 | 9
4.1.3 Fitting monitor
1
2
3
4
5
458778-10
Fig. 8: Fitting and connecting the monitor
1. Pull the video cable and power cord through the
opening in the bottom of the mounting plate (fig. 8,
item 1).
!Take care not to trap any cables when fitting the
mounting plate.
2. Position the mounting plate (fig. 8, item 1) on the
console (fig. 8, item 2) and secure.
3. Attach the mounting (fig. 8, item 3) to the monitor
(fig. 8, item 4) with bolts (M4 x 10) and a spring lock
washer (A4.2).
4. Fit monitor and holder to support plate (fig. 8,
item1).
5. Use the adjusting screw (fig. 8, item 5) to set the
angle of the monitor.
6. Swivel the monitor upwards and connect the video
cable and power cord.
7. Swivel the monitor downwards as far as it will go.
4.1.2 Fitting the operator display unit
458778-05_Pal
1
2
3
4
5
6
7
Fig. 7: Fitting the operator display unit
1. Secure four rubber buffers (fig. 7, item 5) to support
plate (fig. 7, item 3).
2. Place, position and secure support plate (fig. 7,
item 3) in long bores of EPS cover (fig. 7, item 4).
3. Remove retaining panel (fig. 7, item 1) from console
(fig. 7, item 2).
4. Set the console (fig. 7, item 2) onto the support
plate’s (fig. 7, item 3) threaded studs and fasten in
place using a washer and a hex nut.
iThe scope of supply includes two coarse burr fas-
teners and two fine-grade burr fasteners. To secure
the keyboard, fit one coarse and one fine-grade burr
fastener to each side.
5. Secure keyboard (fig. 7, item 6) to console support
(fig. 7, item 2) with a burr fastener (fig. 7, item 7).
6. Unfold legs on left and right sides of keyboard.

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10 | KMA 802/822 | Initial Commissioningen
4.1.4 Connecting the connecting cables
¶The connection cables should be installed and
attached with cable ties according to Chapter 4.4
“Connection cables”.
4.2 KMA 822 (trolley with PC and opera-
tor display unit)
4.2.1 Setting up trolley
458737-21
KMA 822
1
2
4
5
3
Fig. 9: Trolley with PC, monitor and printer
¶Set up the trolley (fig. 9, item 2) next to the injection-
pump test bench.
4.2.2 Fitting keyboard
iFor ideal ease of use, the keyboard should be posi-
tioned at a distance of 40mm from the rear edge of
the flap.
1. Attach the keyboard (fig. 9, item 3) to the trolley flap
with a burr fastener.
2. Route keyboard connecting cable through cable
duct.
3. Attach the keypad connecting cable to the intermediate
panel with a cable tie (strain relief). When doing so,
make sure the length of the keypad connecting cable
between the keypad and connecting cable fastener is
sufficient to ensure that the keypad connecting cable is
not strained on closing the flap.
4.2.3 Fitting the PC
¶Install the PC (fig. 9, item 5) in the trolley (fig. 9,
item 2). Remove the bottom rear wall for this purpo-
se. Install PC (fig. 9, item 5) into the bottom com-
partment from behind.
4.2.4 Connecting the connecting cables
¶Install the connecting cables as described in
Chapter 4.4 Connecting cables, and secure them to
the rear of the trolley with cable ties. Then re-attach
the bottom rear wall to the trolley.

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enInitial Commissioning | KMA 802/822 | 11
4.3 KMA 802 (measuring device)
1
2
3
4
5
6
7
8
458737/8
Fig. 10: Measuring device
1. Attach the plate (fig. 10, item 7) to the swivel arm,
ensuring that the guide pipe (fig. 10, item 6) is
pointing outwards (pointing away from the clamping
bed).
2. Remove the cover (fig. 10, item 2) from the electro-
nics compartment.
3. Insert the gas spring (fig. 10, item 1), with the eye
pointing upwards, into the guide tube (fig. 10,
item 3) and position the complete measuring device
from above. Push the guide tube (fig. 10, item 3) on
the measuring device over the guide tube (fig. 10,
item 6) on the swivel arm.
4. Screw the eye of the gas spring (fig. 10, item 1) to the
guide tube (fig. 10, item 3) on the measuring device.
Raise the measuring device until the cross borehole in
the guide tube (fig. 10, item 3) and the eye borehole
in the gas-spring are in alignment and the hexagon-
socket head bolt can be inserted. Screw on the self-
locking nut.
5. Fit cover (fig. 10, item 2) to electronics compart-
ment.
6. Connect the enclosed hoses (fig. 10, item 4, 8) to
the bottom right and left and connect to the two
connections on the swivel arm. Tighten down termi-
nal (fig. 10, item 5).
4.4 Electrical connection
4.4.1 KMA 800/822
iThe specification and assignment of the PC connec-
tions are described in the PC operating instructions.
1. Connect the keyboard cable to a vacant USB connec-
tion on the PC.
2. Video cable (15-pin connector) to the VGA socket
X9 (video) on the PC.
KMA 800:
1. Insert the PC power cable (230 V) into the X3 plug
connector on the EPS electrical cabinet.
2. Insert the monitor power cable (230 V) into the X3
plug connector on the EPS electrical cabinet.
3. 9-pin Connect sub-D connector X4 (COM2) of PC using
the RS232 connecting cable (3m) to 9-pin sub-D con-
nector X7 on the EPS electrical cabinet.
KMA 822 (trolley):
1. Insert PC power cable (230 V) in socket on the rear
panel of the trolley.
2. Insert the trolley power cable (230 V) into the X3
plug connector on the EPS electrical cabinet.
3. 9-pin Connect sub-D connector X4 (COM2) of PC
using the RS232 connecting cable (8m) to 9-pin
sub-D connector X7 on the EPS electrical cabinet.
4.4.2 KMA 802 (measuring device)
1. Insert connector X1 into 37-pin bush X2 in electrical
cabinet.
2. 9-pin Connect sub-D connector X2 of measuring
device using the RS 232 connecting cable (8 m) to
9-pin sub-D socket X3 (COM1) of the PC
(note designation).
4.4.3 Overflow temperature
¶Connect temperature sensor to BNC socket X3 on
measuring device.

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12 | KMA 802/822 | Initial Commissioningen
4.4.4 Cable routing
Long cable routes, such as from the switch
cabinet to the KMA 822, must be laid so as
not to impede walkways or present risks in
any other way.
To this end, two cable ties are attached to the underside
of the KMA 802 by which cables can be routed safely,
such as the connecting cables to the KMA 822.
It is better to route the connecting cables via the test
bench. This requires extension set 1 687 001 445. The
operators must provide the suspension mounts for the
connecting cables.
4.5 Commissioning
4.5.1 KMA 800/822
1. Switch ON the injection-pump test bench with the
main switch.
2. In the case of the KMA 822 (trolley) switch ON the
switch on the multiple socket (rear of the trolley).
3. Switch ON the PC and monitor with their respective
mains switches.
iIn addition to the mains switch on the front, the PCs
also have a central mains switch at the rear.
4. Check that the operating display is indicated on both
the PC and the monitor.
5. When operating for the first time, the operating
system must be installed, and appropriate settings
(time, national language etc.) completed.
6. Install EPS945 software.
4.5.2 KMA 802 (measuring device)
1
2
3
4
5
B1
458737/9
Fig. 11: Measuring device
1. Remove the cover from the hydraulics compartment
of the measuring device.
2. Remove the screw caps from the top of the two
overflow pipes (fig. 11, item 3) and pour in clean
test oil until the hoses (fig. 11, item 4) are filled as
far as the measuring cells (fig. 11, item 5) without
air bubbles.
3. Remove the twelve locking pieces (fig. 11, item 1)
from the quick-coupling (fig. 11, item 2) and pour in
clean test oil.
4. Insert the twelve locking pieces (fig. 11, item 1).
!Always insert a locking piece (fig. 11, item 1) in the
quick-release coupling (fig. 11, item 2) for a non-
assigned measuring channel.

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enInitial Commissioning | KMA 802/822 | 13
4.5.3 Software settings
1. Switch on the measuring device KMA and start up
software EPS945.
2. The following items must be checked or set in the
EPS945 software under
"Configuration" (see online help for EPS 945):
$calibration values of the quantity measuring cells
$calibration values of the overflow sensors
$function of the temperature display and inputs of
temperature presettings.
iMeasuring cell B1 (fig. 11, item 5) in the hydraulics
compartment of the measuring device corresponds
to measuring cell 1 in the display ”Calibration of the
volume meter".
Procedure:
1. In the display, call up "Injection component test -
main menu" by means of key F7 Configuration.
2. A password request appears.
3. Enter the password "1958" in the input row.
4. Select calibration in the configuration menu item.
Further selection options appear in the window
Calibration.
5. Select each further option in turn and check all data
by means of the measurement record.
iThe measurement records are stored inside the KMA.
6. In the event that the measurement data in the record
do not correspond with the input data, correct them
and store the values using the key F4 Save.
iIf the test bench has not been operated for a prolon-
ged period (e.g. overnight), the room temperature
is displayed. If no temperature sensor is connected,
there is no display.
4.6 Test run
The KMA must not be operated without a
cover.
1. Reinstall cover on measuring equipment.
2. Check the performance of the quantity measurement
cells by clamping the injection pump to the EPS and
operating it.
!During the initial start-up all twelve measuring channels
must first be filled by one injection pump.
iAfter a short time (measuring system is automatically
filled and vented during this time) the individual flow
rates are displayed in the basic "Speed-adjustment"
program.
4.7 Measuring the overflow rate
1
458737/11
The overflow rate can be measured continuously.
In-line injection pump
¶Connect the test-oil return line with an 18 mm dia-
meter ring piece and hollow screw (1) to the top of
the KMA802 measuring device.
Distributor injection pump
¶Connect the test-oil return line with an 18 mm dia-
meter ring piece to the top of the KMA 802 measu-
ring device.

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14 | KMA 802/822 | Prevention of contaminationen
5. Prevention of
contamination
To determine the injection volume / delivery rate, the
continual measuring technology KMA 802 incorporates
precision mechanical components such as change-over
valves or flow meters. Because of the necessary clea-
rances on moving parts, foreign particles ranging in size
from 20 µm – 40 µm can cause malfunction and subse-
quent failure of the measuring system. Smaller particles
< 20 µm pass through the measuring system without
any adverse effect.
On run-in and unopened injection systems, the propor-
tion of foreign particles 20 µm – 40 µm is very low, as
the vehicle-fitted fuel filter upstream of the injection
pump can filter out particles > 10 µm. On new injection
pumps, any critical foreign particles are filtered out as
soon as operation starts on the engine.
More critical are the repaired injection pumps in which
replacements parts such as pump housing or pump
elements have been fitted which still contain residue
from this process which can then enter the measuring
system during subsequent testing of the pump. Ge-
nerally this is caused by insufficient cleaning of these
replacement parts.
To prevent foreign particles from entering the measu-
ring system, the following is recommended (only
applies when testing in-line and distributor injection
pumps):
1. Rinsing before measurement
During the specified warm-up time (3 to 5 minutes),
the injection pump is to be flushed before the first
flow measurement. This is done before starting the
test bench by opening the bleed screw on the test
nozzle holder and then running the pump. The test
oil then flows through the bleed elbow on the test
nozzle holder into the drain channel of the measu-
ring device. The metal particles by-pass the measu-
ring system in this way. To prevent oil splashes,
these elbows can be fitted with transparent hoses,
which lead into the collective drain channel of the
measuring device or into the test-oil tank of the test
bench. The majority of foreign particles then go
directly into the test-oil tank. This oil circuit is provi-
ded with course and fine filters. These filters retain
the foreign particles. Before starting measurement,
the bleed screw on the test nozzle holder must be
re-closed.
2. Installation of auxiliary filters upstream of change-
over valves /flow meters.
iFor KMA 802 measuring technology, there is a retro-
fit kit for subsequent installation in the measuring
system. This retrofit kit 1 687 001 509 includes 6
fine filters, fastening parts and installation instruc-
tions.

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enFaults | KMA 802/822 | 15
6. Faults
6.1 fault memory
Any errors occurring in the system are indicated in a
dialog window. In addition, the operator display unit
KMA800/822 is equipped with a fault storage function.
This is located in the software EPS945-PE/VE/CR on the
program path Configuration / System / Status Informa-
tion or in the measurement display under menu Proto-
col / Status Information. Here, the latest error reports
are filed. Each time the software EPS945-PE/VE/CR is
restarted, all error reports are erased. Error specificati-
on is carried out by error codes.
6.2 Troubleshooting
Fault Remedy
No display on operator
and display device.
Check that monitor and PC are con-
nected and switched on.
With the KMA 822, check that the so-
cket strip on the trolley is connected
and switched on.
No power to EPS socket strip (refer
to instructions for basic test bench).
Check that VGA connecting cable is
connected to PC and to monitor.
When channel is detec-
ted, individual connec-
ted channels are not de-
tected.
Measuring system is not yet comple-
tely filled with test oil (initial start-
up). Run channel detection several
times in succession, or set manually
on an adapted channel.
During flow measure-
ment, severe fluctua-
tions of straight and
angled channels. Oil le-
vel in supply hose of vo-
lume meter rises and
falls during the test.
Volume meter contaminated. (volume
meter B1 on angled channels and vo-
lume meter B2 on straight channels).
This is detected by the extent that
the oil level rises in the supply hose
to the volume meter.
Clean and bleed volume meter (see
Chapter 6.3).
Straight or angled chan-
nels show no volume.
Supply hose to the volu-
me meter is completely
filled with oil.
Volume meter jammed or defective
(volume meter B1 on angled chan-
nels and volume meter B2 on straight
channels). Detection as above.
Clean and bleed volume meter (see
Chapter 6.3).
6.3 Cleaning the volume meter
6.3.1 Cleaning the volume meter
Always wear protective goggles during as-
sembly work in the hydraulics area of the
KMA 802/822.
Always wear protective gloves when working
on the KMA 802/822.
!Inexpert disassembly and assembly may impair ope-
ration or the accuracy of the volume meter (fig. 12,
item 1 and 2).
iComplete removal of the volume meter in order to
clean the control piston or the gear pump is not
necessary.
iParticles in gear pump:
No measurement values, as pump is blocked. Supply
hose to the volume meter is completely filled with
oil.
iParticles in control piston:
Bar charts and measurement values fluctuate con-
siderably. Oil level in the supply hose to the volume
meter rises and falls.
1
B1 B2
2
458737-25_Pal
Fig. 12: Electronics area of measuring device

1 689 989 349 2017-07-01| Robert Bosch GmbH
16 | KMA 802/822 | Faultsen
1. Switch off the EPS 815 at the master switch.
2. Remove the cover from the hydraulics compartment.
3. Remove plastic cap (fig. 13, item 3) and remove LED
with its socket (fig. 13, item 7).
4. Remove (4 screws) flow sensor cap (fig. 13,
item 2) and route LED with cover and connection
cable through flow meter cap.
5. Carefully remove cylinder (fig. 13, item 2) with con-
trol piston (3). Remove control piston.
!If there are grooves on the control piston, the volume
meter must be replaced by customer services.
6. Clean the cylinder (fig. 13, item 2) and control pis-
ton (fig. 13, item 3) in clean test oil and check the
surfaces for scoring.
7. Reinsert the control piston (fig. 13, item 3) in cylin-
der (fig. 13, item 2). Note the installation position:
the control piston cap (fig. 13, item4) must be posi-
tioned on the right.
8. Check that the control piston moves easily by gently
moving the cylinder (fig. 13, item 2).
458737-14Ko
1
23
4
5
6
7
8
9
10
11
12
Fig. 13: Exploded view of volume meter
!When disassembling and assembling the internal
gear (fig. 13, item 9) make sure not to lose the loose
driver (fig. 13, item 12).
!On disassembly and assembly, pay attention to the
installation position of the external gear (fig. 13,
item 9) and the internal gear (fig. 13, item 10). Ensu-
re correct pairing of the external gear (fig. 13,
item 9) and internal gear (fig. 13, item 10).
9. Remove external gear (fig. 13, item 9), sickle (fig.
13, item 8) and internal gear (fig. 13, item 10) with
tweezers, rinse in clean test oil, and reinsert.
iAfter reinsertion, external gear (fig. 13, item 9), sick-
le (fig. 13, item 8) and internal gear (fig. 13,
item 10) must be aligned evenly with the volume
meter housing.
10. Install cylinder (fig. 13, item 2) and control piston
(fig. 13, item 3). Mind the installation position!
11. Replace O-ring (fig. 13, item 1) (spare parts set:
1 687 010 136) and ensure it is correctly seated in
groove.
12. Push LED with socket (fig. 13, item 11) and con-
nection cable through opening of the volume meter
cap (fig. 13, item 7).
13. Replace O-ring (fig. 13, item 5) (spare parts set:
1 687 010 136) and ensure the O-ring is correctly
seated.
14. Fit LED with socket (fig. 13, item 11) in plastic cap
(fig. 13, item 6). Mind the installation position!
15. Attach plastic cap (fig. 13, item 6); ensure that LED
with socket (fig. 13, item 11) is centered in window
of flow sensor cap (fig. 13, item 7).
16. Carefully fit volume meter cap (fig. 13, item 7) and
secure with screws (fig. 13, item 4).
Tightening torque: 11 Nm.
"Volume meter is cleaned.

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enFaults | KMA 802/822 | 17
6.3.2 Venting the volume meter
The volume meter must be vented after cleaning.
1. Clamp and connect injection pump (in-line injection
pump, distributor injection pump, or common rail
pump).
iConnect injection pump hydraulically to KMA in such
a way that the entire flow rate from the injection
pump is channeled directly to the volume meter to
be bled.
Angled measuring channels = flow meter B1
Straight measuring channels = flow meter B2
2. Switch on the EPS 815 at the master switch.
3. Switch on the KMA 802/822.
!On Common Rail pumps, only select test steps with
flow rate ≤30 l/hr. Speed increase simultaneously
leads to an increase in displacement (flow rate).
4. Start the EPS 945 software and select injection
pump.
5. Select test step with high flow rate and start testing.
6. Wrap cloth around hose (fig. 14, item 1) leading to
volume meter B1 or hose (fig. 14, item 2) for volume
meter B2 and crimp for approx. one second using
crimpers. Repeat procedure 5x.
The created interruption and subsequent increase
of the flow cause significant movement of the con-
trol piston in the flow meter and bleed the measu-
ring system.
458737-24_Pal
2
1
Fig. 14: Hydraulic area for measuring device
7. Visually inspect hose (test oil inlet) (fig. 14, item 1
and 2) of volume meter.
Flow rate flows through the volume meter.
The volume meter is vented.
8. Attach the cover for the hydraulics compartment.

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18 | KMA 802/822 | Maintenanceen
7. Maintenance
7.1 Maintenance
The EPS, like any industrial device, requires proper
maintenance at regular intervals.
The maintenance intervals refer to the operation of the
EPS in vehicle service canters for 8 hours per day. Re-
duce the intervals accordingly if the operating time is
extended.
We recommend portable test set 0 986 614 000 (availa-
ble from AA/SWS1) for performing maintenance work.
This contains all the calibrated measuring instruments
and accessories required for maintenance.
Customer service also uses flow-rate standards when
implementing the test service (checking the measuring
accuracy).
7.2 Maintenance intervals
Maintenance work 1*) 2*) 3*) 4*)
Check and, if required, adjust the nozzle opening pressure according to regulations.
Before doing so, check the pressure gage on the nozzle tester. x x
Pressure supply lines: check that sealing cones and bores are in perfect condition;
if required replace with new pressure lines. x
Interchange the nozzle holders and pressure lines
and compare their respective flow rates.
The same delivery rates must be measured.
x
Replace pressure joint with rod filter or sieve filter. x
Measuring device (KMA 802) for any leakages, and if found,
rectify them. x
Measuring device (KMA 802): check for measuring precision. x
Volume meters: perform flow measurement on even and odd ducts in succession and compa-
re the delivery rates with each other:
The same delivery rates must be measured.
x
Exchange the inlet union screw with the copper gaskets.
Oil the copper gaskets! Tightening torque 30 +3 (Nm)
(outlet damping unit on KMA and KMM 60 S3 /80 S3 and upgrade kits)
x
Replace complete hose lines. x
*) Maintenance intervals
1 weekly
2 After testing 200 injection pumps, at the latest after 2 months
3 During a main inspection or, if required, during the test service
4 After 4 years

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enMaintenance | KMA 802/822 | 19
7.3 Cleaning monitor
!To avoid risk of electric shock, never disassemble the
monitor cabinet. Users cannot service the monitor.
User maintenance is restricted to cleaning as explained
below:
!Unplug the monitor from the power outlet before
cleaning.
!Do not clean the screen with ketone-type materials
(e.g. acetone), ethyl alcohol, toluene, ethyl acid, methyl
or chloride.
1. Lightly dampen a soft, clean cloth with water or a
mild detergent. To clean the screen, if possible, use
special screen cleaning tissues or solutions suitable
for the cleaning of antistatic coatings.
2. To clean the monitor cabinet, use a cloth lightly dam-
pened with a mild detergent.
3. Never use flammable cleaning materials for cleaning
your monitor or any other electrical apparatus.
7.4 Spare and wearing parts
Designation Ordering number
Measuring cell <) 1687234011
Damping unit <)
Half shell <)
Inlet union screw <)
1687001364
1685502038
1463456303
Flat seal <) 2916710607
Hose <), transparent
oil-resistant 8 dia. x 2 x 4500
1680707089
Hose <), transparent
oil-resistant 4 dia. x 2 x 7500 mm
1680707110
Hose clamp <) (greater than Ø) 1684680003
Hose clamp <) (less than Ø) 1684680011
Sealing set <)
For quick-coupling on test nozzle holder
Support ring
O-ring
1680209024
1680210111
Restrictor <)
(In front of valve block)
1687417078
Data line
(From measuring device - computer)
3 m for KMA 802
8 m for KMA 822
1684465371
1684465388
In-line filter insert <) (6 items)
(Damping unit – valve block)
1687001509
O-ring for volume meter <) 1687010 136
<) Wearing part

1 689 989 349 2017-07-01| Robert Bosch GmbH
20 | KMA 802/822 | Decommissioning
1. Disconnect the KMA 802/822 from the mains and
detach the power cord.
2. Dismantle the KMA 802/822 and sort out and dispo-
se of the different materials in accordance with the
applicable regulations.
KMA 802/822, accessories and packaging
should be sorted for environmental-friendly
recycling.
¶Do not dispose KMA 802/822 into
household waste.
Only for EC countries:
The KMA 802/822 is subject to the European
directive 2012/19/EC (WEEE).
Dispose of used electrical and electronic
devices, including cables, accessories and
batteries, separately from household waste.
¶Make use of the local return and collection
systems for disposal.
¶Proper disposal of KMA 802/822 prevents
environmental pollution and possible health
hazards.
8. Decommissioning
8.1 Temporary shutdown
In the event of lengthy periods of non-use:
8.2 Change of location
¶If the KMA 802/822 is passed on, all the documenta-
tion included in the scope of delivery must be handed
over together with the unit.
¶The KMA 802/822 is only ever to be transported in
the original or equivalent packaging.
¶Unplug the electrical connection.
¶Heed the notes on initial commissioning.
8.3 Disposal and scrapping
8.3.1 Substances hazardous to water
!Oils and greases as well as refuse containing oil and
grease (e.g. filters) represent a hazard to water.
1. Substances hazardous to water must not be allowed
to enter the sewage system.
2. Substances hazardous to water must be disposed of
in accordance with the applicable regulations.
iPrüföl nach ISO 4113 gehört zur Altölsammelkate-
gorie 1. In der Altölsammelkategorie 1 dürfen keine
Anteile artfremder Stoffe, z. B. Altöle einer anderen
Kategorie oder Benzin oder Diesel enthalten sein.
Die zugehörige Abfallschlüsselnummer entnehmen
Sie dem Sicherheitsdatenblatt des Prüföls.
8.3.2 KMA 802/822 and accessories
¶KMA 802/822 vom Stromnetz trennen.
en