Bosch CH-47976 User manual

User Guide
CH-47976
CH-47976-11 Rev A
02491-049 Rev A
02491-049 Rev A
US Patent. No. 5,020,362
AFIT User Guide
B&W
300 dpi
14"x 8.5"
J Dzuroff
08-08-18

User Guide

© 2018 Hickok Waekon LLC. All rights reserved.
No part of this manual may be reproduced or transmitted in any form or by any means, electronic or
mechanical, without written permission from Hickok Waekon LLC. and Bosch.
Hickok Waekon LLC. and Bosch assumes no responsibility for use of this equipment by untrained or
unauthorized persons.
Printed in the United States of America.
Microsoft and Windows, are either registered trademarks or trademarks of Microsoft Corporation in the
United States and/or other countries.
Adobe, Acrobat, and Adobe Reader are registered trademarks or trademarks of Adobe Systems in the
United States and/or other countries.
All other brand and product names are trademarks, registered trademarks or service marks of their
respective holders.

iiiActive Fuel Injector Tester User Guide
Contents
Safety Information .........................................................................................1
AFIT Hardware................................................................................................5
AFIT Unit and Accessories...............................................................................................................6
The Main Control Unit (MCU) .........................................................................................................8
Using the Keypad......................................................................................................................................8
Using the Connector Panel........................................................................................................................8
The Fuel Management Unit (FMU).................................................................................................9
Cables, Software and Adapters ....................................................................................................10
Software Installation.................................................................................... 11
Step 1—Verify Requirements.....................................................................................................12
Operating System Requirements ............................................................................................................12
Hardware Requirements.........................................................................................................................12
Before You Begin.....................................................................................................................................12
Step 2—Download/Install AFIT Update Utility Program.............................................................13
Download the update utility:..................................................................................................................13
If you are installing the update utility from a download:........................................................................14
Optional Software........................................................................................................................15
To Install Adobe® Reader® ......................................................................................................................15
To View the User Guide or Quick Reference Guide ...................................................................................15
Hookup ........................................................................................................ 17
Step 1—Connect AFIT to the Vehicle...........................................................................................18
DLC Connection.......................................................................................................................................18

iv Active Fuel Injector Tester User Guide
Contents
Direct Injector Connection ......................................................................................................................19
Direct Injector and Fuel Pump Connection..............................................................................................20
Step 2—Connect the Tester to Power..........................................................................................21
Adjusting the Hanger................................................................................................................... 22
Testing ........................................................................................................ 23
Step 1—Connect and Power-up AFIT..........................................................................................24
Step 2A—Select Vehicle..............................................................................................................25
Step 2B—ClearVehicle Selection................................................................................................26
Step 3—Select a Test ..................................................................................................................27
Injector Test ............................................................................................................................................27
Pressure Test ...........................................................................................................................................28
Leak Down Test.......................................................................................................................................28
Viewing Test Results ..................................................................................... 29
Viewing Results on AFIT...............................................................................................................30
Uploading Test Data to a Shop Computer.....................................................................................31
Step 1—Connect the Main Control Unit to the Computer ......................................................................31
Step 2—Upload the Data to the Shop Computer ...................................................................................32
Step 3—Viewing the Test Results on the AFIT PC Application................................................................33
Utilities........................................................................................................ 35
Draining the FMU.........................................................................................................................36
Updating the Database................................................................................................................37
Locating an Injector.....................................................................................................................38
Maintenance................................................................................................ 39
Replacing the Fuel Filter ..............................................................................................................40
Procedure ...............................................................................................................................................40
Adjusting the Contrast.................................................................................................................41
Replacing the Injector/Fuel Pump Fuse........................................................................................41
Replacing the Fuel Schrader Connector Seal ................................................................................42
Uninstalling the AFIT PC Application Software.............................................................................42
Contact Information ..................................................................................... 43
Warranty...................................................................................................... 44

1Active Fuel Injector Tester User Guide
Safety
Information
Before using this tester, carefully read, understand and follow instructions and safety messages
on equipment and in this manual.
The manual cannot anticipate or provide advice and cautions for all situations encountered
by technicians. With this in mind, always follow and refer to the manuals provided by the
manufacturer or the vehicle or equipment being tested or used for all information and testing
procedures whenever diagnosing, repairing or operating such vehicle or equipment.
Failure to follow the instructions, cautions and warnings provided here as well as those provided
by the vehicle and equipment manufacturers can result in fire, explosion, bodily injury and
property damage.
In addition to the information listed here, additional warnings and cautions are listed
throughout the manual. Please read them carefully.

2Active Fuel Injector Tester User Guide
Safety Information
Fuel vapors are toxic and explosive, which can cause severe injury
or death
• Use proper ventilation to avoid breathing fuel vapors.
• Ethanol fuel and gasoline mixed with ethanol are highly poisonous and chemically active.
Blindness and death are possible if exposure to these substances is extensive.
• Minimize prolonged exposure to ethanol as a liquid or vapor. Remember, symptoms of
ethanol exposure can occur after a delay of several days.
• Minimize contact with the skin with the use of gloves (such as nitrile gloves) when there is
possibility of getting ethanol fuel on your hands. If the skin is directly exposed, wash the area
immediately and change any clothes that have become wet with fuel.
• Always wear appropriate protective glasses when testing the pressure of the fuel system
or gas caps. Should fuel get into eyes, flush eyes immediately with water and consult your
physician.
• Follow all federal, state and local regulation for the safe storage and use of the compressed
nitrogen gas used or stored at site.
Vehicles emit flammable vapors which can ignite
• Keep flames, sparks, cigarettes and other ignition sources away from the vehicle at all times.
• In case of fire, never use water to fight flames caused by gasoline or ethanol blended
gasoline. This will cause the flames to spread instead of extinguishing them.
• Use a dry chemical extinguisher to fight flames (preferably one marked ABC, though BC is
acceptable). A foam extinguisher is acceptable only if it is ARF grade, which is resistant to
alcohol.

3Active Fuel Injector Tester User Guide
Safety Information
Before beginning any tests, make sure the equipment and the test
environment are safe
• Test area should be well ventilated.
• When working on and underneath the vehicle, make sure it is properly supported on a hoist
or jack stands.
• When removing the fuel cap , make sure to turn the vehicle off.
• When removing the fuel cap, do so slowly. Allow any pressure to decay before fully removing
the cap.
• When connecting or disconnecting to a fuel line, always make sure to relieve the system
fuel pressure.
Ensure you have proper leak-free connections
• Check all equipment connections before, during and after testing.
• Do not pinch or kink tubing.
• Secure hose clamps when using hose adapters.
• Before connecting fuel lines and hose fittings, apply a few drops of clean engine oil to male
ends to ensure proper connection with female connectors.
• Tug firmly on quick-connect fittings to check for proper connection.
• Make sure the safety catch is seated the adapter groove of any quick-connect couplers.
Use the equipment properly
• Do not use this tester on diesel high pressure fuel lines (100 psi is max.)
• Do not disassemble the FMU. This can cause damage leakage and will void your warranty.
• Do not disassemble the Control Unit except to access the fuse and EPROMs during
replacement. This will void your warranty.

4Active Fuel Injector Tester User Guide
Safety Information
Check all parts periodically, clean and replace if necessary.
Make sure the equipment is in good working condition. This tester is a precision instrument—
keep it clean and repair (or replace) any damaged parts. This includes:
• Fuel injection parts for signs of wear.
• O-ring seal retainers at the FMU/FAH connections for signs of wear; make sure the
connection is tight.
• Glass housing at the FMU/FAH connection for chips or cracks, especially at the edges.

1
5Active Fuel Injector Tester User Guide
AFIT Hardware
This section illustrates and describes the items included with the Active Fuel Injector
Tester (AFIT). Be sure you familiarize yourself with all of the equipment and procedures
before conducting any tests.
For your reference, the following is a list of acronyms used throughout this guide:
AFIT—Active Fuel Injector Tester
DLC—Diagnostic Link Connector
FAH—Fuel Access Hose
FMU—Fuel Management Unit
FPEA—Fuel Pump Electrical Access
MCU—Main Control Unit

6
AFIT Hardware
Active Fuel Injector Tester User Guide
Fuel Management Unit
POWER
AFIT PC Application
Software CD
2Fuel Management
Unit (FMU)
AFIT Unit and Accessories
1Main Control Unit (MCU)
7USB to Serial
Port Adapter
5DLC Adapter
6(2) 6’Serial Cables
3 AFIT PC
Application Software
8Power Adapter 9 12V Power Cord 10 12 V Power Cord
11 Cable A Injector Harness 12 J-Tool Cable Adapter
4Fuel Schrader
Connector Seal
Replacement Kit
13 Cable B Injector Harness

AFIT Hardware
7Active Fuel Injector Tester User Guide
Component Part Number
1 Main Control Unit CH-47976-1
2 Fuel Management Unit CH-47976-2
3 AFIT PC Application Software CD CH-47976-9
4 Fuel Schrader Connector Seal Replacement Kit CH-47976-13
5 DLC Adapter CH-47976-4a
6 (2) 6’Serial Cables CH-47976-10
7 USB to Serial Port Adapter CH-47976-3a
8 Power Adapter (alligator clips) CH-47976-7
9 12V Power Cord CH-47976-6
10 12V Power Cord (wall outlet) CH-47976-8
11 Cable A Injector Harness CH-47976-50
12 J-Tool Cable Adapter CH-47976-60
13 Cable B Injector Harness CH-47976-55
User Guide (not shown) CH-47976-11
Carrying Case (not shown) CH-47976-12
Quick Reference Guide (not shown) CH-47976-14

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AFIT Hardware
Active Fuel Injector Tester User Guide
The Main Control Unit (MCU)
The Main Control Unit (MCU) is used for functions such as selecting and starting tests, monitoring
the status of a test, interfacing with the vehicle, and controlling the Fuel Management Unit (FMU).
Using the Keypad
The main functions of the keypad are:
• UP and DOWN—scroll within a screen
• CANCEL—return to the previous screen
or to cancel a test
• ENTER—start or continue a test
• ON/OFF—power the unit on or off
Note: For certain screens, the buttons may have additional functions, such as turning the
fuel pump on during pressure leak down.
Using the Connector Panel
Use the connector panel on the MCU for power and communication connections:
• Injectors Port—connect the 24-pin
end of the injector harness or J-Cable
adapter to this port when testing on
vehicles without DLC injector control.
• PWR Port—connect the selected power
cord (12V adapter or wall outlet adapter)
here to provide power to the unit.
• FMU Port—connect the interconnect cable from the FMU to this port to provide power to
the FMU and to send test signals to and from the MCU.
• RS-232 Port—connect the 9-pin serial cable here to link with the vehicle or to connect the
MCU to a computer .
• Fuel Pump—connect the fuel pump electrical access (FPEA) cable here when testing on
vehicles without DLC fuel pump control.
Main Control Unit — Front View
ENTERCANCEL
DOWN
ON / OFF
UP
Main Control Unit—Connector Panel
INJECTORS PWR FMU RS-232
FUEL
PUMP
FMU Port
Injectors Port
PWR Port RS-232 Port
Fuel Pump Port

AFIT Hardware
9Active Fuel Injector Tester User Guide
The Fuel Management Unit (FMU)
The FMU handles fuel and pressure measurement. The power LED indicates when it is receiving
power from the MCU.
• Hanger—use to hang the unit from the hood of the vehicle to allow for proper fuel flow
through the FMU.
• Drain Hose—use to capture drained fuel. Make sure to use a container approved for
collecting fuel.
• Interconnect Cable—connect to the MCU to provide power to the FMU and to send and
receive test signals.
• Sight Glass with Replaceable Filter—use to visually monitor the fuel flow and to
examine the fuel for contamination.
• Fuel Access Hose (FAH)—use to connect the FMU directly to the vehicle’s fuel test port.
Fuel Management Unit
POWER
Hanger
Drain Hose
Sight Glass
Interconnect Cable
Fuel Access Hose (FAH)
Fuel Schrader Connector

10
AFIT Hardware
Active Fuel Injector Tester User Guide
Cables, Software and Adapters
• AFIT PC Application Software—install onto the shop computer. Use to analyze and save
the test data uploaded to the computer from the MCU. Also use to download software update
files to the MCU.
• 9-pin Serial Cables (2) 6’ length)—use the cable (along with the DLC adapter) to
connect the MCU to the vehicle’s OBDII connector. Use the other cable to connect the MCU to
the shop computer.
• USB to Serial Port Adapter—if a serial port is not available, use to connect the 9-pin
serial cable to a USB port on your computer. Will require installing driver software (located on
the AFIT CD).
• DLC Adapter—use along with the 9-pin serial cable and the Serial to OBDII Cable to connect
to the vehicle’s OBDII connector.
• Serial to OBDII Cable—connect to the DCL Adapter and then to the vehicle’s OBDII
connector.
• Power Cords—use the 12V power adapter to supply power to the MCU when testing the
vehicle. Only use the wall outlet adapter to supply power to the MCU when connected to
your computer.
• Injector Harness Cables —when needed, use to connect the MCU to the vehicle’s injectors.
• J-Cable Adapter—when needed, use with existing SPX Kent Moore J-Cables to connect the
MCU to the vehicle’s injector.
IMPORTANT
Do not use the AC wall outlet adapter for testing the vehicle.

2
11Active Fuel Injector Tester User Guide
Before you begin to use AFIT for the first time, you will need to install the AFIT PC
Application Software and, depending on your computer, the USB to Serial Port software
driver. This section defines the computer requirements and how to install the software
on to your computer.
Software
Installation

12
Software Installation
Active Fuel Injector Tester User Guide
Step 1—Verify Requirements
Operating System Requirements
It is recommended that you only install the AFIT PC Application Software on computers with one
of the following Microsoft® operating systems (64-bit):
• Windows® 10 Professional
• Windows® 7 Professional
• Administrator level access to the Microsoft® Windows operating system.
Hardware Requirements
It is recommended that you only install the AFIT PC Application on computers with the following
hardware requirements:
• Minimum 100 MB free hard disk space
• Minimum 1 GB of RAM
• CD-ROM drive
• Available serial port or USB port or USB port (Requires using the USB to Serial Port
Adapter when connecting to the computer’s USB port)
• For SIDI Engines CH-47976-500 Adapter Kit (includes DMU and 2 cables) Note: Add
Duramax Engine coverage with CH-47976-505 (2 cables)
• For Duramax Diesel Engines CH-47976-510 Adapter Kit (includes DMU and 2 cables)
Note: Add SIDI Engine coverage with CH-47976-508 (2 cables)
Before You Begin
In order for the update to install properly, you must set the User Account Control (UAC) to the
lowest possible setting:
For computers running Microsoft 10 Professional:
1. Right click the Start button.
2. Click Control Panel.
3. Click System and Security.

Software Installation
13Active Fuel Injector Tester User Guide
4. Under Security and Maintenance Click Change User Account Control Settings.
5. Make a note of your current settings and then slide the setting’s bar to Never Notify.
6. Click OK and then close the Control Panel.
7. Restart your computer.
For computers running Microsoft 7 Professional:
1. Click the Start button.
2. Click Control Panel.
3. Click User Account and Family Safety.
4. Click User Account.
4. Click Change User Account Control Settings.
5. Make a note of your current settings and then slide the setting’s bar to Never Notify.
6. Click OK and then close the Control Panel.
7. Restart your computer.
Step 2—Download/Install AFIT Update Utility Program
Download the update utility:
1. Shut down any applications that you may have running on your computer except for your
internet browser.
2. If you are installing the update utility from a CD:
• If auto-run is enabled on your computer, the installation should begin
automatically—follow the on-screen instructions to complete the installation.
• If the installation does not begin automatically:

14
Software Installation
Active Fuel Injector Tester User Guide
A. Choose RUN from the Start menu.
B. Choose Browse.
C. In the browse box, select your computer’s CD-ROM drive.
D. Double click the Setup.exe file.
E. Click OK to launch the installation program. If a security warning is displayed asking
if you are sure you want to run an .exe file, click OK.
F. Follow the on-screen instructions to complete the installation.
If you are installing the update utility from a download:
• Go to GM Tools website and click on Software Downloads.
• Click the appropriate link to download the upgrade utility.
• When prompted, click OPEN or RUN (varies depending on browser and operating
system). Note: for some browsers, you may only be prompted to save the file. If this is
the case, save the file to your desktop and then double click the file to run it.
• If a security warning is displayed asking if your are sure you want to run the software,
click RUN or install (varies depending on browser and operating system).
• If a security warning is displayed asking if you are sure you want to run an .exe file,
click OK.
• After the file is downloaded, click CLOSE when prompted.
For more in depth updated installation instructions go to the GM Tools website
and go to software downloads: AFIT Update instructions file.
Download the latest software at the GM Tools website. For assistance or to
order service parts contact call: 1-800-GM-TOOLS (1-800-468-6657).

Software Installation
15Active Fuel Injector Tester User Guide
Optional Software
An electronic version of this User Guide and the Quick Reference Guide are automatically
installed on to your computer when installing the AFIT PC Application software. Viewing the
Guides, which are in Adobe® Portable Document Format (PDF), requires Adobe® Reader®
software version 6.0 or higher. If you need to install this software, a copy is included on the AFIT
CD or you can download it from Adobe’s web site at www.adobe.com.
To Install Adobe® Reader®
1. Insert the AFIT CD in to the CD-ROM drive.
2. Choose RUN from the Start menu.
3. Choose Browse.
4. In the browse box, select your CD-ROM drive.
5. Open the Adobe folder and double click AdbeRdr705_enu_distrib.exe.
6. Follow the on-screen instructions to complete the installation.
To View the User Guide or Quick Reference Guide
1. Choose Programs from the Start menu.
2. Select AFIT from the Program menu.
3. Select AFIT User Guide or AFIT Quick Reference from the Program group.