KTS 650

System Tester for

Control-Unit Diagnosis
Robert Bosch GmbH
Copyright 2004
Manual P/N 08002754
Printed in USA 7/04
KTS 650 System Tester for Control-Unit Diagnosis TOC-1
Table of Contents
1. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DANGER OF INJURY/CRUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DANGER OF ASPHYXIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DANGER OF BURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DANGER OF FIRE, EXPLOSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HIGH VOLTAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DANGER OF IMPLOSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DANGER OF ACID BURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
USER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONNECTING TO THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. SCOPE OF DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. DESCRIPTION OF UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
KTS 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DVD/CD DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PS/2 KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MOUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
EXTERNAL MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. PUTTING THE KTS 650 INTO OPERATION. . . . . . . . . . . . . . . . . . 13
BEFORE SWITCHING ON FOR THE FIRST TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLING THE OPERATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TOC-2 KTS 650 System Tester for Control-Unit Diagnosis
NOTES ON THE WINDOWS CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SWITCHING THE KTS 650 ON AND OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ADJUSTING THE BRIGHTNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SOFTWARE UPDATE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONNECTING THE PS/2 KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CONNECTING AN EXTERNAL MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TOUCHSCREEN WITH STYLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
VIRTUAL KEYBOARD WITH STYLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PS/2 KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8. MEASURING MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9. SPECIAL INFORMATION FOR OPERATION VIA THE VEHICLE
BATTERY 23
MULTIMETER, OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CONTROL-UNIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10. PRINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PRINTING (CONTROL-UNIT DIAGNOSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CHANGING THE DEFAULT PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11. WHAT TO DO IF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
THE UNIT CANNOT BE SWITCHED ON AND THE DISPLAY STAYS DARK OR
FLICKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
THE UNIT DOES NOT REACT WHEN THE KEYS ARE PRESSED . . . . . . . . . . . . . 25
MALFUNCTIONS ARE DISPLAYED IN THE INFO BAR DURING OPERATION 25
THE MOUSE POINTER IS DISPLAYED IN A DIFFERENT PLACE AFTER CLICKING
THE TOUCHSCREEN WITH THE STYLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
THE KTS 650 CAN NO LONGER BE OPERATED USING THE STYLUS AND
TOUCHSCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
12. CHANGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13. OPTIONAL EXTRAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
KTS 650 System Tester for Control-Unit Diagnosis TOC-3
14. SERVICE PARTS AND PARTS SUBJECT TO WEAR. . . . . . . . . . . . 28
15. MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
16. DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DISPOSAL OF ELECTRONIC WASTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DISPOSAL OF THE LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DISPOSAL OF RECHARGEABLE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
17. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
KTS 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
POWER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
WEIGHTS AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TEMPERATURE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ELECTROMAGNETIC COMPATIBILITY (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TOC-4 KTS 650 System Tester for Control-Unit Diagnosis
Danger of Injury/Crushing Safety Instructions
KTS 650 System Tester for Control-Unit Diagnosis Page 1
1. SAFETY INSTRUCTIONS
DANGER OF INJURY/CRUSHING
If the vehicle is not prevented from rolling away, there is a danger of people being crushed against a
workbench, for example. Both running and stationary engines have rotating and moving parts (e.g., belt
drives) which may cause injuries to fingers and arms. A special hazard is presented by electrically driven
fans, in that they may be switched on without warning while the engine is stationary and the ignition is
switched off.
SAFETY PRECAUTIONS:
Take steps to prevent the vehicle from rolling away while it is being tested.
Select the park position if the vehicle has an automatic transmission and apply the handbrake or lock the
wheels with chocks (wedges).
Wear work clothes without loose bands and loops.
Keep well away from rotating/moving parts while the engine is running.
When working on or in the vicinity of electrically driven fans, allow the engine to cool down first, then
disconnect the plug of the fan motor.
Keep the tester connecting cables well away from all rotating parts.
Lay the connecting cables in such a way that no one can trip over them.
Lock the brakes on the test system trolley so that it cannot roll away.
Do not place heavy objects on or lean on the sensor holder.
DANGER OF ASPHYXIATION
Car exhaust fumes contain carbon monoxide (CO) - a colorless, odorless gas. If inhaled, carbon monoxide
causes an oxygen deficiency in the body. Extreme caution is therefore essential when working in a pit, as
some of the components of the exhaust gas are heavier than air and settle at the bottom of the pit. Caution is
also necessary when working on LPG-driven vehicles.
SAFETY PRECAUTIONS:
Always ensure effective ventilation and suction (especially when working in a pit).
Always switch on and connect the exhaust hose.
Safety Instructions Danger of Burning
Page 2 KTS 650 System Tester for Control-Unit Diagnosis
DANGER OF BURNING
When working on a hot engine, there is a risk of injury from burning if such components as the exhaust gas
manifold, the turbocharger, the Lambda sensor, etc. are touched or if parts of the body come too close to
them. These components may be heated to temperatures of several hundred degrees Celsius. Depending on
the duration of the exhaust gas measurements, the sampling probe of the exhaust gas measuring instrument
may also become extremely hot.
SAFETY PRECAUTIONS:
Always wear protective clothing, e.g., gloves.
Allow the engine to cool down first (this also applies to auxiliary heating systems).
Keep the tester connecting cables well away from all hot parts.
Do not leave the engine running any longer than necessary for the test or setting.
DANGER OF FIRE, EXPLOSION
There is a risk of fire and explosion from fuels and fuel vapors when work is performed on the fuel system or
on the mixture control system.
SAFETY PRECAUTIONS:
Switch off the ignition.
Allow the engine to cool down first.
Avoid naked flames and potential sources of sparks.
Do not smoke.
Collect any leaked fuel.
Always ensure effective ventilation and suction when working in closed areas.
NOISE
Noise levels in excess of 70 dB(A) can occur when measurements are carried out on a vehicle, especially at
high engine speeds. Damage to hearing may result if human beings are exposed to noise at such levels over
an extended period of time.
SAFETY PRECAUTIONS:
If necessary, noise protection facilities must be provided by the owner at all workplaces in the vicinity of
the testing area.
If necessary, suitable personal noise protection facilities must be used by the operator.
High Voltages Safety Instructions
KTS 650 System Tester for Control-Unit Diagnosis Page 3
HIGH VOLTAGES
Hazardous voltages occur in both the lighting system and the electrical system of a motor vehicle. If contact
is made with live parts (e.g., ignition coil), there is a risk of electric shock from flashover voltages caused by
damaged insulation (e.g., ignition cables which have been attacked by rats). This applies to both the primary
side and the secondary side of the ignition system, to the cable harness and the plug connections, to the
lighting systems (Litronic), and to the tester connections.
SAFETY PRECAUTIONS:
All testers must be connected to properly grounded, shockproof sockets (in accordance with VDE 01 00
or the corresponding country-specific regulations).
Testers must always be connected using the power cables supplied with them.
All extension cables must be fitted with shockproof contacts.
Any cables with damaged insulation must be replaced (e.g., power or ignition cables).
Connect testers to the lighting system and switch them on before connecting them to the vehicle.
Connect testers to the engine ground or to the battery (B-) before switching on the ignition.
Always switch off the ignition before performing any work on the electrical system of the vehicle. The
term work includes connecting testers, replacing parts of the ignition system, removing assemblies
(e.g., generators), connecting assemblies to a test bench, etc.
Wherever possible, tests and settings should always be carried out with the ignition switched off and the
engine stationary.
If tests or settings are carried out with the ignition switched on or the engine running, care must be taken
not to touch any live parts. This applies to all the connecting cables of the testers as well as to the
connections of any assemblies at the test bench.
Test connections must always be made using suitable connectors (e.g., Bosch testing cable set or
vehicle-specific adapter cables).
Make sure that all test connections are properly plugged in and secure.
Switch off the ignition before disconnecting the tester from the engine ground or the battery (B-).
Never open the casing of the screen.
Never open the housing of the tester.
DANGER OF IMPLOSION
There is a danger of the screen tube imploding if the screen is improperly handled (e.g., the tube is subjected
to some form of impact, sudden temperature change, the glass is damaged).
SAFETY PRECAUTIONS:
Make sure that the screen is well vented so that heat can properly dissipate.
Never cover the vents (e.g., with a towel) while the screen is in.
Safety Instructions Danger of Acid Burning
Page 4 KTS 650 System Tester for Control-Unit Diagnosis
DANGER OF ACID BURNING
When exhaust gas measurements are taken, the sampling hoses which are used release a highly caustic gas
(hydrogen fluoride) that can cause acid burning in the respiratory system when heated to temperatures in
excess of 250 C (482 F) or in the event of fire.
RULES OF CONDUCT:
Consult a doctor immediately after inhaling!
Always wear gloves made of neoprene or PVC when removing residues left after a fire.
Neutralize any residues left after a fire with a calcium hydroxide solution. This produces non-toxic
calcium fluoride, which can be washed away.
Acids and alkalis can cause severe burning on unprotected skin. Hydrogen fluoride in combination with
moisture (water) forms hydrofluoric acid.
The condensate which accumulates in the sampling hose and in the condensate container likewise contains
acid.
When replacing the O2 measuring sensor, bear in mind that it contains alkali.
When replacing the NO measuring sensor, bear in mind that it contains acid.
RULES OF CONDUCT:
Rinse any affected parts of the skin immediately in water, then consult a doctor!
NO and O2 measuring sensors are hazardous waste and must be disposed of separately. Your Bosch
specialist supplier can dispose of sensors in the proper manner.
If liquid crystal escapes from a damaged liquid crystal display, it is imperative to avoid direct skin contact,
inhalation, and swallowing.
RULES OF CONDUCT:
Wash the skin and clothing thoroughly with soap and water if it has come into contact with liquid crystal.
If you have inhaled or swallowed liquid crystal, consult a doctor immediately!
If fluid (electrolyte) escapes from batteries and rechargeable batteries, avoid getting it on your skin or in
your eyes.
RULES OF CONDUCT:
If contact with skin or eyes happens nevertheless, wash the affected parts immediately with clean water
and then consult a doctor.
Agreement Important Information
KTS 650 System Tester for Control-Unit Diagnosis Page 5
2. IMPORTANT INFORMATION
AGREEMENT
Your use of the product means that you accept the following conditions:
COPYRIGHT
Software and data are the property of Robert Bosch GmbH or its suppliers and are protected against
unauthorized reproduction under copyright laws, international contracts, and other national legal provisions.
The reproduction or sale of data and software or any part thereof is prohibited and punishable by law; in the
event of violations, Robert Bosch GmbH reserves the right to prosecute and to assert claims for damages.
LIABILITY
As far as possible, all the data in this program are based on information from the manufacturer and
importers. Robert Bosch GmbH furnishes no guarantee for the correctness and completeness of software or
data; we assume no liability for damage caused by faulty software and data. At any event, the liability of
Robert Bosch GmbH is limited to the amount which the customer has actually paid for this product. This
exemption from liability does not apply to damages caused intentionally or by gross negligence on the part
of Robert Bosch GmbH.
WARRANTY
Any use of hardware and/or software that has not been approved by Bosch constitutes a modification of our
products, and hence exclusion of all liability and warranty claims, even if the hardware has been
subsequently removed, or the software erased in the interim.
Our products must not be modified in any way. Furthermore, our products may only be used with original
accessories/original spare parts. Disregard for the above will render all warranty claims invalid.
The present Bosch tester may only be used with operating systems approved by Bosch. Using the Bosch
tester with different operating systems than those which we have approved will render our warranty
obligation null and void, in accordance with our terms of delivery. In addition, we cannot assume liability
for damages and consequential damages which are the result of the use of a non-approved operating system.
NOTE
Before connecting, starting up, and operating test units, always read the
Operating Instructions of the tester thoroughly in order to rule out any
uncertainty and associated risks with regard to safety when working with
testers. All operations and workings as well as the connecting of testers
close to the engine and to the ignition system must be executed only when
the engine does not turn and the ignition circuit is switched off.
General Information User Group
Page 6 KTS 650 System Tester for Control-Unit Diagnosis
USER GROUP
This product may only be used in the automotive sector by skilled personnel who are trained and instructed
in it, such as motor-vehicle mechanics, electricians, foremen, technicians, and engineers.
3. GENERAL INFORMATION
APPLICATION
The KTS 650 is a tester for mobile testing equipment in automotive repair shops. The KTS 650 enables you
to:
Perform control-unit diagnosis of electronic control units in the vehicle to:
read the fault log
display actual values
trigger actuators
provide a graphic display of actual values over time (time curves)
make use of other control-unit specific features, e.g., interval reset
Employ Bosch ESI[tronic] software (component testing, electrical wiring diagrams, installation
locations of components, required test conditions, assembly instructions, service information, etc.)
Use the multimeter for:
voltage measurements
resistance measurements
current measurements (only with optional extras amps clamp 1 687 224 864/06500966 or current
measuring shunt 1 684 503 103/06500965)
Employ a 2-channel oscilloscope to record measured values
The KTS 650 is a high-precision instrument and must not be exposed to heat sources (e.g., direct sunlight),
jolts or vibrations, magnetic fields, or excessive dirt.
TRANSPORT
The connecting cables on the rear of the tester must be disconnected for transport. Moreover, the KTS 650
should only be transported and stored in the supplied case.
Connecting to the Vehicle General Information
KTS 650 System Tester for Control-Unit Diagnosis Page 7
CONNECTING TO THE VEHICLE
The KTS 650 is designed to operate with a supply voltage of 12 V (cars) and 24 V (commercial vehicles).
CAUTION
CAUTION!
Make sure that the diagnostic cable on the KTS 650 is plugged in correctly.
If incorrectly plugged in, the pins on the male connector may be broken
off.
FIGURE 1. Connection Diagram of KTS 650
Scope of Delivery Connecting to the Vehicle
Page 8 KTS 650 System Tester for Control-Unit Diagnosis
4. SCOPE OF DELIVERY
The KTS 650 System Tester comes with the following items:
KTS 650
Universal power pack
Power cord for power pack
OBD-Multiplexer
USB cable, 2 m
Universal cable, 6-way
Measuring lead, red
Measuring lead, blue
Measuring lead, yellow
Ground cable, black
Test prods, red (2)
Terminal, black
Y-connection cable for power supply
Touchscreen stylus (2)
Case
Operating instructions (CD)
External DVD/CD drive
5. DESCRIPTION OF UNIT
The KTS 650 is a modular, portable, fully mobile diagnostic, information, and measuring system.
The device contains a computer unit, a hard disk with pre-installed software, touch-screen display (TFT),
rechargeable lithium-ion battery and the measuring module with multimeter and oscilloscope.
The latest ESI[tronic] A, C and P and Bosch Applications Menu software is pre-installed on the hard disk
at the factory.
For operating the unit, a virtual keyboard is available as well as the stylus for the touchscreen. A PS/2
keyboard specific to the country of use can also be connected.
Data and measured values can be printed out via the USB interface using an external printer.
A liquid crystal display is used, but you can also connect to an external monitor.
Connecting to the Vehicle Description of Unit
KTS 650 System Tester for Control-Unit Diagnosis Page 9
The KTS 650 and accessories are housed in a protective case.
FIGURE 2. KTS 650 and Accessories Arranged in Their Case
1 KTS 650
2 Case
3 OBD-Multiplexer cable
4 Touchscreen stylus
5 Y-connector for connecting the KTS 650 and DVD/CD drive to the power pack
6 Ground cable with terminal
7 Measuring leads for multimeter
8 Universal power pack with power cord
Description of Unit KTS 650
Page 10 KTS 650 System Tester for Control-Unit Diagnosis
KTS 650
OPERATOR AND DISPLAY UNIT
CAUTION
CAUTION!
When the KTS 650 is placed in the engine compartment, there is a risk that
the metallic floor of the tester may short the vehicle battery. When the KTS
650 is hooked onto the steering wheel, there is a risk of triggering the
airbag.
FIGURE 3. KTS 650 Operator/Display Unit
1 Carrying handle
2 LCD with touchscreen
3 On/Off button
4 Windows Start Menu key
5 LED for unit On
6 LED for external power supply
7 LED for battery charge
8 LED for access to hard disk
KTS 650 Description of Unit
KTS 650 System Tester for Control-Unit Diagnosis Page 11
TERMINAL STRIP
NOTE
There is a key to the terminal strip on the back of the KTS 650.
FIGURE 4. KTS 650 Terminal Strip
1 Socket for oscilloscope and U/I-measurements (CH2)
2 Ground socket
3 Socket for oscilloscope and U/R/I-measurements (CH1)
4 Socket for diagnostic cable
5 PCMCIA slot, e.g., for DVD drive
6 Socket (RJ45) for network (LAN)
7 USB interface
8 Socket for microphone
9 Socket for headphones
10 Socket for external monitor (video outlet)
11 Socket for power pack
12 Socket for country-specific PS/2 keyboard (no plug socket for a PS/2 mouse)
Description of Unit DVD/CD Drive
Page 12 KTS 650 System Tester for Control-Unit Diagnosis
DVD/CD DRIVE
The DVD/CD drive is an optional extra for updating the ESI[tronic] software. Please see Software Update
Installation on page 18 for a description of how to connect the DVD/CD drive and install the ESI[tronic]
software.
FIGURE 5. DVD/CD Drive, Front View
1 DVD/CD drawer
2 Access display (lights up when data are being read from the DVD/CD-ROM)
3 CD Eject
4 Emergency Eject
FIGURE 6. DVD/CD Terminal Strip
1 DC input, power pack socket
2 Socket for interconnecting cable to KTS 650
3 Audio sockets
PS/2 Keyboard Putting the KTS 650 into Operation
KTS 650 System Tester for Control-Unit Diagnosis Page 13
PS/2 KEYBOARD
The KTS 650 can also be operated using an external PS/2 keyboard. The PS/2 keyboard is available as an
optional extra in various country-specific versions.
MOUSE
A USB mouse is the only kind of mouse that can be connected to the KTS 650.
EXTERNAL MONITOR
When an external monitor is connected, the same user interface appears as on the LCD of the KTS 650.
Both displays are active.
6. PUTTING THE KTS 650 INTO
OPERATION
BEFORE SWITCHING ON FOR THE FIRST
TIME
Before using the KTS 650 for the first time, make sure that the voltage matches the voltage stated on the
power pack (use the supplied power cord).
BATTERY CHARGING
The battery of the KTS 650 is always charged automatically when external voltage is supplied. When the
battery is nearly empty, it takes approximately 3 hours to re-charge it until it is ready for operation and can
operate the KTS 650. The LED that indicates the battery charge flashes when the charge is < 80%. If the
battery is charged to < 20%, a warning signal (beep) is sounded. In this case, re-charge the battery
immediately. You can read the battery charge at any time on the energy indicator. You can view the energy
indicator on the display by double-clicking with the stylus on the relevant icon in the taskbar.
NOTE
The American power cord forms part of the standard scope of delivery.
Other country-specific power cords are not included in the scope of
delivery.
Putting the KTS 650 into Operation Installing the Operating System
Page 14 KTS 650 System Tester for Control-Unit Diagnosis
INSTALLING THE OPERATING SYSTEM
The Windows XP operating system is pre-installed in the KTS 650 in several languages. When using the
KTS 650 for the first time, you must select a language, which will then be permanently installed.
1. Before commencing installation, check that the power pack is connected.
2. Switch on the KTS 650 with the button.
3a. Use the stylus to select the appropriate language for Windows XP.
After switching the device on the first time, select a language for the Windows operating system in a
menu.
3b. Click with the light stylus on the language you want and follow the on-screen instructions.
After the system has started, the KTS 650 remains in the Bosch Applications Menu start screen. This start
screen now always appears after switch-on (see Switching On on page 16).
The Bosch Applications Menu start screen and all applications are displayed in the chosen language version
of the operating system.
NOTE
The battery energy indicator only provides accurate information about the
battery capacity after several charging and discharging cycles.
NOTE
All other Windows language versions will be deleted. You cannot change
this language at a later date. However, if this is necessary, contact your
authorized Bosch dealer.
NOTE
Until the Windows installation is complete, the KTS 650 can only be shut
down by simultaneously pressing and holding down the and # keys for
about 3 seconds.
NOTE
You must enable the software before you can work with ESI[tronic].
Please observe the ESI[tronic]-Setup and Installation instructions included
with the ESI[tronic] starter kit.
Notes on the Windows Control Panel Putting the KTS 650 into Operation
KTS 650 System Tester for Control-Unit Diagnosis Page 15
NOTES ON THE WINDOWS CONTROL
PANEL
In the Windows XP operating system, the Control Panel menu is normally opened via Settings in the
Windows Start Menu. However, with the KTS 650, the Control Panel is reached via Programs in the
Windows Start Menu. When you open the Control Panel, a warning will appear informing you that under
certain circumstances the unit will no longer function perfectly if you alter certain parameters.
POWER SUPPLY
The KTS 650 can be operated with the following voltage supplies:
Power pack (only use the power pack included in the scope of delivery!).
Vehicle battery [supply via the OBD cable connected to the diagnostic socket in the vehicle. The vehicle
battery voltage (U
Batt
) should equal at least 12V].
Internal rechargeable battery (see Charging the Battery on page 15).
BATTERY OPERATION OF THE KTS 650
The fully charged battery integrated in the KTS 650 takes the form of a back-up battery, guaranteeing
approximately 1 hour of autonomous operation. It is therefore important to ensure that a permanent external
voltage supply is always available (vehicle battery or power pack) when operating the KTS 650 for longer
periods.
CHARGING THE BATTERY
The battery of the KTS 650 is charged automatically. The battery is re-charged whenever the KTS 650 is
connected to the power pack or the vehicle battery (via the diagnostic cable/adapter cable connected to the
diagnostic socket in the vehicle).
NOTE
If the unit no longer functions perfectly due to a change you have made in
the Control Panel, any necessary repairs will be subject to a fee.
NOTE
Do not operate the KTS 650 without the rechargeable battery.
NOTE
If the KTS 650 is operated only with the rechargeable battery, the charge
LED of the tester lights up (Figure 3, item 7).
Putting the KTS 650 into Operation Switching the KTS 650 On and Off
Page 16 KTS 650 System Tester for Control-Unit Diagnosis
Whenever the battery capacity is less than 80%,
the state of charge LED (Figure 3, Item 7) flashes while charging when the KTS 650 is switched off.
the LED for the external supply voltage (Figure 3, Item 8) flashes when the KTS 650 is switched on.
Once maximum battery capacity has been achieved, the KTS 650 switches from high-rate charging to float
charging.
SWITCHING THE KTS 650 ON AND OFF
SWITCHING ON
Switch on the KTS 650 using the key (Figure 3, item 3).
After the system has started, the KTS 650 remains in the Bosch Applications Menu start screen. This start
screen is always displayed when the tester is switched on.
The start screen displays the various applications that can be selected.
Using the stylus, touch the application with which you wish to work. If you are using a PS/2 keyboard, select
the required application using the Cursor keys . Start the application with the hardkey.
NOTE
The Software Installation application is only available if the ESI[tronic]
DVD is inserted in the external DVD/CD drive, and the drive is connected
to the KTS 650. The application is required for the software update (also
see Software Update Installation on page 18).
FIGURE 7. Start Screen
Switching the KTS 650 On and Off Putting the KTS 650 into Operation
KTS 650 System Tester for Control-Unit Diagnosis Page 17
SWITCHING OFF MANUALLY
There are several ways you can switch off the KTS 650.
You can stop the KTS 650 by pressing the On/Off key.
You can open the Windows Start Menu with the # key and bring the KTS 650 to a stop with Shut Down.
You can also select Exit Windows in the Bosch Applications Menu. All active applications are closed
and the KTS 650 switches itself off.
AUTOMATIC SWITCH-OFF
Via Programs / Control Panel / Power Management, you can set parameters which enable you to bring
the KTS 650 to standby mode either in mains or vehicle battery operation and to switch off the monitor or
the hard disk. Open the Power Schemes pull-down menu and set the required parameters.
The diagram below shows you the factory default settings.
NOTE
If the KTS 650 can no longer be operated due to a computer error, you can
switch it off by simultaneously pressing the On/Off key (Figure 3, item
3) and the # Windows Start Menu key (Figure 3, item 4) for at least 3
seconds.
CAUTION
CAUTION!
Do not alter the settings in the menu tabs Warning or Extended.
FIGURE 8. Power Option Properties Default Settings
Putting the KTS 650 into Operation Adjusting the Brightness
Page 18 KTS 650 System Tester for Control-Unit Diagnosis
ADJUSTING THE BRIGHTNESS
You can open the brightness adjustment menu on screen by clicking with the stylus on the Light icon in the
task bar.
Click the + button to make the display brighter; click on the - button to make it dimmer.
Different brightness values have been stored for battery operation and for an external supply voltage.
SOFTWARE UPDATE INSTALLATION
Software installation takes place via the external DVD/CD drive.
CONNECTING THE DVD/CD DRIVE
1. Switch off the KTS 650.
2. Use the supplied Y-connector to connect the power pack to the KTS 650 and the DVD/CD drive.
The appropriate socket is located on the terminal strip of the KTS 650 (Figure 4, item 11).
The CD drive socket is located on the back of the unit.
3. Connect the KTS 650 to the DVD/CD drive. Use the interconnecting USB cable.
CAUTION
CAUTION!
Do not use the DVD/CD drive in a dusty environment.
CAUTION
CAUTION!
The DVD/CD drive has no On/Off switch. The voltage is supplied to the
plugged-in power pack via the Y-cable.
NOTE
Do not yet connect the power pack to the mains!
FIGURE 9. Brightness Adjustment Menu
Light icon
Software Update Installation Putting the KTS 650 into Operation
KTS 650 System Tester for Control-Unit Diagnosis Page 19
4. Insert the interconnecting USB cable in the socket on the back of the DVD/CD drive.
5. Connect the power pack to the mains.
6. Switch on the KTS 650.
7. After you have successfully connected the external DVD/CD drive, please read Proper handling of a
DVD, Inserting the DVD in the DVD drive, and Removing the DVD from the DVD drive before installing
the software.
8. Open Software Installation in the Bosch Applications Menu and follow the instructions. Software update
installation takes approximately 30 minutes.
NOTE
Manufacturing tolerances may result in it being very difficult to insert the
PCMCIA card in the upper slot. In this case, please use the lower slot.
FIGURE 10. DVD/CD Drive Connected to the KTS 650
1 KTS 650
2 DVD drive
3 Power pack
4 Y-connector
5 Interconnecting USB cable
6 Country-specific power cord
Putting the KTS 650 into Operation Connecting the PS/2 Keyboard
Page 20 KTS 650 System Tester for Control-Unit Diagnosis
PROPER HANDLING OF A DVD
Ensure that your hands are clean and free from grease when inserting the DVD in the DVD/CD drive.
Do not touch the blank side of the DVD.
Do not mark, write on, or stick labels on the DVD.
Never use solvents such as benzine, paint thinner, record cleaner, or antistatic agent to clean a dirty DVD.
Simply wipe off fingerprints or dust from the center outwards with a soft cloth.
Keep the DVD away from high temperatures and direct sunlight.
INSERTING THE DVD IN THE DVD DRIVE
1. Open the drawer by pressing the CD Eject button on the DVD drive.
2. Carefully lay the DVD in the drawer with the writing uppermost.
3. Close the drawer by pressing the CD Eject button again.
REMOVING THE DVD FROM THE DVD DRIVE
1. Press the CD Eject button to open the drawer. The drawer opens completely.
2. Take the DVD out of the drawer, holding the outer edge with your thumb and forefinger.
3. Place the DVD in its transport case.
CONNECTING THE PS/2 KEYBOARD
Insert the connector of the PS/2 keyboard into the appropriate socket in the terminal strip of the KTS 650
(Figure 4, item 12).
CONNECTING AN EXTERNAL MONITOR
Insert the monitor/VGA cable into the appropriate socket in the terminal strip of the KTS 650 (Figure 4, item
10). Plug the other end of this cable into the monitor.
CAUTION
CAUTION!
Never use force to push the drawer into the CD drive!
NOTE
If you wish to use a PS/2 keyboard, when using the KTS 650 for the first
time you must select the appropriate country-specific keyboard in the
Bosch Applications Menu start screen via Control Panel / Configuration /
Set.
Touchscreen with Stylus Operation
KTS 650 System Tester for Control-Unit Diagnosis Page 21
7. OPERATION
The KTS 650 is operated by means of:
the touchscreen with stylus, or
the virtual keyboard with stylus, or
the external PS/2 keyboard (optional extra)
TOUCHSCREEN WITH STYLUS
The touchscreen of the KTS 650 is operated using the stylus. The stylus basically has the same functions as
a mouse.
Touching an icon once with the stylus, for example, is the same as clicking once with the left-hand mouse
button or positioning the cursor in an entry field.
Touching the touchscreen twice with the stylus is the same as double-clicking with the left-hand mouse
button. This starts an application program, for example.
Touching the touchscreen for more than 2 seconds with the stylus is the same as clicking with the right-hand
mouse button to open any available Help menus.
NOTE
The monitor has to be plugged in before you switch on the KTS 650.
Operation Virtual Keyboard with Stylus
Page 22 KTS 650 System Tester for Control-Unit Diagnosis
VIRTUAL KEYBOARD WITH STYLUS
The KTS 650 features a virtual keyboard. To open the virtual keyboard, click on the icon in the taskbar.
The chosen character will be shown in an entry field when you touch the key twice with the stylus.
To switch the keyboard over to capital letters and symbols, click on the Shift key. Click on the Shift key
again to change the characters back to small letters and numbers.
To change the character set of the virtual keyboard to the language you require, click on the appropriate icon
in the taskbar. The icon will then display a different abbreviation (e.g., En, Fr, It, etc.).
PS/2 KEYBOARD
If you use the PS/2 keyboard to operate the KTS 650, make sure that the Num. LED is lit; otherwise you will
not be able to enter numbers using the number keys. The table below explains the keyboards most important
functions.
Function Key
Go to a different button, register, or entry field (TAB key)
Move within a button, register, or list (Cursor keys)
Activate or deactivate menus SPACE bar
Select Start button CTRL + ESC
Confirm entries or Next (ENTER)
Cancel ESC
Activate a pull-down menu ALT + letter
Switch between active applications ALT + TAB
Exit active applications
ALT + F4
Open Bosch Applications Menu
F10
FIGURE 11. Virtual Keyboard
Multimeter, Oscilloscope Measuring Module
KTS 650 System Tester for Control-Unit Diagnosis Page 23
8. MEASURING MODULE
With the KTS 650, you have a 2-channel multimeter and 2-channel oscilloscope at your disposal.
Only use the supplied measuring leads with electric shock protection. Always plug the measuring leads into
the KTS 650 first, then into the vehicle.
Do not route the unscreened measuring leads close to strong interference sources such as ignition cables.
For high-resistance low-level encoder signals, use screened measuring lead 1 684 465 490/06500964
(special accessory).
9. SPECIAL INFORMATION FOR
OPERATION VIA THE VEHICLE
BATTERY
MULTIMETER, OSCILLOSCOPE
If you use channel 2 of the KTS 650 for voltage measurements using a multimeter or oscilloscope, the
voltage supply from the vehicle battery will be shut off, for measuring channel 2 is not floating, and
incorrect measurements could therefore result.
CONTROL-UNIT DIAGNOSIS
The voltage supply from the vehicle is cut off automatically before communication with the control unit
commences in order to ensure reliable communication. The LED for external supply goes out to inform you
of this status.
WARNING!
Only use the KTS 550/650 for vehicles, and not for measuring alternating/
direct voltages of > 60 V. If no diagnostic cable is connected, you must
produce a connection to vehicle ground from the KTS 650 using the
supplied ground cable prior to any measurements of U, R,or I. Measuring
without a ground cable may result in voltages which are dangerous to life
due to static charge. Connect the ground cable as close as possible to the
object of measurement.
NOTE
When reading vehicle data in Control-Unit Diagnosis mode, the 1-channel
oscilloscope offers restricted functionality (sampling rate 50 kHz instead
of 100 kHz) and the 2-channel oscilloscope cannot be used.
Printing Printing (Control-Unit Diagnosis)
Page 24 KTS 650 System Tester for Control-Unit Diagnosis
10. PRINTING
A printer can be connected via the USB interface of the KTS 650.
PRINTING (CONTROL-UNIT DIAGNOSIS)
Using the stylus click twice on the psc (print screen) button on the virtual keyboard. The control unit
diagnostic programs print menu is opened.
Two types of print-out are possible:
Hardcopy
Work log (this contains the repair shop address and all previously saved measured values)
A Page Preview function is also available (on-screen display of the work log).
You can print out all displayed screens by selecting Hardcopy.
NOTE If you wish to print out fault log details, actual values, etc. later in the work
log, you must first save these values in the displayed screen by means of
the softkey.
FIGURE 12. Printout Menu
Changing the Default Printer What To Do If
KTS 650 System Tester for Control-Unit Diagnosis Page 25
CHANGING THE DEFAULT PRINTER
Change the default printer PDR 218 by way of the Bosch Applications Menu. Open the Control Panel.
Under Configuration, open the Set / Printer menu. Select the required printer driver and confirm with the
softkey.
11. WHAT TO DO IF
THE UNIT CANNOT BE SWITCHED ON AND
THE DISPLAY STAYS DARK OR FLICKERS
The internal battery has insufficient capacity to start the unit. Connect the external power pack or the
diagnostic cable to the vehicle (ignition on), so that the unit will be ready for operation and the battery will
be charged.
THE UNIT DOES NOT REACT WHEN THE
KEYS ARE PRESSED
The unit must be set to a defined status. To do so, press the and # hardkeys for approximately 3
seconds.
MALFUNCTIONS ARE DISPLAYED IN THE
INFO BAR DURING OPERATION
Follow the instructions on the LCD.
NOTE
Only switch the unit off in this manner if it no longer reacts when any keys
are pressed. Switching the unit off in this way during regular operation
may, in certain circumstances, result in the loss of data from the hard disk.
Data which have been entered during this diagnostic application may have
to be re-entered.
Changing the Battery The Mouse Pointer Is Displayed In A Different Place After
Page 26 KTS 650 System Tester for Control-Unit Diagnosis
THE MOUSE POINTER IS DISPLAYED IN A
DIFFERENT PLACE AFTER CLICKING THE
TOUCHSCREEN WITH THE STYLUS
You must re-calibrate the touchscreen. Open the RBsystem menu via Programs/Control Panel in the Start
Menu. Open the TouchScreen Adjustment program. First click Run. You can now adjust the touchscreen.
Take care not to alter any other parameters of this program.
The touchscreen calibration menu offers a total of 20 calibration points, which you must click one after the
other. This will enable very precise calibration.
On completion, you can then check the calibration. Use the stylus to click on different places on the LCD
and compare these with the mouse.
THE KTS 650 CAN NO LONGER BE
OPERATED USING THE STYLUS AND
TOUCHSCREEN
It is possible that the touchscreen has been adjusted incorrectly. Connect a USB mouse to the KTS 650 and
complete the touch-creen adjustment procedure. The adjustment procedure is described in the above section.
12. CHANGING THE BATTERY
Only use the Original Bosch battery pack for the KTS 650!
The battery is installed in the rear of the unit. Proceed as follows:
1. Switch off the KTS 650.
2. Undo the screws (Figure 13, item 1) and open the cover panel (Figure 13, item 3).
3. Disconnect the fan connector (Figure 13, item 2), if present.
4. Undo the screws (Figure 13, item 4) and remove the battery cover (Figure 13, item 5).
5. Disconnect the battery connector (Figure 13, item 6).
6. Replace the battery pack (Figure 13, item 7).
NOTE
In order to avoid parallax errors, your eyes must be directly vertical above
the calibration points. Click on the calibration points as accurately as
possible.
The KTS 650 Can No Longer Be Operated Using The Stylus and TouchScreen Changing the Battery
KTS 650 System Tester for Control-Unit Diagnosis Page 27
WARNING!
Do not heat, burn, short-circuit, or mechanically damage the battery; do
not charge with excessive currents or with reverse polarity.
Improper treatment of the battery results in a risk of explosion, bursting, or
fire.
Suitable extinguishing agents: Water, CO
2
, sand.
CAUTION
CAUTION!
Dispose of used battery packs in accordance with the appropriate
guidelines or regulations.
FIGURE 13. Changing the Battery of the KTS 650
Optional Extras The KTS 650 Can No Longer Be Operated Using The Stylus
Page 28 KTS 650 System Tester for Control-Unit Diagnosis
13. OPTIONAL EXTRAS
14. SERVICE PARTS AND PARTS
SUBJECT TO WEAR
Designation Part Number
CARB adapter box 1 684 462 346 / 06500969
OBD-extension lead (26-pin; 2 m) 1 684 465 489 / 06500962
OBD-Multiplexer 1 684 465 506 / 06500950
NOTE
For vehicle-specific connecting cables and other measuring leads, refer to
the Program Description 1 689 979 858.
Designation Part Number
Y-connector
a
a. Parts subject to wear.
1 684 448 309 / 06500978
Case 1 685 438 144 / 06500979
OBD-Multiplexer cable
a
1 684 465 520 / 06500950
Universal cable 1 684 465 488 / 06500953
Measuring lead, red
a
1 684 430 065 / 06500956
Measuring lead, blue
a
1 684 430 066 / 06500957
Measuring lead, yellow
a
1 684 430 067 / 06500958
Ground cable, black
a
1 684 431 068 / 06500961
OBD-extension lead
a
1 684 465 489 / 06500962
Disposal of Electronic Waste Maintenance
KTS 650 System Tester for Control-Unit Diagnosis Page 29
15. MAINTENANCE
The housing and display of the KTS 650 should only be cleaned with a soft cloth and neutral cleaning
agents. Do not use abrasive cleaning agents or rough workshop cloths.
16. DISPOSAL
DISPOSAL OF ELECTRONIC WASTE
Please dispose of electronic waste by returning components for recycling.
DISPOSAL OF THE LCD
Please dispose of the LCD in accordance with local regulations governing the disposal of hazardous waste.
DISPOSAL OF RECHARGEABLE
BATTERIES
Dispose of the rechargeable battery in accordance with the local regulations concerning disposal of
hazardous waste.
Technical Data KTS 650
Page 30 KTS 650 System Tester for Control-Unit Diagnosis
17. TECHNICAL DATA
KTS 650
PC board
Celeron, 650 MHz
512 MB RAM (main memory)
40 GB hard disk
TFT 12" color display, 800 x 600 pixels
Lithium-ion battery; 7.2 V; 6 Ah
Control-unit diagnosis via interface protocols ISO9141-2, SAE J1850VPW, SAE J1850PWM and CAN ISO
11898 ISO 15765-4 (OBD), OBD diagnosis to ISO 15031.
MULTIMETER
Channel 1 (CH1) floating
Channel 2 (CH2) non-floating
Operating voltage via vehicle
battery or power pack
10 V ... 30 V DC
Wattage approx. 40 W
Accuracy of DC measurement (CH1 and CH2):
Measuring ranges 0 to 200 V, auto ranging
Accuracy 0.75 % of measured value, plus
0.25 % of measuring range
Resolution 100 V - 100 mV (depending on
measuring range)
Multimeter Technical Data
KTS 650 System Tester for Control-Unit Diagnosis Page 31
Accuracy of AC and r.m.s. measurements (CH1 and CH2):
AC frequency range 5 Hz - 400 Hz
Measuring ranges 0 to 200 V, auto ranging
Accuracy 3 % of measured value, plus
0.25 % of measuring range
Resolution 100 V - 100 mV (depending on
measuring range)
Accuracy of resistance measurement (CH1):
Measuring ranges
0.1 to 1 M, auto ranging
Accuracy 0.75 % of measured value, plus
0.25 % of measuring range
Resolution
0.1 ... 1000 (depending on
measuring range)
Current measurement range (CH1 and CH2):
100 A clamp 0 to +/- 100 A
600 A clamp 0 to +/- 600 A
Shunt (CH1 only) 0 to 600 mA
General input resistance
1.5 M
Diode test Test voltage max. 2 V
Test current < 2 mA
Technical Data Oscilloscope
Page 32 KTS 650 System Tester for Control-Unit Diagnosis
OSCILLOSCOPE
POWER PACK
WEIGHTS AND DIMENSIONS
Measuring ranges 0 to 200 V
Coupling DC, AC
Signal source U, I-clamp, I-shunt
Trigger mode Standard, auto, auto threshold
Trigger source CH1, CH2
x-deflection 5 ms to 100 s
From a time-base sweep of 1 s, the oscilloscope is run in scrolling mode.
y-deflection for U 200 mV to 200 V
y-deflection with 600A amps clamp
(1 mV/A)
200 A, 500 A, 600 A
y-deflection with 100A amps clamp
(1 mV/A)
20 A, 50 A, 100 A
y-deflection with 600 mA shunt 200 mA, 500 mA, 600 mA
Input voltage 90 - 264 VAC
Input frequency 47 - 63 Hz
Output voltage 15 V
Operating temperature 0 C to 40 C
Dimensions (L x W x H) 300 x 400 x 125 mm
Weight (without connecting cables) 4200 g
Temperature Limits Technical Data
KTS 650 System Tester for Control-Unit Diagnosis Page 33
TEMPERATURE LIMITS
ELECTROMAGNETIC COMPATIBILITY
(EMC)
This is a Class A product in accordance with EN 55 022.
Operating temperature 0 C to 40 C