Document No.

DE0624 Rev 3
Bosch Automotive Service Solutions

Mechanical Design Standard Reference

Heat Treatments ...............................................................................................................................................2

Paint Specifications .........................................................................................................................................2

Zinc Plating........................................................................................................................................................2

Nickel-Chromium Plating ................................................................................................................................2

Nickel-Tin Plating .............................................................................................................................................2

Hard Chrome Plating........................................................................................................................................2

Black Oxide .......................................................................................................................................................2

Black Zinc Phosphate Coating .......................................................................................................................2

Anodizing...........................................................................................................................................................2

Product Marking ...............................................................................................................................................2

General Drawing Interpretations and Definitions..................................................................................................3

Procurement Source Notes ...................................................................................................................................4

Sales Bill (Phantomed item) Guidelines.................................................................................................................5

Abbreviations & Symbols on Drawings .................................................................................................................6

Driver Handles ......................................................................................................................................................7

Square Drive Specifications...................................................................................................................................8

Wrench Openings .................................................................................................................................................9

Sheared / Punched Holes ....................................................................................................................................10

Sheared Edges ....................................................................................................................................................11

Black Pipe Specifications.....................................................................................................................................12

Marking Date Codes............................................................................................................................................13

Marking Date Codes............................................................................................................................................14

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 1 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Design Standards
Brazing Welding of Steel
Heat Treatments Paint Specifications
Zinc Plating Nickel-Chromium Plating
Nickel-Tin Plating Hard Chrome Plating
Black Oxide Black Zinc Phosphate Coating
Anodizing Product Marking

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 2 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
General Drawing Interpretations and Definitions

Interpretation of Dimensions - All dimensions are to be considered absolute.

Dimensions, regardless of the number of decimal places, are to be used as if they were
continued with zeros.

Ref. (Reference) Dimensions - A dimension without tolerance used for informative or

permissible purposes only. i.e. (1.500), (STK) or (see Item text).

Dual Dimensions - If the drawing has dual dimensions, the conversion will be displayed
with brackets around the dimension. Do not confuse these bracketed dimensions with
reference dimensions as described above

Metric Dimensions If drawings are dimensioned in metric, there will be a metric

designation above in the title block. If in metric, and dual dimensioned, the inch conversion
will be in brackets and to be used for reference only.

Max or Min Dimensions - When a "max" (maximum) dimension if specified, the other limit
is zero unless limited by other dimensions. When a "min" (minimum) dimension is
specified, the other limit is infinity unless limited by other dimensions.

Basic Dimensions - A theoretically exact dimension, which describes size, form, or

location to which tolerances are applied. The tolerance is specified in conjunction with other
dimensions, or in notes. Permissible variations include .500 basic, .500 BSC, or .500 with
a rectangular box around the dimension.

Pre 1984 Drawings - On weldment level drawings of the Equipment Product Line dated
prior to 1984 (Pre-Cad), dimensional call outs are to be considered reference only.

Scaling of Drawings - Drawings are generally prepared to scale. However, methods of

reproduction make scaling unreliable; therefore unacceptable for the inspection of parts.

Stock Tolerances - Many older Borroughs, Kent-Moore and OTC drawings have the
designation "STK associated with dimensions of the part. This refers to this dimension as
being a stock dimension and, therefore, carries the manufactures stock tolerance. Many
tools were designed using this industry standard stock tolerance for functional fit of the tool. It
must, therefore, be assumed that these dimensions, if machined, should adhere to stock
tolerances as found in steel supply books. Typically these stock tolerances are held tighter
than our title block tolerances.

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 3 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions

Procurement Source Notes

RE: Supplier Designation on Drawings or Item Text.

Only the following designations will be used on purchase commodity drawings or Item Text:

1. Approved Source
2. Recommended Source
3. (Nothing)

Definitions:
1. Approved Source
A. This is the only product acceptable to Design Engineering, no substitutions
are allowed without Design Engineering approval.
B. Design Engineering must list the manufacturer and manufacturer's part
number.
C. More than one approved source may be listed. The words "alternate
source" or Purchased from should no longer be used.

2. Recommended Source
A. A recommended source is used only to give Purchasing a starting point.
Any other source may be used as long as the product meets the
specifications per text or the drawing.

3. (Nothing)
A. This method leaves it up to Purchasing to solicit a vendor with no guidance
or recommendation from Design. This is not recommended for standard off
the shelf items. Used primarily for items that are outside manufactured, per
a drawing.

Note: Previous to these guidelines, the phrase Purchase from or Purchase complete from
is to be interpreted the same as Approved Source.

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 4 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Sales Bill (Phantomed item) Guidelines
Note: Sales Bill is a term used to describe an upper level phantomed saleable item. The item
phantomed is the lower level stock item. The lower level item is picked and shipped with a
designated label and suitable packaging. There should be no routing or inventory of a sales bill.
1. ACCOUNTABILITY REQUIREMENT
Sales Bills will not be used where there is a necessity to monitor and control the product very closely.
2. CONVERSION COST
Anticipated assembly and shipping preparation costs which exceed 5% of the standard manufacturing
cost or 25 dollars should be included as part of the product cost and this product will not normally be
considered for management as a Sales Bill.
Note: If the Sales Bill method is used for these products, the additional cost must be included when
determining the selling price.
3. QUANTITY TO ASSEMBLE
Anticipated order volume should not exceed 10 units per customer order to be considered for
management as a Sales Bill. -
Note: If the shipping volume per order changes at a later date the Shipping Department will request a
review by the Product Manager to determine if the product should continue to be managed as a Sales
Bill.
4. FREQUENCY OF ORDERS
Anticipated frequency of orders should not exceed 10 units per month to be considered for management
as a Sales Bill.
Note: If the frequency of orders changes, the Shipping Department can request a review by
Manufacturing Engineering to determine if the product should continue to be managed as a Sales Bill.
5. WHERE USED FOR COMPONENT MATERIALS
At least one component must have multiple sources of demand before the item can be considered for
management as a Sales Bill. Packaging material is excluded from this test.
6. WHERE USED FOR A SALES BILL
A Sales Bill is always an end level item and can not have a where used.
7. COMPONENTS PER BILL OF MATERIAL
No more than 10 components should be allowed on the Bill of Material for a product to be considered for
management as a Sales Bill.
8. COMPLEXITY OF ASSEMBLY
The only assembly that can be done on a Sales Bill is something that can be done without the use of
special tools, special skills or the need for a drawing.
9. STAMPING OR LASER MARKING
No metal stamping or laser marking can be done on a Sales Bill
10. DESIGNATED SHIPPING AND PRODUCT LOCATION
All finished components listed for inclusion in the Sales Bill must be inventoried at the same designated
shipping location to be considered for management as a Sales Bill.
11. PACKAGING CONFIGURATION
All Sales Bills that have Anticipated Distribution Usage must be assembled using packaging and part
number identifiers that can be recognized by the distributor if the product is to be managed as a Sales
Bill. Labels are on each Sales Bill.
Note: Package marking must be consistent from one order to the next to ensure that box 1 of 2 etc. is
always marked in that manner.
12. SPECIFICATION OF PACKAGING MATERIALS
A. All Sales Bills should have labels specified.
B. Whenever special packaging has been designed for a product, that packaging must be listed as a part of the Sales
Bill of material for that product.
13. RESPONSIBILITY
Manufacturing Engineering will determine if a product is to be managed as a Sales Bill through the use of
these guidelines.

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 5 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Abbreviations & Symbols on Drawings

S.F.M. Surface Feet Per Minute

I.P.M. Inches Per Minute
I.P.R. Inches Per Revolution
R.P.M. Revolution Per Minute
F.P.M. Feet Per Minute
P.D Pitch Diameter
REF. Reference
I.D. Inside Diameter or Dimension
O.D. Outside Diameter or Dimension
Indicates Diameter
Machining Symbol - Indicates mandatory removal of material by
machining, or a surface previously machined.
Centerline
Chamfer or radius optional - This symbol preceded by a dimension
permits manufacturing the option of producing either a 45' chamfer of
C/R the size specified, or a radius of the size specified. Part must have one
or the other.
Surface texture (R.A.) - This symbol denotes a surface finish
requirement and applies to the entire surface within the dimensions
defining that surface. The particular surface finish required is
designated by this symbol and a maximum reading permitted when
surface is checked on stylus type instrument.
NOTE: All drawings with R.M.S. now measured with R.A. scale.
DBC Diameter of bolt circle
TIR Total indicator reading
INCL Included angle
CSK or CTSK Countersink
CHAM Chamfer only
RAD. or R Radius only
CBORE Counterbore
U.O.S. Unless otherwise Specified
Symbol for Micro. i.e. in is micro inch and m is micrometer

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 6 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Driver Handles
Below are specifications of commonly used branded drive handles within Service Solutions.
OTC 39224 is a ball detent drive handle. The pilot diameter is .745/.742 X .840/.900 long with the ball
detent centerline located .360/.390 from the end. The body diameter is 1.000 stk. X 7.875 long.
Mating hole specifications requires a 19.10 /19.3mm (.752/.760) diameter with a min. depth of 22.85mm (.900). A
standard lead-in chamfer of 1.00 /2.00mm X 45 should be used.
Miller Special Tools C-4171 is a ball detent drive handle. The pilot diameter is .618/.615 X .860/.890
long with the ball detent centerline located .360/.390 from the end. The body diameter is 1.000 stk. X 10
long.
Mating hole specifications require a 15.80 /16.00mm (.623/.630) diameter with a min depth of 22.85mm (.900). A
standard lead-in chamfer of .50 /1.50mm X 45 should be used. Alternate design included a counterbore of 18.80
/19.50mm (.740/.770) diameter on the back side with a dimension of 10.40 /11.20mm (.410/.440) from the front side.
This allowed the detent ball to pass through the hole and expand into the counterbored area and helped grip the
tool.
Kent-Moore used 3 style handles.
The first is a threaded style handle J-8092. The thread is .750 -10 UNC X .562 full thread and .750/.730 to
the driving shoulder. The body diameter in 1.250 X 9.375 long.
Mating hole specifications are as shown.
16.90 /16.60mm (.665 /. 654) Dia X 34.00mm (1.34) deep tap drill
.750 -10 UNC - 2B Thd. 20.50mm (.810) min depth
19.80mm (.780) Dia. C Bore, 6.00mm (.250) deep
25.40 /23.85mm (1.000/.940) Dia. X 90 Ctsk (included)

(Datum A is primary. Remaining datums to be specified by designer.)

The second is a ball detent drive handle J-7079-2. The pilot diameter is .496/.490 X .780/.720 long with the ball
detent centerline located .240/.260 from the end. The body diameter is 1.000 X 8 long.
Mating hole specifications are as shown.

12.65 /12.75mm (.498 /.502) Dia.X 19.80mm (.780) min. depth

16.50 /15.50mm (.650 /.610) Dia.X 90 Ctsk (included)

(Datum A is primary. Remaining datums to be specified by designer.)

The third is a threaded style handle, J-26090, which was originally used for the Nissan account. The thread is M12 x
1.5, which is undercut at the shoulder allowing full engagement. The length to the shoulder is .625 inches.

The mating hole specification is M12 x 1.5 with a minimum depth of 19mm (.750). Standard countersink to major
diameter is acceptable.

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 7 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Square Drive Specifications
Male Drive
Drive Square O.D. Turn External
Size Size mm Diameter mm Chamfer mm
1/4 6.40 8.40 6.10 Dia. X 30
6.27 7.90 5.60
3/8 9.57 12.70 9.40 Dia. X 30
9.44 12.20 8.90
1/2 12.75 16.90 12.45 Dia. X 30
12.62 16.40 11.95
3/4 19.10 25.40 18.80 Dia. X 30
18.97 24.90 18.30
1 25.45 34.00 25.15 Dia. X 30
25.32 33.50 24.65
Female Drive
Drive Square Max Drill Min Across Internal
Size Size mm Size mm (in) Corners mm Chamfer mm

6.42 8.40 Dia. X 120 Ctsk

1/4 6.95 (.273) 8.50 Min.
6.60 9.15
9.60 12.70 Dia. X 120 Ctsk
3/8 10.25 (.403) 12.80 Min.
9.78 13.70
12.77 17.00 Dia. X 120 Ctsk
1/2 13.85 (.546) 17.00 Min.
12.98 18.30
19.12 25.50 Dia. X 120 Ctsk
3/4 20.35 (.801) 25.50 Min.
19.33 27.20
25.50 34.30 Dia. X 120 Ctsk
1 27.50 (1.082) 34.30 Min.
25.70 36.30

Note: Across corners dimensions shall

be considered to be positioned to the center of the
square within .00 at MMC.
Illustration shown to the right

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 8 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Wrench Openings
INCH wrench openings. (Min / Max tolerances are mm)
Width Wrench Opening Countersink Width Wrench Opening Countersink
Across Flats Across Flats
Nominal MIN. MAX. MIN. MAX. Nominal MIN. MAX. MIN. MAX.
5/32 4.00 4.15 4.00 4.50 15/16 24.00 24.20 27.00 27.50
3/16 4.80 4.95 5.00 5.50 1 25.55 25.80 28.85 29.35
7/32 5.60 5.75 5.90 6.40 1-1/16 27.10 27.35 30.40 31.15
1/4 6.40 6.55 6.80 7.30 1-1/8 28.75 29.00 32.25 33.00
9/32 7.15 7.30 7.70 8.20 1-1/4 31.95 32.20 35.90 36.65
5/16 8.00 8.15 8.65 9.15 1-5/16 33.55 33.80 37.75 38.50
11/32 8.80 8.95 9.50 10.10 1-3/8 35.15 35.40 39.60 40.35
3/8 9.60 9.75 10.50 11.00 1-7/16 36.75 37.00 41.40 42.15
7/16 11.15 11.30 12.35 12.85 1-1/2 38.30 38.60 43.25 44.00
1/2 12.80 12.95 14.15 14.65 1-5/8 41.50 41.80 46.90 47.65
9/16 14.40 14.55 16.00 16.50 1-11/16 43.10 43.40 48.75 49.50
5/8 16.00 16.15 17.80 18.30 1-3/4 44.70 45.00 50.50 51.30
11/16 17.60 17.75 19.65 20.15 1-13/16 46.30 46.60 52.40 53.15
3/4 19.20 19.35 21.50 22.00 1-7/8 47.90 48.20 54.25 55.00
13/16 20.80 20.95 23.35 23.85 2 51.10 51.40 57.90 58.65
7/8 22.35 22.55 25.15 25.65

METRIC wrench openings. (Min / Max tolerances are mm)

Width Wrench Opening Countersink Width Wrench Opening Countersink
Across Flats Across Flats
Nominal MIN. MAX. MIN. MAX. Nominal MIN. MAX. MIN. MAX.
3 3.04 3.16 3.20 3.60 27 27.16 27.40 30.40 31.15
4 4.05 4.17 4.20 4.60 28 28.17 28.41 31.55 32.50
5 5.05 5.18 5.30 5.80 29 29.17 29.42 32.75 33.70
6 6.06 6.19 6.45 6.95 30 30.18 30.43 33.90 34.85
7 7.06 7.20 7.60 8.10 31 31.18 31.44 35.05 36.00
8 8.07 8.21 8.75 9.25 32 32.19 32.45 36.20 37.15
9 9.07 9.22 9.90 10.40 33 33.19 33.46 37.35 38.30
10 10.08 10.23 11.05 11.55 34 34.20 34.47 38.50 39.50
11 11.08 11.24 12.20 12.70 35 35.20 35.48 39.65 40.65
12 12.09 12.25 13.35 13.85 36 36.21 36.49 40.80 41.80
13 13.09 13.26 14.50 15.00 37 37.21 37.50 41.95 42.95
14 14.10 14.27 15.70 16.20 38 38.22 38.51 43.15 44.15
15 15.10 15.28 16.80 17.30 39 39.22 39.52 44.30 45.30
16 16.11 16.29 18.00 18.50 40 40.23 40.53 45.45 46.45
17 17.11 17.30 19.15 19.65 41 41.23 41.54 46.60 47.60
18 18.12 18.31 20.30 20.80 42 42.24 42.55 47.75 48.75
19 19.12 19.32 21.45 21.95 43 43.24 43.56 48.90 49.95
20 20.13 20.33 22.60 23.10 44 44.25 44.57 50.05 51.10
21 21.13 21.34 23.75 24.25 45 45.25 45.58 51.20 52.25
22 22.14 22.35 24.90 25.40 46 46.26 46.59 52.35 53.40
23 23.14 23.36 26.05 26.55 47 47.26 47.60 53.50 54.55
24 24.15 24.37 27.20 27.70 48 48.27 48.61 54.70 55.75
25 25.15 25.38 28.35 28.85 49 49.27 49.62 55.85 56.90
26 26.16 26.39 29.25 30.00 50 50.28 50.63 57.00 58.05

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 9 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Sheared / Punched Holes

The terminology used for punched holes is defined as shown below.

Rollover

1. Hole size and location shall be measured only in the punch entered side.
Hole size and tolerance is noted on the D.E. drawing.
2. Maximum breakout shall be 12 % of the material thickness per side unless
otherwise noted on the D.E. drawing.
3. Burrs are permissible as specified on class table. Burrs that have been
pushed back into a hole are permissible if they do not violate minimum hole
size.
4. Shear area, the depth of shear area, measured from the punch enter side
shall be a min. of 15% of material thickness. If additional shear depth is
required it must be noted on the drawing.

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 10 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Sheared Edges

Feature size dimensions apply only to the shear area and not to the breakout
area see below.

Values are shown in English. .002/.020 converts to .05/.50 in mm.

Title block specifications do not apply to sheared edges. Deburring requirements shall be
specified as shown above.

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 11 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Black Pipe Specifications
Round
Welded ---- Plain Ends Specifications
S = Standard wall for schedule 40. H = Heavy wall for schedule 80
Wt. Per Wall I.D. O.D. Length In
Nom. Size Schedule Ft. (lbs.) Wall MM I.D. MM O.D. MM Ft. (ref)
S 1/8 40 0.24 0.068 1.73 0.269 6.83 0.405 10.287 21
S 1/4 40 0.42 0.088 2.24 0.364 9.25 0.54 13.72 21
H 1/4 80 0.54 0.119 3.02 0.302 7.67 0.54 13.72 21
S 3/8 40 0.57 0.091 2.31 0.493 12.52 0.675 17.15 21
H 3/8 80 0.74 0.126 3.20 0.423 10.74 0.675 17.15 21
S 1/2 40 0.85 0.109 2.77 0.622 15.80 0.84 21.34 21
H 1/2 80 1.09 0.147 3.73 0.546 13.87 0.84 21.34 21
S 3/4 40 1.13 0.113 2.87 0.824 20.93 1.05 26.67 21
H 3/4 80 1.47 0.154 3.91 0.742 18.85 1.05 26.67 21
S 1 40 1.68 0.133 3.38 1.049 26.64 1.315 33.40 21
H 1 80 2.17 0.179 4.55 0.957 24.31 1.315 33.40 21
S 1-1/4 40 2.27 0.14 3.56 1.38 35.05 1.66 42.16 21
H 1-1/4 80 3 0.191 4.85 1.278 32.46 1.66 42.16 21
S 1-1/2 40 2.72 0.145 3.68 1.61 40.89 1.9 48.26 21
H 1-1/2 80 3.63 0.2 5.08 1.5 38.10 1.9 48.26 21
S 2 40 3.65 0.154 3.91 2.067 52.50 2.375 60.33 21
H 2 80 5.02 0.218 5.54 1.939 49.25 2.375 60.33 21
S 2-1/2 40 5.79 0.203 5.16 2.469 62.71 2.875 73.03 21
H 2-1/2 80 7.66 0.276 7.01 3.323 84.40 2.875 73.03 21
S 3 40 7.58 0.216 5.49 3.068 77.93 3.5 88.90 21
H 3 80 10.25 0.3 7.62 2.9 73.66 3.5 88.90 21
3 160 14.32 0.438 11.13 2.624 66.65 3.5 88.90 21
S 3-1/2 40 9.11 0.226 5.74 3.548 90.12 4 101.60 21
H 3-1/2 80 12.51 0.318 8.08 3.364 85.45 4 101.60 21
S 4 40 10.79 0.237 6.02 4.026 102.26 4.5 114.30 21
H 4 80 14.98 0.337 8.56 3.826 97.18 4.5 114.30 21
S 5 40 14.62 0.258 6.55 5.047 128.19 5.563 141.30 16-24R
H 5 80 20.78 0.375 9.53 4.813 122.25 5.563 141.30 16-24R
S 6 40 18.97 0.28 7.11 6.065 154.05 6.625 168.28 16-24R
H 6 80 28.57 0.432 10.97 5.761 146.33 6.625 168.28 16-24R

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 12 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Marking Date Codes

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 13 of 14

QMS electronic document is the controlled copy
 Document No. DE0624 Rev 3
Bosch Automotive Service Solutions
Marking Date Codes

Print Date: 12/8/2011 Bosch Automotive Service Solutions Confidential Page 14 of 14

QMS electronic document is the controlled copy