No compromise in truck business:Commercial Vehicle filtersfrom Bosch

Alltrucks: combining the servicecompetence of three strong partners

The commercial vehicle segment is changing as vehicles become more efficient, less polluting and safer. Maintenance and repair expectations are rising, and mixed vehicle fleets are standard. Our solution for your commercial vehicle service is Alltrucks Truck & Trailer Service, a shared brand of the automotive suppliers Bosch, Knorr-Bremse and ZF.

Alltrucks – the independent full service workshop system with aninternational approach. The use of shared knowledge for all keyworkshop areas gives multi-brand commercial vehicle workshopsa decisive advantage in day-to-day dealings with customers.

Please contact the Alltrucks system headquarters for additional information:

Alltrucks partnership – your advantages▶ Individual field support▶ Exclusive multi-brand

vehicle diagnostics▶ Technical data▶ Training from a single source▶ Technical hotline▶ Marketing support▶ Quality management

You can get original Bosch quality here:

For more information visit: www.bosch.com

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The complete range of truck filters

f Fuel filters f Oil filters f DENOX filters f Air filters f Cabin filters f Special filters

Phone 089 / 46 22 466-0 Workshop contact 089 / 46 22 466-44E-mail info@alltrucks.com Website www.alltrucks.com

What drives you, drives us.Technology from Bosch is used in practically every vehicle in the world. For us, the focus is on people and helping them to stay mobile.

We have been dedicated to people for more than 125 years with our pioneering spirit, research, production and expertise.

Our dedication is an unwaivering commitment to providing them with a unique combination of parts, diagnostics, workshop equipment and services:

▶ state-of-the-art solutions for efficient vehicle repairs▶ innovative workshop equipment and software – also available on

favorable lease terms▶ the world’s largest range of new and remanufactured spare parts▶ fast, reliable delivery service▶ expert customer care via our hotline▶ extensive range of training courses▶ specific sales and marketing support▶ plus many other services

Bosch products and services▶ Diagnostics▶ Diesel systems▶ Gasoline systems▶ Brake systems▶ Spark plugs▶ Energy systems▶ Batteries▶ Filters▶ Wiper systems▶ Light technology▶ Comfort electronics▶ Hybrid/e-mobility▶ Technical hotline▶ Knowledge database▶ Service training▶ Workshop concepts

You can get original Bosch quality here:

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For more information visit: www.bosch.com

The new Bosch packaging designHigh performance forquality-oriented customers

f Globally consistent, appealingpackaging design

f Easily recognizable brand f Reliability thanks to premium

Bosch quality

The complete range of truck filters

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f System competence regarding filters: f Inventor and global leader concerning diesel f injection systems, developer of the Denox- f tronic system f Safety thanks to first-class product quality f Updated product range with more than 200

Satisfied customers, little effort required for warehousing and ordering, consis-tent use of the latest technologies – numerous USP stand for Bosch filters:

new releases per year f High availability of goods, in more than 100 countries across the globe

f Strategic partner for the future through training courses and seminars

f Strong brand that is trusted by its customers

Successful with Bosch filtersTriple European-Truck-Racing- Champion Jochen Hahn relies on Bosch filter

Bosch: A strong partner in filtration business

Oil filtersProtect the engine from existing pollutants, such as rust or metal particles in the oil.

DENOX filtersProtect the components of the SCR catalytic converter from contamination – require ment for correct AdBlue dosing.

Air filtersProtect the engine against dirt particles in the intake air.

Fuel filtersProtect the injection system and the engine from foreign particles, water, and other residues in the fuel.

Cabin filters Protect the passengers against pollen, dust and pollutants and to protect the air-conditioning system; additional protection against harmful and foul-smelling gases with activated carbon filters.

Special filtersSpecial filters for special tasks – from the air dryer cartridge and coolant, to hydraulic fluid filters and oil separators.

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Established diesel markets

Increased impurity due to particles

Harsh conditions for filters

Because diesel doesn’t necessarily mean dieselIn global terms, the quality of diesel varies consider-ably. Depending on the region and the climatic conditions, the concen-tration of water and dust may be extremely high. Bosch therefore provides various diesel filters that are coordinated with the individual diesel quali-ties of the corresponding country.

Impure diesel fuel – an important issue in several countries

Source: SGS World Wide Fuel Surveys summer 2006 to winter 2010/2011

Indispensable: Effective water separationWater is the enemy of all injection systems, especially diesel high-pressure pumps and injection nozzles(injectors). Therefore all Bosch diesel filters possessa particularly reliable water separation function.A prerequisite for this function is the star-shaped folding of the filter medium and a special, water-resistant resin coating.

How does water get into the diesel? f It is present in the fuel f Through condensation in the tank

Causes for inadequate water separation f Non-compliance with replacement intervals f Use of cheap filters

Expensive consequences f Corrosion damage to the injection system,

the engine, and the pump f Wear damage due to rust particles

Dirt on fuel tank inlet

Corrosion

at the high-

pressure

pump

housing

Corrosion at

the injector

A commercial vehicle is almost always on the road.This means constant high demands for all filtertypes and – in international transport – largedeviations in fuel quality in different countries.The technical requirements for commercial vehiclefilters are therefore much higher than for car filters.

Requirements for filters

Cars Commercial vehicles

Service intervals + ++(+)

Flow rate + ++

Vibration resistance + ++

Dirt collection capacity + ++(+)

Pulsation resistance + ++

Size + ++(+)

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Constant reliability with every kilometeryou go: high-quality Bosch filters

Professionals Cannot Afford “Cheap Filters”Budget is a main issue for the transport sector.Saving at filter replacement is very dangerous though.Bosch common-rail diesel filters reliably protect the mostsophisticated injection system that exists. High pressures exceeding 2,200 bar and the low production tolerancesof the components require maximally clean diesel fuel.Not separated water and particles otherwise generate atremendous destructiveness and thus unavoidably lead toincreased wear concerning the injection nozzles.

Movie clip on the internet:Be informed about the operating principle of Bosch truck-diesel filters and the risks of cheap filters.

f Development: The Simultaneous Engineering Team sticks to an elaborate procedure with precisely defined milestones when developing a new filter.

f Production: High-quality materials, neat and accurate processing, and well-defined quality checks ensure the consistently high quality of Bosch filters.

f Release: Only if the product manager lets the filter pass the final technical release process, new Bosch filters are made available for sale.

f Income-Goods Inspection: Each delivery is subjected to random-sample tests before being stocked.

f Field Observation: If a fault is detected, it is taken as a basis to learn from mistakes and optimize series production.

5 steps to quality: Each Bosch filter is subjected to a 5-step process before being brought to market:

Development

Monitoring

Release

Production

Checks

Bosch-Filter-Quality

“I have always acted according to the prin-ciple that I would rather lose money than trust. The integrity of my promises, the belief in the value of my products and of my word of honor have always had a higher priority to me than a transitory profit.”

Robert Bosch, 1918

Comparison of Costs

Common-rail injection system

Set of InjectorsHigh-pressure pump

Bosch filters: pre and main filter

~ 5 000 EUR ~ 3 000 EUR ~ 1 500 EUR2 x ~ 50 EUR

Losses when stationary A commercial vehicle makes money every day. An out-of-action vehicle costs the carrier around 2,000-3,000 euros a day. Still worse is the sudden engine damage with cooling system failure, resulting in the need to compensate for spoiled goods. That is why engines and injec-tion systems need reliableprotection – with quality filters from Bosch.

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Change the oil filters regularly according to the vehicle manufacturer’s specifications! Consequences of clogged filter:

f Premature engine wear, even to the extent of engine damage f Reduced engine power f Increased oil consumption f Escape of oil f Pollution caused by oil leakage

Bosch oil filters:For optimum engine performance

Oil filter insertThe oil filter housing is connected permanently to the engine block. When changing the filter, only the filter insert and the seals are replaced.

Oil filter exchange box When changing the filter, the entire oil filter is re-placed and bolted directly to the engine block using a connecting flange.

Oil filter designs

Oil filters – Design and operation

1 Sealing 2 Threaded connection 3 Double beading 4 Non-return valve 5 Filter medium 6 Support jacket 7 Pressure-resistant filter housing 8 Bypass valve

A Inflow of contaminated oil B Filtration of the oil C Clean oil is conducted to

the engine

Specially for commercial vehicles: Oil bypass filtration In commercial vehicles, a large amount of particles collect in the oil over time, above all soot particles.This causes premature aging of the oil and engine wear. In addition to the main flow filter, which filters the entire

quantity of oil with each cycle, commercial vehicles usu-ally also have a bypass filter. This cleans 5 to 10 % of the oil in a separate circuit.

Fresh engine oil Good lubricationproperties

Aged engine oil With soot conta-mination, poor lubricationproperties

The advantages of Bosch oil filters f Protection of the engine and retaining engine oil

functionality in the long term thanks to high particle separation rate, moisture resistance, and tensile strength

f Long service life thanks to large filter surface f Protection of the environment and engine as oil

losses are prevented f Immediate engine lubrication during cold-starts

thanks to non-return valve

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How to recognize high quality:

Change the diesel filter regularly according to the manufacturer’s specifications. Consequences of clogged filter:

f Power loss of the engine, even to the extent of an engine standstill

f Impairment or interruption of the fuel supply f Impairments to the output of the fuel pump, even to the

extent of a short-circuit f Increased wear f On diesel vehicles: Internal corrosion of engine components

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Water separation

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Time (min)

Water separation does not fulfill the norm requirements Risk of corrosion in fuel injection system!

f Norm requirement (ISO 4020)f High-quality filter, e.g. Bosch f Low-quality filter

Dust retention capacity

Bosch filter: 15.34 gr, Low-quality filter: 1.46 gr10 times lower lifetime!

f System limit: engine stopf High-quality filter, e.g. Bosch f Low-quality filter

Pres

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r)

Life-time (km) China 20,000 30,000Life-time (km) Europe 60,000 90,000

Efficiency

100

90

80

70

3-5 5-10 10-15 15-20 20-25 >3060

f Norm (ISO TR 13353)f High-quality filter, e.g. Bosch f Low-quality filter

Much lower efficiency 6 times more particles enter in the fuel injection system!

Effici

ency

(%

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Particles (μm)

Design and operation of filter exchange boxes

1 Sealing 2 Fitting flange 3 Double beading 4 Multilayer filter medium 5 Water chamber 6 Water drain screw

A Inflow of contaminated diesel B Dirt and water filtration of the diesel C Cleaned diesel is conducted to engine

Crucial for commercial vehicles: Diesel filters with water separators Due to the high flow rate, water separators are often built into commercial vehicles to pre-filter water and coarse particles. The actual diesel filter then performs the task of finely filtering the fuel.

The advantages of Bosch fuel filters f Protection of the injection system through

high particle separation rate f Full engine performance thanks to large

filter surface and low flow resistance f Robust housing f Long, reliable service life through special

filter medium coating

Bosch fuel filters: From the specialist for injection systems

How to recognize high quality:

Moisture resistance throughimpregnation with synthetic resin

Inflammation protection through special coating

Permanently stable pleatgeometry through sufficiently dimensioned glue beads

Kein By-Pass von ungefilterter Luft durch hochwertige Dich-tung aus Polyurethan

Large dust-holding capacity through high number of pleats

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Design and operationof the air filter

1.5 kg, that is the dust quantity the air intake of a bus with a 160-kW engine collects at a distance of 30 000 km.

1.5 kg of dust

Microfiber filter medium with artificial resin impregnation

Filtering of dust and dirt particlesSealing lipmade ofpolyurethane

The advantages of Bosch air filters f High efficiency and reliability during the entire

filter service life thanks to robust pleat geometry

f Long service life and thus protection of the engine thanks to high particle separation rate, moisture resistance, and tensile strength, as well as chemical and thermal stability

f Lower fuel consumption thanks to excellent dirt collection capacity and low flow resistance

Change the air filters regularly according to the vehicle manufacturer’s specifications! Consequences of clogged filter:

f Poor air-fuel mixture preparation, resulting in reduced engine power and increased pollutant emissions

f Increased fuel consumption f Increased wear in the engine due to particles f Problems when starting the engines

Bosch air filters: Top quality engine protection

Higher separation degree for commercial vehicles A separation degree of 99.9 % is required for air filters in commercial vehicles, whereas 99.8 % is sufficient for cars. The flow of dust in commercial vehicles must therefore be reduced by half. This is achieved by fine pores in the filter medium. Construction site vehicles are usually equipped with additional air filters, for example second ary filter inserts and cyclone separators.

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How to recognize high quality:

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Dust, pollen, and dirt particlesFine dust, diesel soot, and bacteria

Standard cabin filters

1 Preliminary filter 3 Carrier fleece2 Microfiber fleece

Activated carbon cabin filters

1 Preliminary filter 3 Carrier fleece2 Microfiber fleece 4 Activated carbon

Stability and increasedfilter surface throughspecial embossing of thefilter medium

Robust pleat geometry –even when exposed tohumidity

Reliable absorption of harmful gases and odors through▶ High-quality activated

carbon▶ Sufficient amount of

activated carbon▶ Firm connection with

the carrier fleece

Shape is perfectly gearedto the installation space – and is still highly flexiblein order to ease theinstallation under difficult circumstances

Reliable filtrationperformance through high-quality fibers

Change cabin filters every 20,000 km or after one year! Consequences of clogged filter:

f Poor vision due to misted windows and reduced safety f Increased concentration of pollutants (up to 6 times

higher than outside the vehicle) f Allergic reactions, e.g. sneezing f Restricted operation of the air-conditioning system due

to deposits on the evaporator

Dust, pollen, and dirt particlesFine dust, diesel soot, and bacteriaHarmful and foul-smelling gases

Unbelievable technology: The activated carbon layer f Natural material made of coconut shells that are carbonized

and crushed in a hermetically sealed environment f Formation of the porous structure in high-temperature

steam (up to 800 °C) f Enormous surface area: 1 gram of activated carbon has an

interior surface of approx. 1,000 m2

f 1 teaspoon of activated carbon equates to the surface area of a football pitch

Cabin filters from Bosch are impressive: f Health: Filtering of almost 100% of all dust and

dirt particles, pollen, bacteria, and spores f Comfort: Noticeably better air immediately f Safety: Reduction of lubrication film on the

windows, so reduced glare f Growing market: Equipping of almost all new vehi-

cles with air-conditioning system and cabin filters

Bosch Cabin filters: Improving comfort, safety and health

Design andoperationof thecabin filters

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Recommended replacement interval:Depending on the circumstances of their application, DENOX filters should be replaced every 120 000 to 320 000 km. Please check the manufacturer'sinstructions!

Design and operationof the DENOX filters

Type/KIT

DENOX 1Service

F 00B H40 096 • • • • • MAN

DENOX 1 Service

F 00B H40 230 • • • • • DAF, MAN, IVECO,Scania, Volvo

DENOX 1 Repair

F 00B H40 025 • • • DAF, MAN, IVECO,Scania, Volvo

DENOX 2.1 Service

1 457 436 006 • • • Case, IVECO, KHD,Renault, Volvo

DENOX 2.1 Repair

1 457 030 020 • Case, IVECO, KHD,Renault, Volvo

DENOX 2.2 Service

1 457 436 033 • • • Cummins, Mack, Nissan, Renault, Volvo

DENOX 6.5Service

1 457 436 039 • • • Perkins, CNH, JCB,Daimler, India, CAMC (China)

Denoxtronic system and SCR catalytic converter: Position and function of DENOX filters

Temp.-sensor

Temp.-sensor

Temp.-sensor

Levelsensor

Engine coolantlines for AdBluetank heating

Engine coolantlines for coolingof dosing module

Dosingmodule

Actuators

Supply module

Dosingcontrolunit(optional)

AdBluetankBackflow

line

Inlet line

Sensors

SCR-catalyst

Engine CAN

Diagnostic CAN NOxsensor

EDC control

DENOX-filter

Pre-filter

Compensation elementLidHousing

Filtered AdBlue Cellulose

Lid

Compensation element

O-ringAdBlue drain screwAdBlue outlet

AdBlue inlet

Bosch DENOX filters:Clean AdBlue for a precise dosing

Purpose of the DENOX filter f The Denoxtronic AdBlue dosing system and

the SCR catalytic converter reduce nitrogen oxide emissions

f The DENOX filter is integrated in the supply module and protects the injector, thus supporting correct AdBlue dosing

Excellent durability thanks to intelligent Bosch quality f High rate of dirt separation due to phenolic resin

coating and large surface area of the filter medium f Resistance to aggressive AdBlue thanks to high-

quality materials f Due to its high water content, AdBlue freezes at just

–11 °C and expands. Compressible compensating elements prevent damage to the filter and the supply module

f Integrated electric heating to quickly warm up frozen AdBlue

Main advantages of Bosch DENOX filters: f Reliable protection of the dosing module as

perfectly adapted for it f Ensures the correct function of the dosing

module, thus supporting compliance with emission standards

f High durability and long service life f Filter protection, even at low temperatures

Filter change for DENOX filter 2.1The filter is screwed to the housing cover of the Denoxtronic supply module and is extracted from the housing along with the cover. If the filter has loosened from the cover or is stuck in the housing it can be extracted using an extraction tool.

DENOX filter extraction tool for Denoxtronic 2.1The extraction tool is used only if the filter has loosened from the cover or is stuck in the housing (part number: 0 986 613 295).

Filter change for DENOX filter 2.2The filter is removed from the Denoxtronic supply module using an extraction tool, which is included in the service kit.

Consequences of poor dehumidification ofcompressed airWhen compressed, the air heats up and absorbs water vapor which condenses when it cools to the ambient temperature:

f Risk of malfunctions in valves due to water freezing in cold weather

f Corrosion in air reservoirs, valves, and cylinders

f Erosion of oil lubricant film in braking system components

Advantages of the Bosch air dryer cartridge: f Large reserves for water absorption f Extremely high resistance to pulsation and

burst pressure f Excellent performance even under difficult

conditions f Service life increased even further with addition

of oil pre-separator

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1 Housing2 Compression spring3 Oil separator4 Air dryer container5 Air dryer granulate6 Fleece7 Prefilter8 Sealing ring9 O-ring10 Thread plate

A Compressed, humid air passes the prefilter, separation of coarse particlesB Separation of oil mistC Drying of compressed air in the air dryer containerD Dry, clean compressed air is conducted back to pneumatic system

Regeneration of the air dryer cartridgeThe water droplets in the compressed air are stored in the fine pores in the granulate. During the regen-eration cycle a vent valve opens. The pressure in the air dryer cartridge falls, dry air from the regenera-tion-air tank flows in the opposite direction through the granulate and in doing so, absorbs moisture and transports it out. The regeneration cycle will always take place if the pneumatic system has sufficient compressed air in the reser-voirs, irrespective of the moisture content of the granulate.

Recommended replacement intervalThe air dryer cartridge should be changed once a year.

Bosch air dryer cartridge Other air dryer cartridges

Oil separator

Air dryer granulate

Air dryergranulate

Oil mist is separatedbefore air reaches the air dryer granulate

→ water-absorption capability remains fully intact, extended service life

Oil mist is separated after the air passed the air dryer granulate

→ deteriorated water-absorption capability, reduced service life

Smart design for extended service life

Design andoperation ofair dryer cartridges

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3 4 5 1 Air2 Surface3 Pore4 Fine channel5 Water molecule

Microstructure of air dryer granulate

The air dryer granulate has a grain size of 1-3 mm. Pores and tiny channels in the granulate create a large internal surface area for collecting water molecules. The amount of granulate within an air dryer cartridge – around 1 kg – has an internal surface area of 1 million m2, which is equivalent to approx. 20 football pitches.

Purpose of the air dryer cartridge f Dehumidification and removal of particles

and droplets of oil from the compressed air

Use of compressed air in commercial vehiclesCompressed air is used in commercial vehicles for many functions:

f Service brake and parking brake systems f Trailer braking system f Air suspension f Operating doors, e.g. on buses f Traction control

The Bosch air dryer cartridge: Dry and clean compressed air in commercial vehicles

Oil separator

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Purpose of the coolant filter f To protect the fine channels in the cooling

system from deposits using mechanical filtration and chemical additives

Consequences of insufficient coolant filtration f Corrosion in the cooling system f Formation of foam at low cooling temperatures f Deposits of calcium and magnesium f Excess acid and bacterial growth f Cavitation and pitting on metal surfaces

Purpose of the crankcase oil separatorSeparation of the oil mist from blow-by gases

How are blow-by gases formed?When the engine is operating, gases flow out of the combustion chamber, through the gaps in the con-struction between the piston and cylinder wall into the crankcase. Even with optimum sealing, these blow-by gases make up approximately 0.5% to 2% of the entire gas volume in the cylinders. Blow-by gases contain fuel residue, soot particles and oil mist.

If the coolant is not filtered sufficiently,cavitation may occur, with vapor-filled cavitiesforming in the coolant. The result: Damage tothe cylinder due to pitting.

The advantages of Bosch coolant filters f Specially impregnated filter medium

for long service life and high particle collection capacity

f Corrosion-resistant filter housing and components

f Easily soluble chemical additives f Coolant-resistant seals f Longer change intervals

Recommended replacement interval The coolant filter should be changed regularly, together with the oil filter.

Recommended replacement intervalFor short-distance trips and in distribution transport, crankcase oil separators should be changed every 40,000 km; for long-distance trips they should be changed every 80,000 km.

Design and operationof coolant filters

Oil separation: Protection for the engineand the environmentBefore emission standards such as Euro IV were introduced, blow-by gases were simply released into the environment to prevent a dangerous increase of pressure in the crankcase. Nowadays, they must be returned to the intake duct of the engine. The problem with doing so: The oil and other particles contained in the gas must be separated first, other-wise they will contaminate and damage turbochargers, air mass meters, intercoolers, valves, and catalytic converters. The oil separator performs this task reliably.

Bosch Coolant filters:Perfect protection for the cooling system

1 Filter cover 2 Double beading 3 Sealing 4 Housing 5 Filter medium 6 Inhibitor tablet

A Inflow of contaminated coolant B Coolant is filtered and added with chemical additives C Cleaned coolant is conducted to radiator

Bosch Oil separators:Essential for the engine, good for the environment

The advantages of Bosch oil separators for crankase ventilationEfficient separation of oil that emerges at the crankcase ventilation system

f Effective filtration and collection of aerosols f Efficient separation of oil from blow-by gases to

keep the intake section clean f Supports compliance with emission standards

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Properties of hydraulic fluidHydraulic fluid is used to transfer pressures in hydraulic systems. These pressures can be up to 400 bar and above, which means that the hydraulic fluid has to meet demand-ing requirements:

f Low temperature-sensitivity for viscosity (fluidity) f Low compressibility f Low tendency to form foam f High shear stability, i.e. lubricant film does not tear even

with high mechanical load

The advantages of Bosch hydraulic-fluid filters f High dirt collection capacity for longer

change intervals f Effective separation of water, therefore no

corrosion of components and no chemicalreaction of the fluid

f High pressure resistance: Stable even at high differential pressure

Recommended replacement interval:Hydraulic-fluid filters should be replaced every 500 to 1000 hours of operation, at latest after one year.

Bosch Diagnostics: test equipment, software and know-how from a single source

Workshop solutions saving both time and moneyFor professional servicing of modern vehicles, Bosch provides test equipment, ESI[tronic] 2.0 workshop software, service trainings and hotline with knowledge database from a single source.

Test equipment for today’s workshopsfAir-conditioning servicefDiesel system testfECU diagnosisfEmission analysisfWheel alignmentfVehicle system analysisfBattery servicefBrake testers and test lanesfTire changersfWheel balancersfHeadlight testers

ESI[tronic] 2.0 softwareApart from ECU diagnosis, the workshop software includes technical information such as circuit diagrams, service and repair instructions as well as system information. ESI[tronic] 2.0 stands out for its high market coverage regarding common trucks, LCVs, trailers and buses on the European market.

Service training: automotive knowledge from one of the world's largest and most innovative automotive supplier fTrainings with over 60 % of practical contents

by vehicle experts with workshop experience fInteractive online access to technical and vehicle-

repair trainings

Bosch Hotline – expert assistanceProfessional cross-brand vehicle-repair assistance for all vehicle systems

ESI[tronic] 2.0 Truck: diagnosis, maintenance plans and information for trucks, trailers, buses and LCVsf ECU diagnosis with latest dataf Troubleshooting with guided search instructionsf All data required for inspection and servicing

at a glance f In cases of service or repair, the workshop

has any required data at its disposal

Bosch Hydraulic-fluid filters:Filters that can take the pressure

Purpose of the hydraulic-fluid f To transfer very high pressures in hydraulic

systems, for example for moving digger arms and wheel loader buckets

Purpose of the hydraulic-fluid filter f To protect the hydraulic system from contami-

nants such as dust, metal particles, and water