5.

CALIBRATE E-TES HEATER
a. Plug in the air mover power cord and the two E-TES heater power cords.
The air mover and E-TES heater must be plugged into separate circuits. Check your
dealership electrical system to ensure the circuit you are plugging into can operate the air
mover and E-TES heater.
b. Press SELECT to set the Air Flow switch trigger point. Follow the
screen directions using the DOWN button to set the levels with the air
mover OFF & ON.

c. Turn the air mover OFF. When the air mover is off and the
number stops changing, press DOWN(most cases this will be 0.) This is
the Off Set Point. (Shown as 033 in this example)

d.
Then turn the air mover ON at high speed. Press DOWN as
soon as the number on the display steadies out (50-300). This is the
ON Set Point. (Shown as 076 in this example)
If you need assistance with the E-TES heater contact
the Bosch Technical Assistance Line - 1-800-933-8335
(Option 4)
DO NOT CONTACT TAS for E-TES Heater concerns.

11

DRYING PROCEDURE (Normal procedure after initial setup)
1.

ATTACH HEATER TO VEHICLE
a. Lift the vehicle
b. Place the E-TES heater below the rear of the vehicle.
c. Connect the air mover power cord and the two E-TES heater
power cords (if not already connected)

d.

Insert the right-side hose into the right-side frame rail until it is
secure.

e.

Using a bungee cord or straps around the frame rail, secure the
left-side hose to the left side frame rail. The outlet of the hose
must be center with the frame rail opening.
DO NOT wrap the bungee cord around any fuel, evap,
or brake hoses. Only put the bungee cord around the
frame rail and air duct hose to avoid damage to
vehicle components.

4.

2.

TURN THE AIR MOVER ON THE HIGH SETTING

3.

TURN THE E-TES HEATER ON AND DRY FRAME
a. Flip the switch on the E-TES Heater to the “on” position
b. Check that the air coming out of the heater is warm.
c. Leave the heater and air mover ON and attached to the vehicle
for 3 hours.
The drying procedure being performed as written is
critical for the wax application procedure success. If
the drying procedure is not performed correctly the
maximum rust prevention will not be achieved.

REMOVE E-TES HEATER AND HOSES FROM VEHICLE

12

5.

DRY THE OPEN SECTION OF THE FRAME AND INNER CAB MOUNTS
a. Using the 2ft air gun, remove all water from the open section of the frame and the inside of the cab
mounts on both the right and left side of the frame. All the water between the metal reinforcements in the
open section of the frame MUST BE REMOVED before proceeding
IT IS CRITICAL THAT YOUR SHOP AIR SYSTEM NOT HAVE WATER IN IT.
Confirm by spraying the air gun at a piece of carboard (or other water absorbant material)
to confirm that no water is present. If water is present then the shop air dryer may need to
be drained or replaced.

13

11-15 MODEL YEAR CLEANING PROCEDURE

Before starting this process, review the SCK0D E-Learning Cleaning
section for key details
1.

USE EXTENDED WIRE BRUSH TO CLEAN THE RH FRAME RAIL
BOXED SECTION
a. Inspect the brush to confirm the bristles are not lose or worm
If the wire brush has worn down to the point of not
being effective or you have an issue with any other
tool related to K0D contact Bosch Technical
Assistance Line - 1-800-933-8335 (Option 4) for
instructions on how to acquire replacement parts
b.

Insert the brush into the frame rail as shown in the illustration
DO NOT insert the brush beyond the point shown in the
illustration below, otherwise brush damage will occur

NOTE: When handling the Power Tool Wand, make sure to hold
onto the plastic handle for safety

c.

With the drill direction set to clockwise, run the drill in and out of the box section frame to break free
rocks, dirt, and rust. DO NOT SET THE DRILL DIRECTION TO COUNTERCLOCKWISE
NOTE: The amount of time needed to run the brush will vary from frame to frame. The typical
time will be 5 to 10 minutes per side however it may take longer depending on how dirty the
frame is and the type of dirt/debris in the frame

14

2.

USE WIRE BRUSH WITH DRILL TO CLEAN THE LH FRAME RAIL
BOXED SECTION
a. Insert the wire brush (power tool) below the brake lines.

Be careful not to damage the brake lines when inserting
the wire brush

b.

Clamp the plastic handle to the frame rail using a C-Clamp to
avoid damage to the brake lines
NOTE:
Depending on the vehicle, you may need to add something
below the plastic handle (such as a piece of wood) if the
C-Clamp is not able to secure the plastic handle.

c.

With the drill direction set to clockwise, run the drill in and out of the box section frame to break free
rocks, dirt, and rust.

NOTE: The amount of time needed to run the brush will vary from frame to frame. The typical time will
be 5 to 10 minutes per side however it may take longer depending on how dirty the frame is and the
type of dirt/debris in the frame

Be careful not to damage the brake lines when removing the wire brush

d.

Install the cab mount frame plug
Plug Part Number: 90950-A1008

15

3.

4.

CLEAN BOTH FRONT CAB MOUNTS
a. If there is hardened dirt or other difficult to remove debris, use the
rubber mallet to hit the outside of the cab mount to break up the
debris
b. Using the 2ft Air Gun, blow out all the dirt and debris inside the
cab mount focusing on the inner corners.

CONFIRM CAB MOUNTS CLEANLINESS
a. Using the endoscope provided to your dealer in the J0M campaign, confirm the inside of the cab mount
is clean focusing on the inner corners
NOTE: The images below show the “minimum cleanliness” that the cab mounts can be. The
frame can be cleaner than the images below but cannot be less clean.
b.

If the cab mount is not clean enough, repeat steps 1-2 until clean

Inner Corner of the Cab Mount

5.

CLEAN THE OPEN SECTION OF THE FRAME (both LH and RH)
a. Clean the welds and area highlighted in the illustrations below using the wire brush (Hand Tool) show in
the illustrations below until no dirt, debris, or rust is present on the welds
NOTE: The cross member may not be present on short wheel base frames

FRONT

16

6.

REMOVE DIRT AND DEBRIS FROM FRAME
a. Using the 2ft Air Gun, blow out all the dirt and debris working from the front of the vehicle to the back
using the various plug holes. You may have to remove plugs from the frame to blow out all debris. Only
remove the plugs in the sections being cleaned.
NOTE: It will normally take 4 to 5 passes with the air gun to remove the all the debris from the
frame

NOTE:
Confirm no rocks or other debris are stuck in the channel shown below on the LH and RH side of the
frame

7.

REMOVE DUST AND DEBRIS FROM OPEN SECTION (LH AND RH SIDE)
a. Blow any dust, or debris that might be on the opens section shown below.
NOTE: The cross member may not be present on short wheel base frames
FRONT

17

8.

CONFIRM FRAME CLEANLINESS
a. Using the endoscope provided to your dealer in the J0M campaign, confirm the inside of the frame is
clean by inserting the endoscope into various plug holes
NOTE: The images below show the “minimum cleanliness” that the frame can be. The frame can
be cleaner than the images below but cannot be less clean.
b.

If the frame is not clean enough repeat the cleaning procedure until clean enough

The frame must be cleaned before applying the wax. If the frame is not completely clean
then the wax coating will not adhear to the frame properly

If the wire brush has worn down to the point of not being effective or you have an issue with
any other tool related to K0D contact Bosch Technical Assistance Line - 1-800-933-8335
(Option 4) for instructions on how to acquire replacement parts

18

WAX APPLICATION WORK PROCEDURE
A. CIRCUIT OF THE APPLICATION UNIT

19

1.

B. COMPONENTS OF THE APPLICATION UNIT
SYSTEM

Control Panel
1. Air inlet port
2. Air closing lever
3. Air pressure Gauge
4. Air regulator

3
1

Heater
Adjust Dial

Temperature
Gauge

4
2

120V power
supply cable

Sealer Gun
(Low Pressure)

Ground cable

Short/Long Wand Spray Gun
(High Pressure)

Wax pail

Suction pipe
Filter drain hose / lever

Inlet drain lever

2.

Inlet drain hose

SETTINGS

Pump Output
Pressure Gauge
14 MPa (2031 psi)

Back Pressure
9 MPa (1305 psi)

Adjust air regulator

Adjust black dial

High Pressure
12 MPa (1741 psi)

Adjust red dial

Sealer Pressure
0.5 - 4 MPa (73 - 580 psi)

Adjust red dial

20

1.

C. WAND SPECIFICATION
WAND
SHORT WAND

LONG WAND

2.

SEALER GUN
1. Simple tubular tip.
2. The amount of wax applied is judged visually.
WAND TIP
The tip of the short wand has 5 orifices to spray out wax.
The tip of the long wand has 6 orifices to spray out wax.

3.

WAND TOP MARK
The punch marks found on the wand tip side and gun side are the TOP marks.
Confirm that the TOP mark is facing upward at all time.
Tip Side (Tip & Wand)

Gun Side (Wand & Joint)

21

4.

INSTALLATION OF THE WAND TO THE GUN (SHORT & LONG WAND)
Connect the short or long wand to the gun by sliding in (Quick connector).
Adjust the wand connecting portion to set the TOP mark upward.
DO NOT use red shop towels or other lint products when handling the wands as they will
cause a clogged tip. Only use lint free towels when handling the wands

Direction for RH side

Direction for LH side

22

D. INITIAL SET UP
1.

PREPARE THE WAX PAIL
Press the center of the cap and remove.
Remove the plastic inner cap.
Open the lever and remove the lid.

Remove the strainer from the suction pipe and insert the
pipe into the cap hole of the lid.
Reinstall the strainer to the pipe and then reinstall the wax
lid to the can.
Be careful to NOT let the pipe, strainer
and lid contact foreign materials when
working and DO NOT allow any foreign
materials enter the wax pail.

2.

ADD THROAT SEALING LIQUID
a) A bottle of Throat Sealing Liquid (TSL) can be found on
attached near the wheel of the pump assembly. This
bottle will be used as part of maintenance of the pump.
Store the bottle in an accessible area.
b) Before pump operation fill the white colored TSL dish halfway with TSL fluid.
Contact Bosch Technical
Assistance line to order additional
TSL fluid.
Bosch Technical Assistance Line 1-800-933-8335 (Option 4)

3.

CHECK THROAT SEALING LIQUID LEVEL
a) Remove the TSL cover screw and remove the cover
b) Confirm the TSL dish is filled half way with TSL fluid
You will need to check the TSL level
every day, or if the pump has been
moved before pump operation.

4.

SYSTEM SET UP
Lock the triggers of the high pressure spray gun and sealer
gun.
Connect the short wand to the high pressure gun

23

Connect the ground cable.
DO NOT connect to vehicle ground.

Connect the shop air hose to the air inlet port.
Open the air closing lever.
Open the filter drain lever (yellow).
Turn the air regulator to adjust the air pressure to less than
0.07 MPa (10 psi) on the air pressure gauge.
Place a container under the filter drain hose and wait until
white wax continuously comes out.
Close the filter drain lever (yellow) once all the air is
removed.
Turn the inlet drain lever (black) to drain side (arrow to inlet
drain hose side) and place a container under the filter drain
hose and wait until white wax continuously comes out.
Close the inlet drain lever (black) once all air is removed by
turning the arrow back towards the inlet feed line.

Confirm the heater adjust dial is set to off
Connect the 120V power supply cable.
DO NOT turn the heater on until the
entire system is primed with wax and
free of air otherwise damage may
occur
Adjust the heater adjust dial to 6 to warm up the wax.
Confirm the green light turns on when heater adjust dial
first adjusted.
Note: It can take 30 minutes or more to bring the wax
up to temperature depending on room temperature.
Continue with the process while the wax heats up.

24

Turn the air regulator to adjust the pump output pressure to
14 MPa (2031 psi).
NEVER set the pressure to be over
14 MPa (2031 psi).
Turn the high pressure regulator (red dial) to adjust the
high pressure to 12 MPa (1741 psi).
NEVER set the pressure to be over
12 MPa (1741 psi).
Confirm the inlet drain lever (black) is pointing towards the
inlet feed hose.

Turn the back pressure regulator (black dial) to adjust the
back pressure to 9 MPa (1305 psi).

Turn the sealer pressure regulator (red dial) to adjust the
sealer pressure to 0.5 - 4 MPa (73 - 580 psi).
NOTE:
Adjust the pressure within the range to make it easy to
work with when applying wax.
Do Not set the pressure to be over
4 Mpa (580 psi)

Operate the sealer gun to drain wax.
Reference Value: 100 ml
Operate the high pressure spray gun to drain wax.
Reference Value: 100 ml

25

5.

SET UP CONFIRMATION
Confirm that the wax temperature is 40 ºC (104 ºF) on
temperature gauge.
NOTE:
If the wax temperature is not heated enough, please
wait for a couple of minutes. It may be necessary
to turn the dial to a higher level depending on air
temperature in the shop.
DO NOT warm up the wax temperature higher than
50 ºC (122 ºF).
If the wax has been overheated the system will need
to be flushed with new wax prior to application
If the system needs to be drained due
to overheating the wax you must drain
2L of wax from the inlet drain lever
(black)
Confirm pump cycle rate.
Standard Value: 7 – 10 times/min
NOTE:
If the pump cycle rate is faster or slower than the
standard value, turn the back pressure regulator to
adjust the rate within the range.
Confirm that the pump output pressure is 14 MPa (2031 psi).
If not, adjust the air regulator to meet 14 MPa (2031 psi).
NEVER set the pressure to be over
14 MPa (2031 psi).
Confirm that the high pressure is 12 MPa (1741 psi).
If not, adjust the high pressure regulator (red dial) to meet
12 MPa (1741 psi).
NEVER set the pressure to be over
12 MPa (1741 psi).
Confirm that the sealer pressure is 0.5 - 4 MPa
(73 - 580 psi).
NEVER set the pressure to be over
4 MPa (580 psi).

Check each line for wax leakage.
If there is any wax leakage, stop using the system immediately and contact the
following number for assistance:
Bosch Technical Assistance Line - 1-800-933-8335 (Option 4)

26

E. SETTINGS AFTER WORK
1.

SETTINGS AFTER WORK
Close the air closing lever.
Turn the heater adjust dial off.
Disconnect the shop air hose.
Disconnect the 120V power supply cable and ground
cable.
Cover the guns and wands with plastic wrap to protect
them from dust.
Close the lid of the wax pail securely and wrap the cover of
the pail with plastic wrap. Store the wax pail indoors
avoiding any heat source.
NOTE:
The wax can be used for 2 months once opened. After
that it must be replaced with new wax.

27

F. REMOVAL PARTS
Reference the appropriate repair manual on TIS for parts removal procedures.

28

G. MASKING AROUND WORK STALL
NOTE:
Depending on the shop layout, it may be necessary to put barriers to prevent accidental over spray
Masking on the floor is unnecessary. (if wax falls from the frame, clean the spill right away to avoid a
fall hazard)
1.

VEHICLE MASKING
NOTE:
In this work, masking needs to be done only partially as
the drips and scattering are few.
Using an infrared thermometer ensure the exhaust has
cooled.
Cover the holes from which wax can spill out using shop
cloths or the likes.

Protect each brake tube as the wand may hit them.
(LH Side Only)

29

2.

PLUG HOLES IN THE FRAME
Apply all the plugs other than the ones indicated with stars (★) on Hole Plugs Installation Check Sheet found
in appendix.
DO NOT install the plugs indicated with stars (★) until the wax application is completed. Those
plug holes will be used when inserting a wand to apply wax.
NOTE:
You may have to remove certain stickers to install optional equipment.
Some vehicles may not have plug holes or may have plugs already installed depending on the
vehicle specification or model year.
Make sure all the plugs are flush with the frame.
Make sure the surface of the frame is clean before you apply stickers.
Apply masking tape to the holes shown in the illustration from which wax can spill out.
NOTE:
The masking tape has to be applied on both LH and RH side of the frame even when the illustrations
show only one side.

30

H. APPLY WAX WITH SHORT WAND

Before starting this process, review the SCK0D E-Learning Spray
Application section for key details
1.

PREPARE FOR WAX APPLICATION
CHECK THE REMAINING WAX AMOUNT