Bosch DCI 700 Setup guide

Common-rail injector test bench
DCI 700
en Repair instructions Common-rail injector test bench

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1 User instructions............................................................................................................................................ 4
1.1 Symbols used in the documentation............................................................................................................... 4
1.2 Warnings in the documentation...................................................................................................................... 4
1.3 Target group.................................................................................................................................................... 4
1.4 Safety instructions.......................................................................................................................................... 4
1.5 Other applicable documents........................................................................................................................... 4
1.6 Opening the DCI 700 Help Center................................................................................................................... 5
1.7 Tools and aids needed..................................................................................................................................... 5
1.8 Protective clothing and equipment................................................................................................................. 5
1.9 Cleanliness requirements................................................................................................................................ 5
1.10 Disposal........................................................................................................................................................... 6
1.10.1 Substances hazardous to water....................................................................................................................... 6
2 Variant overview............................................................................................................................................. 6
2.1 Voltage variants............................................................................................................................................... 6
2.2 Software and rmware versions...................................................................................................................... 6
3 Overview of DCI 700...................................................................................................................................... 6
3.1 Component overview.................................................................................................................................... 11
3.1.1 Installation panel........................................................................................................................................... 11
3.1.2 electronic control.......................................................................................................................................... 12
3.1.3 Measurement block return A-B...................................................................................................................... 14
3.1.4 Measurement block return C-D..................................................................................................................... 15
3.1.5 Measurement block for injection................................................................................................................... 15
3.1.6 Processor unit............................................................................................................................................... 16
3.1.7 Swivel mechanism......................................................................................................................................... 17
3.1.8 High-pressure unit......................................................................................................................................... 18
3.1.9 High-pressure rail.......................................................................................................................................... 18
4 Modes........................................................................................................................................................... 19
4.1 Safety shutdown............................................................................................................................................ 19
5 Repair........................................................................................................................................................... 19
5.1 Changing the high-pressure pump................................................................................................................ 19
5.1.1 Preparation.................................................................................................................................................... 19
5.1.2 Removing the cover for motor compartment and electrical compartment.................................................... 20
5.1.3 Removing the protective doors...................................................................................................................... 20
5.1.4 Removing the pump plate.............................................................................................................................. 21
5.1.5 Removing the high-pressure pump................................................................................................................ 23
5.1.6 Assembling the high-pressure pump............................................................................................................. 24
5.1.7 Attaching the pump plate.............................................................................................................................. 25
5.1.8 Installing the protective doors....................................................................................................................... 27
5.1.9 Leak tightness test........................................................................................................................................ 27
5.1.10 Installing the cover for the motor compartment and electrical compartment.............................................. 28
5.2 Replacing the ow meter............................................................................................................................... 28
5.2.1 Preparation.................................................................................................................................................... 28
5.2.2 Removing the cover from the hydraulics compartment................................................................................. 29
5.2.3 Removing the upper cover from the hydraulics compartment...................................................................... 29
5.2.4 Removing the ow meter............................................................................................................................... 30
5.2.5 Installing the ow meter................................................................................................................................ 32
5.2.6 Entering the calibration values...................................................................................................................... 34
5.2.7 Final steps..................................................................................................................................................... 36
5.2.8 Installing the cover on the hydraulics compartment..................................................................................... 36
5.2.9 Installing the cover on the hydraulics compartment..................................................................................... 37
5.3 Changing the frequency converter................................................................................................................ 37
5.3.1 Preparation.................................................................................................................................................... 37
5.3.2 Removing the cover for motor compartment and electrical compartment.................................................... 38
5.3.3 Removing the mounting panel....................................................................................................................... 38
5.3.4 Removing frequency converter A1................................................................................................................. 40
5.3.5 Installing frequency converter A1.................................................................................................................. 40
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5.3.6 Installing the mounting panel........................................................................................................................ 42
5.3.7 Installing the cover for the motor compartment and electrical compartment.............................................. 44
5.3.8 Final steps..................................................................................................................................................... 44
5.4 Changing circuit board A3............................................................................................................................. 44
5.4.1 Preparation.................................................................................................................................................... 44
5.4.2 Removing the cover from the electronics compartment............................................................................... 45
5.4.3 Removing the cover from the hydraulics compartment................................................................................. 45
5.4.4 Removing the upper cover from the hydraulics compartment...................................................................... 46
5.4.5 Removing circuit board A3............................................................................................................................ 47
5.4.6 Installing circuit board A3.............................................................................................................................. 49
5.4.7 Installing the cover on the hydraulics compartment..................................................................................... 51
5.4.8 Installing the cover on the hydraulics compartment..................................................................................... 52
5.4.9 Installing the cover on the electronics compartment.................................................................................... 52
5.4.10 Final steps..................................................................................................................................................... 53
6 Calibrating components............................................................................................................................... 53
6.1 Calibrating the rail sensor B80...................................................................................................................... 53
7 Troubleshooting............................................................................................................................................ 55
7.1 After the DCI 700 is switched on the screeen remains dark and the operating display does not light up on
the monitor.................................................................................................................................................... 55
7.2 Touchscreen not responding......................................................................................................................... 55
7.3 The message "Disconnected" is displayed in the "DDM" software................................................................ 55
7.4 After the injector has been removed, a large amount of test oil emerges from the injection chamber......... 55
7.5 Test oil emerges at the knurled nut on the injection chamber during the test............................................. 55
7.6 The values for the amount of test oil are too high when injectors are tested............................................... 55
7.7 The values for the amount of test oil are too low when injectors are tested................................................ 55
7.8 No amounts of test oil are measured when injectors are tested................................................................... 55
8 Software and rmware................................................................................................................................. 56
8.1 System recovery............................................................................................................................................ 56
8.2 Updating "DCI" software............................................................................................................................... 57
8.3 Updating the rmware................................................................................................................................... 57
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1. User instructions
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1.1 Symbols used in the documentation
Warning of possible physical damage to the
component or product or of environmental
pollution.
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Practical hints, recommendation or reference
to other information.
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Warning of danger for the operator during
subsequent procedures.
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Single-step procedure.
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Optional step.
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Result of a procedure.
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Reference to a gure. Example: 12(2)
means gure 12, item 2.
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Reference to a page.
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1.2 Warnings in the documentation
Warning notices warn of dangers to the user or people in the vicinity. Warnings also indicate the type, source and
consequences of the danger as well as preventive action.
Warning notices have the following structure:
Signal word
Warning symbol Type, source and consequences of the danger.
Actions and instructions to prevent the danger.
The signal word indicates the likelihood of occurrence and the severity of the danger in the event of non-observ‐
ance:
Signal word Likelihood of occurrence Severity of danger with non-observance
DANGER Immediate threat of danger Death or severe injury
WARNING Possible impending danger Death or severe injury
CAUTION Possible dangerous situation Minor injury
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1.3 Target group
Repair of the DCI 700 may only be performed by service technicians.
Service technicians must be trained and certied by Robert Bosch GmbH or its regional representatives / subsidia‐
ries. If a service technician is already certied, he may train other employees in the organization authorized by Rob‐
ert Bosch GmbH in servicing the DCI 700
For specic work, the service technician needs the following additional qualications (country-specic):
Electrotechnical knowledge for working on electrotechnical systems and equipment (see accident prevention regu‐
lation for electrical systems and equipment, e. g. DGUV V3 in Germany)
All warranty claims (personal injury, faulty equipment) are rendered null and void if the DCI 700 is opened or modi‐
ed by unauthorized individuals.
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1.4 Safety instructions
All the pertinent safety instructions can be found in the separate manual for DCI 700". These instructions
must be carefully studied prior to start-up, connection and operation of the DCI 700 and must always be ob‐
served.
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1.5 Other applicable documents
•1 689 989 343 – DCI 700 original instructions
•1 689 978 630 – DCI 700 installation instructions
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• 1 689 979 860 – Important information and safety instructions for Bosch Diesel Test Equipment
• Service information 200108_084 – Information regarding DGUV regulation 3 for electrical systems and equipment
• DCI 700 Help Center
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1.6 Opening the DCI 700 Help Center
1. In the "DCI" software, select <?>.
2. Select the "Help Center" tab.
The link takes you to the DCI 700 Help Center: http://cdn.esitronic.de/helpcenter/DCI700/start.html
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1.7 Tools and aids needed
•General tools for mechanics and electricians
•60 mm wrench
•Torque wrench with range of 10 – 50 Nm
•Torque wrench with range of 4 – 18 Nm
•PC/laptop
•Multimeter
•Reference pressure sensor 1 681 032 095
•Adapter nut 1 683 345 064 (M16 – M20)
• Adapter nut 1 683 345 070 (M16 – M18)
•Adapter 1 681 398 035 (M16 – M16)
•USB stick
• Mounting device 0 986 617 285 for adjusting the drive coupling
• Mounting device 1 687 012 187 for installing and removing the drive motor
• 2x Rectangular wooden strips (59 x 5 x 350 mm) for removing the mounting panel
•Test oil collecting container (with no leaks)
• Round rod Ø10 x 150 mm
• Threadlocker, e.g. Loctite 243
• Datalogic D9530-HP hand scanner. The Datalogic D9530-HP hand scanner is also used for Bosch QualityScan.
• USB extension cable (3 m) 1 684 465 565
•Cloths for catching and wiping up test oil
• Lint-free paper towels
• Cleaned containers with a cover. The containers are needed to hold the components removed during repair and
prevent their contamination.
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1.8 Protective clothing and equipment
• Protective gloves
•Safety goggles
• Safety shoes
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1.9 Cleanliness requirements
Exceptional cleanliness is required during repair and as soon as the measuring circuit or high-pressure circuit has
been opened. The smallest particles can damage the tester and test specimen. To prevent this, the following meas‐
ures must be implemented and observed when performing repairs.
•Always perform repairs in a clean environment with clean air.
•When performing repairs, make sure no other work is in progress which could emit particles into the air. If the
requirements cannot be met, perform repairs at a clean workspace with an extraction device.
•Clean up the workplace before performing repairs.
•Clean the workplace and tools with lint-free paper towels.
•Always keep and transport the components removed in clean containers with a cover.
•Do not leave measurement blocks and ow meters open.
•Do not blow out the measuring circuit and high-pressure circuit with compressed air.
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1.10 Disposal
1.10.1 Substances hazardous to water
Substances hazardous to water must be disposed of in accordance with the applicable regulations.
Oil, grease and refuse containing oil or grease (e.g. lters) are hazardous to water and the environment. Sub‐
stances hazardous to water must not be allowed to enter the sewage system.
Test oil as per ISO 4113 is classied under waste oil collection category 1. Category 1 waste oil must not
contain any foreign substances such as waste oils of a different category, gasoline or diesel. See the test oil
safety data sheet for the correct waste code number.
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2. Variant overview
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2.1 Voltage variants
Tester Rated voltage
0 683 725 001 380 – 480 V
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2.2 Software and rmware versions
For the software and rmware versions, see EDIS under "Overview lists >> Software version >> Overview of all
software versions".
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3. Overview of DCI 700
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 1: Front view of DCI 700
(1) Protective door with handle
(2) Rail for protective door
(3) Cover for electronics compartment
(4) Cover for motor compartment and electrical compartment
(5) Human Machine Interface
(6) Main switch
(7) Locking knob for keyboard shelf
(8) Height-adjustable feet
(9) Cover for transformer compartment
(10) Keyboard shelf
(11) Replacement date for protective cover
(12) Front cover of test oil area
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 2: Rear view of DCI 700
(1) Cover for heat exchanger compartment and test oil area
(2) Hydraulics compartment cover
AB
CD
ABCD
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 3: Test area
(1) Storage tray
(2) Storage compartment with holders for the accessories
(3) Injection chamber device
(4) Swivel fixture with high-pressure rail
(5) Locking handle for swivel fixture
(6) Scale plate
(7) Switch box for door monitoring
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AB
CD
ABCD
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 4: Ports
(1) Return test connection for injectors A and B
(2) Injector A actuation port
(3) Injector B actuation port
(4) Injection test connection for injectors A, B, C and D
(5) Return test connection for injectors C and D
(6) Injector C actuation port
(7) Injector D actuation port
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 5: Test oil area opened
(1) Drain cock for test oil in the test area
(2) Wing screw for fastening the test oil tank
(3) Handle for the test oil tank
(4) Drain cock of the test oil tank
(5) Test oil tank
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45 884 6-23_ko
max.
max.
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 6: Test oil tank pulled out
(1) Filling level indicator for minimum quantity (min.)
(2) Filling level indicator for maximum quantity (max.)
(3) Fastening screw for the test oil tank cap
(4) Test oil tank cap
(5) Test oil filter
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 7: Motor compartment and electronics compartment open
(1) Front cover of electronic control
(2) Drive motor
(3) Counterweight
(4) Electrical cabinet
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 8: Back of DCI 700
(1) Rear cover of electronic control
(2) Measurement block return channels C and D
(3) Measurement block for injection
(4) Measurement block return channels A and B
(5) Heat exchanger
(6) Test oil tank
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3.1 Component overview
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3.1.1 Installation panel
T2 A1/A6
G1
64
5SL2
F2
Q2 Q3
SL3
F1
2
1 3
SL1
SL4
7 9
SL5
8 10
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 9: Overview of mounting panel
(1) Line transformer T2 – Voltage supply for processor unit and monitor
(2) Circuit breaker F2 – Primary-side protection for line transformer T2
(3) Fuse F3 (fuse rating = 1 AT) – Secondary-side protection
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(4) Frequency converter A1
(5) Power supply unit G1 – 24 V voltage supply for circuit board A2
(6) Circuit breaker F1 – Main protection, 16 A (200 V version only)
(7) Contactor Q2 – Main contactor
(8) Contactor Q3 – Intermittent contactor for test oil heater E1 – E3
(9) Circuit board A6 – RS485 serial communication interface to circuit board A3
(10) USB port – Interface for "ConverterWorks" software
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3.1.2 electronic control
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 10: Overview of electronic control
(1) Circuit board 1 688 400 577 (A3) – Sensor circuit board
(2) Circuit board 1 688 400 545 (A4) – CPU circuit board
(3) Circuit board 1 688 400 593 (A2) – Power circuit board
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 11: Circuit board A3 connections
(1) Port X105 (RJ45) – Not used
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(2) Port X101 (RJ45) – Communication to frequency converter A1
(3) USB port X103 – Communication to processor unit
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1 2 3 4 5 6 7 8 9 10111213141516
 12: LED overview
(1) V49 – P3V3_F
(2) V37 – P5V
(3) V36 – P5V_A1
(4) V96 – P6V5
(5) V101 – P14V
(6) V158 – DG 4
(7) V157 – DG 3
(8) V82 – DG 2
(9) V74 – DG 1
(10) V282 – Door 1
(11) V330 – Door 2
(12) V442 – P5V_A21
(13) V395 – P5V_A2
(14) V279 – P15V
(15) V278 – P24V_LN
(16) V277 – P24V
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Q18 Q17 Q16 Q15 Q19
X314 Q14 Q13 Q12 Q11
Q20
X312 X315 X313 X311
12345678 9 10
 13: Relay overview
(1) Relay Q18 – Switches off electrical measurement of injector D
(2) Relay Q17 – Switchover of electrical measurement, energizing of injectors B and D
(3) Relay Q16 – Switchover of electrical measurement, energizing of injectors B and D
(4) Relay Q15 – Switches off electrical measurement of injector B
(5) Relay Q19 – Activation of electrical measurement, energizing of injectors A to D
(6) Relay Q20 – Switchover from insulation test to actuator test (for piezo)
(7) Relay Q14 – Switches off electrical measurement of injector C
(8) Relay Q13 – Switchover of electrical measurement, energizing of injectors A and C
(9) Relay Q12 – Switchover of electrical measurement, energizing of injectors A and C
(10) Relay Q11 – Switches off electrical measurement of injector A
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3.1.3 Measurement block return A-B
B24 B23
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 14: Measurement block return channels A and B
(1) Pressure control valve K14
(2) Temperature sensor B54
(3) Flow meter T24 for channel D
(4) Flow meter T23 for channel C
(5) Temperature sensor B53
(6) Pressure control valve K13
(7) Pressure sensor B23
(8) Inlet filter, channel A
(9) Inlet filter, channel B
(10) Pressure sensor B24
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3.1.4 Measurement block return C-D
B22 B21
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 15: Measurement block return channels C and D
(1) Pressure control valve K12
(2) Temperature sensor B52
(3) Flow meter T22 for channel D
(4) Flow meter T21 for channel C
(5) Temperature sensor B51
(6) Pressure control valve K11
(7) Pressure sensor B21
(8) Inlet filter, channel C
(9) Inlet filter, channel D
(10) Pressure sensor B22
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3.1.5 Measurement block for injection
B44 B43 B42 B41
T14 T13 T12 T11
B14 B13 B12 B11
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 16: Measurement block for injection
(1) Temperature sensor B44
(2) Flow meter T14 for channel D
(3) Temperature sensor B43
(4) Flow meter T13 for channel C
(5) Temperature sensor B42
(6) Flow meter T12 for channel B
(7) Temperature sensor B41
(8) Flow meter T11 for channel A
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(9) Pressure sensor B11
(10) Inlet filter, channel A
(11) Pressure sensor B12
(12) Inlet filter, channel B
(13) Pressure sensor B13
(14) Inlet filter, channel C
(15) Pressure sensor B14
(16) Inlet filter, channel D
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3.1.6 Processor unit
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 17: Overview of processor unit
(1) Power supply unit G2 – 15 V voltage supply for power supply unit for motherboard A8
(2) Motherboard A3
(3) Slot bracket A11– Expansion with 4x USB 2.0 ports
(4) Fan
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PS2
Mouse
HDMI1
PS2
Keybo.
COM Port1
COM Port2
COM Port3
VGA1
RJ-45
USB 2.0
USB1
USB0
RJ-45
USB 3.0
USB1
USB0
Line
Out
Mic.In
SATA1SATA2
LVDS1
ATX12V1
COM4
COM6
BLT_PWR1
Battery
USB2_3
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 18: Connections and jumper settings for motherboard A3
(1) RAM memory module
(2) Connection 1 for slot bracket A11
(3) Power supply connection
(4) Fan connection
(5) Connection 2 for slot bracket A11
(6) mSATA flash module
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3.1.7 Swivel mechanism
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 19: Swivel mechanism
(1) Swivel bearing
(2) Swivel fixture
(3) Frame
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3.1.8 High-pressure unit
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 20: High-pressure unit with drive
(1) High-pressure rail
(2) Pressure lines
(3) High-pressure pump
(4) Drive flange
(5) Drive coupling
(6) Drive motor
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3.1.9 High-pressure rail
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 21: High-pressure rail
(1) Pressure-control valve K20 – Safety element
(2) High-pressure connection, position "A", with blind plug
(3) Hose fitting for return quantity – Return to heat exchanger
(4) Port for additional sensors and components
(5) Pressure limiter, max. 280 MPa
(6) Rail pressure sensor – Pressure measurement in the rail
(7) Pressure-control valve K30 – Pressure control in the rail
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 22: High-pressure rail components
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 23: Tightening torques
(1) Initial tightening 70 Nm; loosen 90°, second tightening 85 +5 Nm
(2) 110 +5 Nm
(3) 135 +5 Nm
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 24: Tightening torque for pressure line
(1) 60 +5 Nm
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4. Modes
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4.1 Safety shutdown
The safety shutdown protects the DCI 700 from overheating and is activated in the following situations:
•Float switch B1 in the test oil tank has been actuated, e.g. in response to insu󹓜cient test oil in the test oil tank.
•Temperature switch B3 has been actuated at > 70 °C, e.g. in response to excessively high test oil temperature.
Resetting of the temperature switch takes place at < 55 °C.
• Temperature safeties B5, B6 or B7 in the heater have tripped, e.g. in response to lack of test oil in the test oil
tank.
Consequences
As soon as one of the above-mentioned safeties trips, the contactors Q2 and Q3 open. Contactors Q2 and Q3 are
no longer actuated, with the following consequences:
•Power is disconnected from the frequency converter A1 => Drive motor comes to a stop.
•The test oil heaters E1 – E3 are switched off => Test oil tempering ends.
•A fault message is displayed.
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5. Repair
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5.1 Changing the high-pressure pump
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5.1.1 Preparation
1. Close all applications and shut down the operating system.
2. Disconnect the DCI 700 at the main switch and secure against reactivation.
3. Unplug the mains plug or disconnect from mains electricity.
4. Remove attached injectors from the high-pressure rail. The swivel xture with the high-pressure rail must swivel
freely.
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5.1.2 Removing the cover for motor compartment and electrical compartment
1. Close the protective door.
2. Using a square box wrench, open both electrical cabinet locks (1 and 3). The square box wrench is included in
the scope of delivery of the DCI 700.
3. Lift cover (2), pull to the right and remove.
— If necessary, remove the protective conductor on the inside of the cover.
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 25: Removing the cover
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5.1.3 Removing the protective doors
Voraussetzungen:
Before removing the protective door, disconnect the DCI 700 at the main switch (4) and secure against reactiva‐
tion.
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1. Open the protective door (3). The door contact (2) for the safety switch must be located outside the switch box
for door monitoring (1).
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 26: Preparing to replace the protective cover
2. With the aid of another person, lift and remove the protective door.
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