Bosch DCI 700 User manual

Common-rail injector test bench
DCI 700
en Original instructions Common-rail injector test bench
es Manual original Banco de ensayo de inyectores Common Rail
fr Notice originale Banc d'essai d'injecteurs Common Rail
ja 取扱説明書原本の翻訳 コモンレールインジェクターテストベンチ
no Original driftsinstruks Common Rail-injektortestbenk
pt Manual original Banco de teste de injetores Common Rail
zh 原版操作说明书的译文 共轨喷油器试验台

1 689 989 473 | 2021-08-24 Robert Bosch GmbH
1 Notes on the documentation... ...................... 3
1.1 Using the documentation... ............................. 3
1.2 Symbols used in the documentation... ........... 3
1.3 Warnings in the documentation... ................... 3
1.3.1 Meaning of the the signal words... .................. 3
1.3.2 Structure of warnings specic to sections... ... 3
1.3.3 Structure of embedded warnings... ................ 3
2 Safety... .......................................................... 3
2.1 IMPORTANT SAFETY INFORMATION... ............. 3
2.2 Warnings and mandatory-action signs on the
product... ........................................................ 4
2.3 Target group... ................................................. 4
2.4 Other applicable documents... ........................ 4
2.5 Intended use... ................................................ 4
2.6 Foreseeable misuse... ..................................... 5
2.7 Warranty and liability... ................................... 5
2.8 Protective clothing and equipment... .............. 5
3 Product description... .................................... 5
3.1 Scope of delivery... ......................................... 5
3.2 Optional accessories... .................................... 5
3.3 Prerequisites... ................................................ 6
3.4 Symbols on the product... ............................... 6
3.5 Symbols on the rating plate... ......................... 6
3.6 Denition of terms... ....................................... 6
3.7 Overview of DCI 700... .................................... 6
3.8 Component description... ............................... 8
3.8.1 Human Machine Interface... ............................ 8
3.8.2 Computer unit... .............................................. 9
3.8.3 Swivel xture with high-pressure rail... ........... 9
3.8.4 High-pressure rail... ......................................... 9
3.8.5 Injection chamber... ...................................... 10
3.8.6 Connection adaptations for injector return... 11
3.8.7 Adapter cables... ........................................... 11
3.9 Functional description... ............................... 12
3.9.1 Test... ............................................................ 12
3.9.2 Test oil supply... ............................................ 12
3.9.3 Flow measuring... .......................................... 12
3.9.4 Test oil conditioning... ................................... 12
3.9.5 Test oil cooling... ........................................... 12
4 Operation... .................................................. 12
4.1 Switch on DCI 700... ..................................... 12
4.2 Switch off DCI 700... ..................................... 13
4.3 Stopping the DCI 700 in the event of a prob‐
lem... ............................................................. 13
4.4 Testing injectors... ......................................... 13
4.5 Updating "DCI" software... ............................ 13
4.6 Opening the DCI 700 Help Center... ............. 13
4.7 Adjust the height of the HMI... ...................... 13
4.8 System recovery... ......................................... 13
5 Maintenance... .............................................. 15
5.1 Cleaning... ..................................................... 15
5.2 Maintenance... ............................................... 15
5.2.1 Maintenance intervals... ................................ 15
5.2.2 Changing test oil... ........................................ 16
5.2.3 Changing the test oil lter... .......................... 19
5.2.4 Changing the test oil lter in the inlet lter... ....
....................................................................... 20
5.2.5 Changing the protective cover... ................... 23
5.3 Checking the measuring accuracy... ............. 24
5.4 Spare and wearing parts... ............................ 24
5.5 Faults... ......................................................... 24
5.5.1 Problems performing functions... ................. 24
6 Decommissioning... ...................................... 25
6.1 Changing location... ...................................... 25
6.2 Provisional shutdown... ................................. 25
6.3 Disposal... ..................................................... 26
6.3.1 Re-use and disposal of the DCI 700 ... .......... 26
6.3.2 Substances hazardous to water... ................. 26
7 Technical data... ........................................... 26
7.1 DCI 700 specications... ............................... 26
7.2 Intended operating conditions... ................... 26
7.2.1 Location... ..................................................... 26
7.2.2 Ambient temperature... ................................. 26
7.2.3 Humidity... ..................................................... 26
7.2.4 Air pressure... ................................................ 26
7.3 Dimensions and clearances... ....................... 26
7.4 Test oil conforming to ISO 4113-CV-AW... ..... 27
7.5 Sound power level... ..................................... 27
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1. Notes on the documenta‐
tion
---
1.1 Using the documentation
Before commissioning, connecting and using Bosch
products, it is essential to go through the operating in‐
structions and safety instructions. By doing so, you can
eliminate any uncertainties in handling Bosch products
and associated safety risks upfront, which is in the in‐
terest of your own safety and will help avoid damage to
the products.
Always keep these original operating instructions with
the safety instructions and the other documents sup‐
plied at hand.
These original instructions describe the common-rail
injector test bench DCI 700.
The "DCI" software and how to connect and test
injectors is described in the DCI 700 Help Center.
Initial commissioning of the DCI 700 is described
in the installation instructions 1. 689 978 630.
---
1.2 Symbols used in the documentation
Warning of possible physical damage to the
component or product or of environmental
pollution.
---
Practical hints, recommendation or reference
to other information.
---
Warning of danger for the user during subse‐
quent procedures.
---
Single-step procedure.
---
Optional step.
---
Result of a procedure.
---
Reference to a gure. Example: 12(2)
means gure 12, position 2.
---
Reference to a page.
---
1.3 Warnings in the documentation
---
1.3.1 Meaning of the the signal words
Warnings warn of dangers to the user or people in the
vicinity. The signal word in the warning indicates the
likelihood of occurrence and the severity of the danger
if it is disregarded.
Signal word Likelihood of occur‐
rence Severity of danger if disregarded
DANGER Immediate, imminent
danger
Death or severe injury
WARNING Possible impending
danger
Death or severe injury
CAUTION Possible dangerous sit‐
uation
Minor injury
---
1.3.2 Structure of warnings specic to sections
Warnings specic to sections refer to several steps
within a dangerous sequence of actions. Warnings spe‐
cic to sections are placed before a dangerous se‐
quence of actions.
Signal word
Warning
sign Type, source and consequences of the danger.
Measures and instructions to prevent the
danger.
---
1.3.3 Structure of embedded warnings
Embedded warnings refer to an individual dangerous
step. Embedded warnings are placed before a danger‐
ous step. The remedies are embedded in the sequence
of actions.
SIGNAL WORD – type and source of danger. Possi‐
ble consequence if disregarded.
---
2. Safety
---
2.1 IMPORTANT SAFETY INFORMATION
BEFORE OPERATING THE DCI 700, READ ALL SAFETY
INSTRUCTIONS. ALWAYS KEEP THE OPERATING IN-
STRUCTIONS WITHIN EASY REACH.
Hazard source operating behavior
Risk of burns – The high test pressures generate high
temperatures on parts, operating materials and compo‐
nents and can lead to personal injury.
Wear protective gloves.
Allow parts and components to cool down before
touching them.
---
Malfunctions – Malfunctions in the operating behavior
can lead to personal injury.
Before using DCI 700, read the original operating in‐
structions and the safety instructions carefully.
Only use accessories approved by Bosch.
In case of damage to the DCI 700 or to electrical lines,
do not commission the DCI 700.
DCI 700 Operate in accordance with the electrotech‐
nical rules.
DCI 700 Only operate if all protective devices,
e.g. protective covers, are tted and safety-related de‐
vices, e.g. extraction devices, are present and func‐
tional.
If the operating behavior changes, shut down the
DCI 700 immediately and eliminate the fault.
DCI 700 Do not operate unattended.
---
Hazard source test oil
Risk of deagration and explosion – ignition of test oil
or test oil vapors can cause personal injury.
Ensure proper on-site ventilation and venting of the
work area.
Avoid open ames or sources of sparks in the work
area. Do not smoke.
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Only use test oil complying with ISO 4113-CV-AW. Do
not use or add substances such as diesel fuel or gaso‐
line.
Change the test oil according to the maintenance in‐
structions.
---
Irritants – Test oil and test oil vapors may cause irrita‐
tion to eyes, skin and respiratory tract.
Wear protective equipment.
Ensure proper on-site ventilation and venting of the
work area.
Do not inhale test oil vapors.
Do not swallow test oil.
Do not carry oily rags in your clothes. Remove oily
clothing.
Clean skin contaminated with oil thoroughly with wa‐
ter and skin-friendly detergent or soap.
---
Risk of injury – Leakage can cause test oil to escape at
high pressure and temperature and may result in per‐
sonal injury.
Wear protective equipment.
DCI 700 Use only with complete and functional safety
equipment.
Never reach into the escaping test oil jet.
In case of leakage, switch off DCI 700 and wait until
the test oil pressure has decreased. Then eliminate
the leakage.
---
Risk of injury – If there is oil or oil residue on the oor,
there is a risk of accidents and personal injury.
Remove oil and oil residue on the oor immediately.
In case of leakage, switch off DCI 700 and wait until
the test oil pressure has decreased. Then eliminate
the leakage.
---
2.2 Warnings and mandatory-action signs
on the product
All warning signs must be in legible condition.
Read and understand the operating instruc‐
tions before working with the DCI 700.
---
Wear safety goggles when working on the
DCI 700.
---
Wear protective gloves when working on the
DCI 700.
---
Warning – Hot surfaces. Do not touch hot
surfaces.
---
Access prohibited for persons with pacemak‐
ers or implanted debrillators.
---
Before entering, switch off DCI 700 and dis‐
connect mains plug.
---
2.3 Target group
The product may only be used by trained and instruc‐
ted personnel. Apprentices or personnel undergoing
training or instruction may use the product only under
the continual supervision of an experienced person.
Children must be supervised to ensure that they do not
play with the product.
Work on electrical systems or equipment must only be
performed by qualied electricians or trained person‐
nel under the guidance and supervision of an electri‐
cian.
Only personnel with su󹓜cient knowledge and experi‐
ence in hydraulics is allowed to work on hydraulic devi‐
ces.
Instruction on testing diesel components at a Bosch
training center is mandatory.
---
2.4 Other applicable documents
•1 689 978 630 – assembly instructions DCI 700
•DCI 700 Help Center – online help for DCI 700. Call is
made in the software "DCI" via the button <?>.
---
2.5 Intended use
The common-rail injector test bench DCI 700 (also
called DCI 700) Is used to test the majority of common
rail injectors manufactured by Bosch, Delphi, Denso
und Siemens/VDO/Continental.
Injectors must be tested and measured in accordance
with the instructions. Approved accessories must be
used for adaptation.
The following injectors may be tested with the specially
designed connectors:
•Bosch CRI 1x and CRI 2x
• Bosch CRI piezo (CRI 3x)
• Bosch CRIN with CRI connection features
• Bosch CRIN 1x, CRIN 2x and CRIN 3x (special acces‐
sories required)
• Bosch CRIN 4x (special accessories required)
• Delphi DFI, Denso Gx and Siemens/VDO/Continental
PCR-I (special accessories required)
The DCI 700 is only intended for commercial and not
for private purposes.
Warning! This product may cause high-frequency inter‐
ference in residential environments so that interference
suppression may be necessary.
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2.6 Foreseeable misuse
Misuse ( ) with corresponding intended use ( ):
Use of diesel fuel and instead of test oil.
Only use test oil complying with ISO 4113-CV-AW.
---Separator---
Failure to observe maintenance intervals.
Perform maintenance according to the specied
maintenance intervals.
---Separator---
Use of manually created test sequences with incor‐
rect parameters.
Only use the test sequences specied by Bosch.
---Separator---
Setting incorrect calibration values.
Enter correct calibration values.
---Separator---
Use outside the allowed ambient conditions.
Use the DCI 700 only under the allowed ambient
conditions.
---Separator---
Testing of damaged injectors or injectors that have
not been cleaned.
Prior to clamping, test and clean the injectors as
specied.
---Separator---
2.7 Warranty and liability
The use of unapproved hardware and software will re‐
sult in a modication of our products and thus to the
exclusion of any liability or warranty, even if such hard‐
ware and software have been removed or deleted again
in the interim.
No modications may be carried out on our products.
Our products may only be used with genuine accesso‐
ries and genuine spare parts. Otherwise, all warranty
claims will be rendered null and void.
This product may only be operated using operating sys‐
tems approved by Bosch. If the product is operated
with an operating system other than the one approved,
then the warranty obligation expires in accordance with
our terms of delivery. Furthermore, no liability can be
assumed for damages and consequential damages that
have their cause in the use of an operating system that
has not been released.
---
2.8 Protective clothing and equipment
•Safety goggles
•Safety shoes
•Protective gloves
When working on the DCI 700, always wear your per‐
sonal protective clothing and equipment.
---
3. Product description
---
3.1 Scope of delivery
Denomination Order number
DCI 700 -
1x parts set with monitor, mounting and key‐
board shelf
1 685 200 173
Denomination Order number
1x cable gland for cable diameters of 13 to
18 mm
1 683 391 564
1x adapter nut for cable gland 1 680 365 012
1x parts set with 4 injector chamber devices 1 687 016 196
4x knurled nut D7 1 683 373 087
4x O-ring insert D7 without O-rings 1 680 109 141
40x O-ring 12 x 2 mm for O-ring insert D7 and
D9
1 680 210 123
40x O-ring 7 x 4 mm for O-ring insert D7 1 680 210 124
40x O-ring 9 x 3 mm for O-ring insert D9 1 680 210 132
4x hose assembly for the injected-fuel quanti‐
ty
1 687 410 056
4x hose assembly for the return quantity 1 680 712 382
4x return adapter for Bosch CRI 1 687 016 215
4x return adapter hose assembly for Bosch
CRI 2.18 and CRI 2.20
1 683 351 066
4x return adapter hose assembly for Bosch
CRI 3
1 680 712 315
4x adapter nut M14x1.5 1 683 345 066
2x storage tray 1 685 520 631
1x drain hose for emptying the heat exchanger 1 680 712 392
1x square box wrench 1 681 982 011
4x adapter cable for Bosch CRI 1, CRI 2x and
CRI 3x
1 684 465 900
4x adapter cable for Bosch CRI 3-25 and
CRI 3-27
1 684 465 895
1x protective hose yellow (450 mm) -
1x recovery USB stick 1 688 400 654
1x original instructions 1 689 989 473
1x installation instructions 1 689 978 630
---
The order numbers are not part numbers. The or‐
der numbers are used to identify the items inclu‐
ded in the scope of delivery. Components that
can be ordered are identied as spare parts or
wearing parts.
---
3.2 Optional accessories
•1 687 010 607: accessory set for testing Bosch com‐
mercial-vehicle common-rail injectors (CRIN 1x, CRIN
2x, CRIN 3x)
•1 687 010 608: accessory set for testing Bosch com‐
mercial-vehicle common-rail injectors (CRIN 4.2)
•1 687 010 609: accessory set for common-rail injec‐
tors from third-party manufacturers (Delphi DFI, Den‐
so Gx and Siemens/VDO/Continental PCR-I)
•1 685 200 178: holding device for hand scanner
More information: Website of Bosch Automotive
Service Solutions for conguring your test and re‐
pair equipment: https://component-test.bosch-au-
tomotive.com/en/en/sharedActions/countrySelec-
tor .
---
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3.3 Prerequisites
• Observe construction measures according to national
regulations.
• For installation location and mains voltage system,
see DCI 700 Installation instructions 1 689 978 630
• Internet connection
---Separator---
3.4 Symbols on the product
Injected fuel quantity test connection.
---
Return quantity test connection.
---
3.5 Symbols on the rating plate
Attention: general warning sign indicating
danger. Before commissioning, connecting
and using Bosch products, it is essential to
read the operating instructions and the safe‐
ty instructions, in particular, carefully.
---Separator---
The DCI 700 is subject to the European di‐
rective 2012/19/EU (WEEE). Dispose of used
electrical and electronic devices, including
cables, accessories and batteries, separately
from household waste.
---Separator---
Certication for the Russian Federation
---Separator---
EU declaration of conformity
---Separator---
3.6 Denition of terms
Injector
Common rail injector.
---Separator---
Bosch CRI
Bosch common rail injector for passenger cars.
---Separator---
Bosch piezo CRI
Bosch common rail injector for passenger cars piezo
actuator.
---Separator---
Bosch CRIN
Bosch common rail injector for commercial vehicles.
---Separator---
Delphi DFI
Delphi common rail injector for passenger cars.
---Separator---
Denso Gx
Denso common rail injector for passenger cars.
---Separator---
Siemens/VDO/Continental PCR-I
Siemens/VDO/Continental Piezo common rail injector
for passenger cars.
---Separator---
3.7 Overview of DCI 700
12
6
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5
10
9
4
3
2
1
8
11
7
 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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1
458922-33_Pal
2
 2: Rear view of DCI 700
(1) Cover for heat exchanger compartment and test oil area
(2) Hydraulics compartment cover
AB
CD
ABCD
2
1
3
4
5
6
7
458922-48_Pal
 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
AB
CD
ABCD
5
1
458922-49_Pal
7
6
23
4
 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
2
2
3
458922-34_Pal
1
453
 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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1
2
45 884 6-23_ko
max.
max.
458922-35_Pal
4
3
5
12
 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
458922-37_Pal
1
2
3
 7: Rear of DCI 700 without cover on heat exchanger com‐
partment and test oil area
(1) Quick-release coupling for draining the test oil
(2) Heat exchanger
(3) Test oil tank
---
3.8 Component description
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3.8.1 Human Machine Interface
45
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2
3
67
8
 8: Human Machine Interface
(1) Monitor with touch controls
(2) Locking knob for tilt setting
(3) Locking knob for swivel adjustment
(4) Keyboard (not included in scope of delivery)
(5) Mouse (not included in scope of delivery)
(6) Keyboard shelf
(7) Locking knob for swivel adjustment
(8) Access to computer unit
The monitor (1) can be tilted and swiveled on the mon‐
itor column and has a touch-sensitive screen (touch
control). The software is controlled by touching or
swiping across the glass surface.
Connections, control elements and operation of
the monitor are described in the monitor's oper‐
ating instructions.
After the corresponding locking handle (2) or (3)is re‐
leased, the monitor can be tilted and swiveled.
A commercially available keyboard (4) and mouse (5)
can be used to supplement touch control. The keyboard
and mouse can be placed on the swiveling keyboard
shelf (6) . After the locking knob (7) is released, the
keyboard shelf can be swiveled.
Height adjustment of the HMI is described in the
chapter  13 "Adjust the height of the HMI" .
The computer unit is located behind the access (8).
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3.8.2 Computer unit
USB
USB
HDMI
458922-62_Pal
1
2
34
5
6
7
8
7
1
9
10
11
12
 9: Computer unit connections
(1) Serial interface (RS232)
(2) Monitor connection (VGA)
(3) Network connection (RJ45)
(4) USB 3.0 ports
(5) USB 2.0 ports
(6) Microphone and headphone port
(7) Mouse, keyboard
(8) HDMI
(9) Vent grille
(10) USB add-ons
(11) Voltage supply (power supply unit)
(12) Cable holder
The operating system, the "DDM" software and the
"DCI" software are installed on the computer unit. The
Windows rewall and virus scanner are activated to
protect against attacks from the Internet.
The computer unit is connected to the actuation unit
and the monitor. The USB ports on the front provide
the ability to connect additional USB devices, e.g. a
USB stick. The DCI 700 is connected to the Internet via
the network connection.
---Separator---
3.8.3 Swivel xture with high-pressure rail
AB
CD
ABCD
3
458922-50_Pal
2
1
 10: Swivel xture
(1) Swivel fixture with high-pressure rail
(2) Locking lever
(3) Scale plate
The injectors connected to the high-pressure rail are
placed in the vertical position with the aid of the swivel
xture (1). The injection chambers are mounted on the
injectors in this position and the injectors connected
electrically and hydraulically. The swivel range of the
swivel xture is 0° to 90°.
The marking "P" (rearmost position) on the scale plate
(3) marks the position "P". The injectors are connected
to or removed from the high-pressure rail in this posi‐
tion. In addition, the inlet lter and the connecting ca‐
bles for the injectors are accessible in position "P".
To swivel, pull the locking lever (2). After the locking
lever has been released, place the swivel xture (1) in
the desired position. Once the desired position has
been reached, release the locking lever and allow the
detent to engage the scale plate (3).
---Separator---
3.8.4 High-pressure rail
458922-43_Pal
1
23
5
6
3
7
4
 11: High-pressure rail
(1) Pressure control valve K20
(2) High-pressure connection, position "A", with blind plug
(3) Hose fitting for return quantity
(4) Port for additional sensors and components
(5) Pressure limiting valve
(6) Rail pressure sensor
(7) Pressure control valve K30
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The high-pressure rail is fastened to the swivel xture
and supplies the injectors with test oil during the test.
458922-44_Pal
12
3
 12: High-pressure connection "D"
(1) Threaded plug
(2) Adapter nut
(3) Port with threaded plug for SST pressure sensors
The injectors are connected to the high-pressure ports
of the high-pressure rail for the test. High-pressure
ports that are not used are sealed with threaded plugs
(1).
The high-pressure ports have replaceable adapter nuts
which must be change depending on the thread size of
the high-pressure port for the injector (see DCI 700
Help Center). The scope of delivery includes two
adapter nuts for the following thread sizes:
•Adapter nut M12x1.5 (1 683 345 065)
• Adapter nut M14x1.5 (1 683 345 066)
The pressure limiting valve (5) limits the pressure in the
high-pressure rail. If a pressure > 280 MPa Is reached in
the high-pressure rail, the pressure limiting valve opens
and the test oil is released into the test area.
The rail pressure sensor (6) measures the pressure in
the high-pressure rail. The output signals from the rail
pressure sensor are evaluated by the electronics and
provided for pressure control and display on the
screen.
Pressure control valve K20 (1) functions as a safety
valve and opens if pressure control valve K30 (7) can
no longer release the pressure. Pressure control valve
K30 adjusts and maintains the pressure in the high-
pressure rail.
---Separator---
3.8.5 Injection chamber
458922-40_Pal
AB
1
2
4
5
3
 13: Injection chamber with attached injector
(1) Injector
(2) Injection chamber
(3) Guiding rod
(4) Hose assembly for injection quantity 1 687 410 056
(5) Injection test connection for measurement channel A
For the test, the injection chamber is pushed over the
injector nozzle and fastened to it by turning the knurled
nut clockwise. An O-ring in the injection chamber seals
the injection nozzle radially.
Depending on the diameter of the injection nozzle
(7 mm or 9 mm) of the injector, the O-ring insert with
the O-rings (2) on the injection chamber and the
knurled nut (1) must be changed (see DCI 700 Help
Center). The O-ring inserts and the knurled nuts are
marked with D7 for nozzle diameter 7 mm and D9 for
nozzle diameter 9 mm.
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458922-39_Pal
1
2
3
 14: Injection chamber with O-ring insert and knurled nut
(1) Knurled nut
(2) O-ring insert
(3) Injection chamber
During the test, the injector injects test oil into the in‐
jection chamber. From the injection chamber, the test
oil ows back to the measurement channel via the hose
assembly 1 687 410 056 for the test connection.
---Separator---
3.8.6 Connection adaptations for injector return
458922-53_Pal
AB
458804-16
1
2
123
AB
 15: Test oil return connection with return adapter 1 687 016
215
(1) Hose line for return quantity 1 680 712 382
(2) Return adapter 1 687 016 215
(3) Return connection of the injector
The hose assembly 1 680 712 382 is connected to the
injector return by means of the connection adaptations
(return adapter or hose assemblies) (for connection,
see DCI 700 Help Center).
Return adapter 1 687 016 215
Return adapter for adapting the test oil return connec‐
tion of the injector. For most Bosch CRI.
458922-54_Pal
1
2
 16: Return adapter 1 687 016 215
(1) Return adapter 1 687 016 215
(2) O-ring (9.5 x 2 mm)
Hose assembly 1 683 351 066
Hose assembly for adapting to the test oil return con‐
nection of the injector. For Bosch CRI 2.18 and
CRI 2.20.
1 683 351 066
123
458922-55_Pal
 17: Hose assembly 1 683 351 066
(1) O-ring (3.5 x 1.25 mm)
(2) O-ring (5 x 1 mm)
(3) Knurled nut
Hose assembly 1 680 712 315
Hose assembly for adapting to the test oil return con‐
nection of the injector. For Bosch piezo CRI.
1 680 712 315
458922-56_Pal
 18: Hose assembly 1 680 712 315
---Separator---
3.8.7 Adapter cables
During the test, the injectors are actuated electrically
by way of the adapter cables. One adapter cable is nee‐
ded for each injector.
Adapter cable 1 684 465 900
For Bosch CRI 1, CRI 2x and CRI Piezo and CRIN with
CRI connection features.
458922-51_Pal
 19: Adapter cable 1 684 465 900
Adapter cable 1 684 465 895
For Bosch CRI piezo 3-25 and 3-27.
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458922-52_Pal
25 ±5
Cod.A
Cod.B
 20: Adapter cable 1 687 465 895
---
3.9 Functional description
---Separator---
3.9.1 Test
The DCI 700 contains all components, e.g. a high-pres‐
sure pump and a high-pressure rail for pressure genera‐
tion, test oil tank, ow meter, actuation circuit boards,
computer unit and a HMI needed to test common rail
injectors.
Both solenoid valve-controlled and piezo-controlled in‐
jectors can be tested.
Injectors are tested when the protective door is closed.
The safety switch on the protective door immediately
interrupts the test process and decreases the test oil
pressure completely if the protective door is opened.
The "DCI" software is installed on the computer unit
and is used to test common rail injectors. The "DCI"
software includes a database (license-dependent) with
test sequences for injectors. Each test sequence in‐
cludes different test steps (leak test, EM, VL, LL, ...)
with actuation proles that must be completed in suc‐
cession during the injector test.
After the test, the results can be displayed in a test
protocol and printed out.
---Separator---
3.9.2 Test oil supply
As soon as the injector test is started, the drive motor
of the DCI 700 starts and operates the high-pressure
pump at a rotational speed that depends on the test
step. Simultaneously, the fuel pump starts and delivers
test oil from the test oil tank to the high-pressure pump
through the test oil lter.
The high-pressure pump draws test oil into the high-
pressure chamber, pressurizes the test oil and directs it
further to the high-pressure rail via high-pressure hose
assemblies. A portion of the test oil that does not need
to be supplied to the injectors is returned to the test oil
tank. The cooler test oil ows through the injected fuel
quantity block, cooling the injected fuel quantity from
the injector.
A pressure control valve that opens or closes depend‐
ing on the amount of test oil is used to regulate the
pressure in the high-pressure rail. A bypass through
which the test oil can ow opens when needed. The
test oil ows to the heat exchanger through hose as‐
semblies, where it is cooled before owing back to the
test oil tank.
---Separator---
3.9.3 Flow measuring
Once the injector test has started, the actuation elec‐
tronics actuate the injectors using a dened control
progression that depends on the test step and injector.
The injectors start to inject.
The test oil injected by the injector (injected fuel quan‐
tity) is collected in the injection chamber and ows into
the measurement channel at the "Injection" test con‐
nection through a hose assembly. At the same time, the
test oil ows out of the injector return (return quantity)
into the measurement channel at the "Return" test con‐
nection through a hose assembly. One measurement
channel for the injected fuel quantity and one measure‐
ment channel for the return quantity are provided for
each injector.
The test oil ows through an inlet lter where it is l‐
tered immediately downstream from the test connec‐
tion. The pressure drop across the inlet lter is moni‐
tored. If a fouled inlet lter is detected, the user Is noti‐
ed by a message from the "DCI" software that the the
test oil lter in the inlet lter must be changed.
After passing through the inlet lter, the ltered test oil
ows to the ow meter through channels in the meas‐
urement block. The test oil ows through the ow me‐
ter and the ow meter measures the amount of test oil.
The values determined for the amount are displayed by
the "DCI" software. The test of oil is directed back to
the test oil tank through the heat exchanger after the
measurement.
---Separator---
3.9.4 Test oil conditioning
As soon as the DCI 700 is switched on, the test oil
heater in the test oil tank starts and heats the test oil.
The heater control then brings the test oil to the re‐
quired test oil temperature of 40 °C.
To protect against overheating, a minimum amount of
test oil must be kept in the test oil tank. The amount
that is monitored by a oat switch in the test oil tank. If
the amount of test oil drops, the oat switch detects
this and the "DCI" software informs the user by means
of a message. In addition, a thermal switch and heater
fuse are installed in the test oil tank as a safety ele‐
ment; in the event of a fault, they are actuated in suc‐
cession.
---Separator---
3.9.5 Test oil cooling
The injected and hot test oil is mixed with the cooler
test oil from the high-pressure pump and the test oil
tank in a distributor. The mixed test oil ows through a
heat exchanger, which transfers the heat to the ambi‐
ent air. A fan on the heat exchanger assists the cooling
process.
---Separator---
4. Operation
---
4.1 Switch on DCI 700
All protective devices e.g. protective covers and safe‐
ty-related devices e.g. extraction devices are present
and functional.
Test equipment is correctly set up and connected.
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1. DCI 700 Switch on at the main switch.
The Windows operating system starts.
The lighting in the working space switches on.
Conditioning of the test oil in the test oil tank be‐
gins.
2. Start the "DCI" software.
 DCI 700 is ready for operation.
---
4.2 Switch off DCI 700
1. The "DCI" software and other open applications
close.
2. Shut down the Windows operating system.
3. DCI 700 Switch off at the main switch.
Before switching the DCI 700 on again, wait
30 seconds after switching it off.
4. When not using DCI 700, padlock the main switch.
---
4.3 Stopping the DCI 700 in the event of
a problem
1. In the event of a problem, stop the test with <Stop>.
Actuation of the injectors is stopped.
The drive motor shuts down in a controlled man‐
ner.
The pressure in the high-pressure rail is released.
2. Rectify the fault.
3. Continue the test or restart.
Switch off the DCI 700 at the main switch only in
an extreme emergency. Switching off by the main
switch while a test is being conducted can dam‐
age the computer unit or the operating system.
---Separator---
4.4 Testing injectors
DANGER
Touching hot injectors and the hot test acces‐
sories (e. g. the injection chamber) can cause
severe burns.
Allow injectors and test accessories to cool.
Put on protective gloves before removing the
injection chamber.
Connecting and testing injectors (see DCI 700 Help
Center).
---Separator---
4.5 Updating "DCI" software
Updating software "DCI", see DCI 700 Help Center.
---Separator---
4.6 Opening the DCI 700 Help Center
1. In the "DCI" software, select <?>.
2. Select the "Help Center" tab.
---Separator---
4.7 Adjust the height of the HMI
3
458922_65_Pal
1
2
4
5
 21: Adjust the height of the HMI
(1) Monitor
(2) Locking knob for swivel adjustment
(3) Torx screws for clamping device
(4) Keyboard shelf
(5) Locking knob for swivel adjustment
The monitor or keyboard shelf attached to the
monitor column can drop as soon as the clamping
device for the monitor or keyboard shelf is re‐
leased. In this case, the monitor or keyboard
shelf could be damaged.
1. Turn locking handle (1) or (5) clockwise to tighten it.
2. Loosen both Torx screws (3) for the clamping de‐
vice.
3. Hold the monitor or keyboard shelf and release lock‐
ing handle (1) or (5).
4. Adjust the height of the monitor or keyboard shelf.
Then, turn locking knob (1) or (5) clockwise to tight‐
en it.
5. Tighten both Torx screws (1) for the clamping de‐
vice.
---Separator---
4.8 System recovery
If the current software version causes problems or if
the DCI 700 is to be sold, reset the DCI 700 to factory
settings.
System recovery will delete all data and settings
from the DCI 700, e.g. licensing information, log
les, user settings, protocols, images.
Internet connection required
Keyboard required
Customer number and password for login on DDM
---Separator---
Resetting the DCI 700 to factory settings
1. Backing up data and settings (see DCI 700 Help
Center).
2. Remove the cover from the computer unit.
3. Insert the recovery USB stick into an unused USB
port (1) or (2) of the computer unit.
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USB
USB
HDMI
1
2
458922-66_Pal
 22: USB ports
4. If a keyboard is not connected, connect the key‐
board to an unused USB port of the computer unit.
5. Close all running applications.
6. Shut down the Windows operating system.
7. Switch off the DCI 700 at the master switch.
8. After 30 seconds, switch on the DCI 700 at the main
switch.
The computer will boot up.
Recovery starts (duration: approx. 30 minutes).
9. Read and follow the instructions on the screen.
10. When prompted, remove the recovery USB stick.
11. Shut down the computer unit by pressing any key on
the keyboard.
The computer unit shuts down.
12. Switch off the DCI 700 at the master switch.
The DCI 700 is reset to the factory settings.
---Separator---
Installing the operating system
After shutting down, wait 30 seconds before switch‐
ing the DCI 700 back on.
1. Switch on the DCI 700 at the main switch.
The computer will boot up.
The language selection will be displayed.
2. Read and follow the instructions on the screen.
3. In the "Log into Microsoft" window, use / create a
Microsoft e-mail address or proceed without an e-
mail address by using <Join the domain instead>.
You will be prompted to specify a name and pass‐
word. Entering a name is required. The password
is not necessary to operate DCI 700.
The Microsoft services offered during installation
(e.g. online speech recognition) are not required
for the DCI 700.
The operating system is now installed.
The DDM (Diagnostics Download Manager) soft‐
ware will be started.
---Separator---
Setting up the DDM software
1. Select a country and language in the "License
Agreement" window.
2. Enable option I accept the agreement.
3. Select <Next>.
4. In the Login tab, enter customer number and pass‐
word.
5. Select <Test login>.
The following message will be displayed: Suc-
cessful.
Should the message Login failed be displayed,
correct the user name and / or password and try
the login information again.
---Separator---
Installing the DCI software
1. In the DDM software, select the Updates tab.
If the "DDM" software nds a new update version,
the "DDM" software immediately starts the down‐
load and retrieves the update. The My Contracts
tab can be used to disable automatic update
downloads.
2. Use <Search now> to search for updates.
Updates will be downloaded from the download
server.
The following message will be displayed: Down-
load completed.
3. Install the "DCI" software by selecting <Install now>.
The DCI 700 must not be switched off while an up‐
date is being installed.
4. Select a language.
5. Read and follow the instructions on the screen.
6. Restart the DCI 700 after the installation.
The "DCI" software is installed.
---Separator---
Setting up and licensing the "DCI" software
1. Start the "DCI" software.
A message will be displayed stating that licensing
is required.
2. Use <Close> to ignore the message.
3. Load the backed-up data and settings again (see
DCI 700 Help Center).
If a data backup is not available, all settings must
be made again (see DCI 700 installation instruc‐
tions).
4. Select the "Subscription" (Licensing) tab.
5. If necessary, perform the licensing process for DCI
and BQS (see DCI 700 Help Center).
The "DCI" software is set up.
---Separator---
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5. Maintenance
---
5.1 Cleaning
The DCI 700 must be switched off by the main
switch for cleaning.
Use only soft, lint-free cloths for cleaning.
Use only damp cloths for cleaning surfaces, and do
not scrub hard.
DANGER – Do not spray cleaning agents directly
onto the components. The liquid may nd its way
inside the device and cause electric shock or short
circuit.
Only use neutral cleaning agents or plastic cleaners to
clean the DCI 700 housing, working area lights, pro‐
tective screen and monitor.
For a more thorough cleaning job, the protective
screen can be removed from the protective door
(see  23 "Changing the protective cover" ).
Only use a cleaning agent suitable for LCD displays to
clean the screen.
Flush and clean the test oil tank every time the test oil
is changed (see  16 "Changing test oil" ).
---Separator---
5.2 Maintenance
5.2.1 Maintenance intervals
DANGER
Risk of electric shock from hazardous voltage!
Work on electrical systems or equipment must
only be performed by qualied electricians or
trained personnel under the guidance and su‐
pervision of an electrician.
DCI 700 Before opening, switch it off and dis‐
connect it from the mains voltage system.
---
The maintenance intervals listed apply to operation of
the DCI 700 for 8 hours per day. If the operating time is
longer, e.g. In a multi-shift environment, reduce the
maintenance intervals accordingly.
The specied maintenance intervals as well as the legal
and national deadlines for inspections and mainte‐
nance must be observed.
Use-dependent
If the DCI 700 detects a fouled inlet lter or test oil l‐
ter, the user is informed by a message.
Change the lter insert in the inlet lter (see  20
"Changing the test oil filter in the inlet filter" ).
Change the test oil lter (see  19 "Changing the test
oil filter" ).
---
Once a day
Inspect the adapter cables for scuff marks and bare
spots. Replace damaged electrical cables or compo‐
nents immediately.
Checking the high-pressure rail, injection chambers
and test connections for leaks. Eliminate leaks imme‐
diately.
Inspect the adapter nuts and sealing surfaces at the
high-pressure connections of the high-pressure rail for
damage. Replaced damaged adapter nuts. Have dam‐
aged high-pressure connections replaced by customer
service.
Inspect the hose assemblies for the injected fuel
quantity and return quantity for cracks and scuff
marks. Replace damaged hose assemblies immediate‐
ly.
Inspect the protective cover for porous spots, cracks
and dents. If the protective cover is damaged, change
it immediately (see  23 "Changing the protective cov-
er" ).
Check the fan on the heat exchanger for unusual
noises. In the event of loud or scraping noises from
the fan, notify customer service.
---
Once a week
Drain contaminated oil in the test area.
Clean the test area and metal shelves in the work
area. Observe the cleaning instructions (see  15
"Cleaning" ).
Clean the protective insert in the protective door. Ob‐
serve the cleaning instructions (see  15 "Cleaning" ).
Clean the work area lights. Observe the cleaning in‐
structions (see  15 "Cleaning" ).
Clean the guide rails and drive rollers. Lightly oil the
guide rails.
Clean and lightly oil the guide rods for the injection
chamber devices.
Tighten the Torx screws for the monitor and keyboard
shelf clamping device.
---
Every 2 months or after 1500 injector tests
Change the test oil (see  16 "Changing test oil" ).
---
Once a year
Inspect all hoses and hose assemblies for cracks and
scuff marks. Replace damaged hoses or hose assem‐
blies immediately.
Inspect the electrical cables on the rotating frame for
scuff marks and bare spots. Replace damaged electri‐
cal cables or components immediately.
DANGER! – Danger of electric shock. DCI 700 Dis‐
connect from the mains voltage system.
Inspect the amount measurement blocks for injection
and return for leaks. Eliminate leaks immediately.
Inspect the heat exchanger for leaks. If leaks are
found, notify customer service.
Check the locking handle of the rotating frame and
positioning arm. Replace a damaged locking handle or
positioning arm.
---
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Every 2 years
Inspect the power supply cable for scuff marks, bare
spots and discoloration. Replace a damaged or discol‐
ored power supply cable immediately.
DANGER! – Danger of electric shock. DCI 700 Dis‐
connect from the mains voltage system.
Inspect the motor connection cable for scuff marks
and bare spots. Replace a damaged motor connection
cable immediately.
DANGER! – Danger of electric shock. DCI 700 Dis‐
connect from the mains voltage system.
Inspect the electrical connection in the junction box
of the drive motor, on the power supply, on the fre‐
quency inverter and at the main switch for loose at‐
tachment. Tighten loose connections.
DANGER! – Danger of electric shock. DCI 700 Dis‐
connect from the mains voltage system.
Electrostatic discharge can damage components
on the circuit boards. Implement ESD protective
measures before starting maintenance work. Use
only ESD-capable tools.
Remove dust particles and dust balls from the elec‐
tronics compartment and computer unit.
Clean the vent screen on the drive motor.
Clean the vent screen on the frequency inverter.
Check whether the fan of the frequency inverter is
blocked. Clear any blockage.
Inspect the signal cable of the frequency inverter for
stuff marks, bare spots and discoloration. Replace a
damaged or discolored signal cable immediately.
Clean the fan and cooling ns of the heat exchanger.
Clean the vent grilles of the heat exchanger cover and
test oil area.
Clean the vent grille on the test bench housing.
Use the EP test service to check the measuring accu‐
racy (see  24 "Checking the measuring accuracy" ).
---
Every 6 years
Change all hydraulic hose lines.
---
Every 8 years
Change the protective insert in the protective door.
---
5.2.2 Changing test oil
---
5.2.2.1 Draining the test oil tank
1. End all computer applications.
2. Shut down the Windows operating system.
3. Switch off the DCI 700 at the main switch (2).
4. Remove the front left cover (1).
1
2
458922_03_Pal
 23: Preparing to change the test oil
5. Release the two wing screws (1) and (4). Do not re‐
move the wing screws.
6. Use the handles (2) and (3) to pull the test oil tank
out of the test bench.
1
4
2
3
458922-04_Pal
 24: Test oil tank
7. Release the two wing screws (1) and (3). Do not re‐
move the wing screws.
8. Slide the test oil tank cap (2) aside.
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458922-05_Pal
1
3
2
 25: Opening the test tank oil cap
9. Place a collecting container (2) under the drain cock
of the test oil tank.
10. Open the drain cock of the test oil tank (1) and
drain the test oil out of the test oil tank (lling ca‐
pacity = approx. 50 liters) into the collecting con‐
tainer.
–Alternative: Use an external test-oil pump to
pump the test oil out of the test oil tank and into
a collecting container.
1
2
458922-06_Pal
 26: Draining the test oil
11. Dispose of the used test oil. Comply with disposal
instructions (see  26 "Substances hazardous to wa-
ter" ).
---Separator---
5.2.2.2 Flushing the test oil tank
1. Flush the empty test oil tank with test oil. Collect
the test oil emerging from the drain cock in a col‐
lecting container.
2. Clean the test oil tank with lint-free cloths.
3. Flush again until all dirt residues have been removed
from the test oil tank.
4. Close the drain cock of the test oil tank.
458922-26_Pal
 27: Closing the drain cock
5. Dispose of the used test oil. Comply with disposal
instructions (see  26 "Substances hazardous to wa-
ter" ).
---Separator---
5.2.2.3 Emptying the heat exchanger
1. Remove the lower cover (1) on the back of the
DCI 700.
1
458922-07_Pal
 28: Back of DCI 700
2. Place the end of the drain hose (2) without a quick-
release nipple into a collecting container.
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3. Insert the drain hose (2) into the quick-release cou‐
pling (1) until it snaps in place.
The test oil drains from the heat exchanger into
the collecting container.
1
2
458922-09_Pal
 29: Connecting the drain hose
4. Once the heat exchanger is empty at, open the
quick-release coupling and remove the drain hose
from the heat exchanger.
5. Dispose of the used test oil. Comply with disposal
instructions (see  26 "Substances hazardous to wa-
ter" ).
6. Attach the cover.
---Separator---
5.2.2.4 Filling with test oil
1. Check whether the drain cock of the test oil tank (2)
is closed.
Fill the test oil tank only with fresh and clean test
oil to ISO 4113-CV-AW. For approved test oil, see
 27 "Test oil conforming to ISO 4113-CV-AW" . Fill‐
ing quantity = approx. 50 liters.
2. Fill the test oil into the test oil tank through a ne
lter (1) up to the "max." marking (3) .
max.
max.
1
2
45 884 6-23_ko
458922-10_Pal
3
2
1
 30: Filling with test oil
3. Slide the test oil tank cap (2) onto the test oil tank.
4. Tighten the two wing screws (1) and (3).
458921-48_Pal
1
3
2
 31: Closing the test oil tank cap
5. Use the handles (2) and (3) to push the test oil tank
into the test bench.
6. Tighten the two wing screws (1) and (4).
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1
4
2
3
458922-04_Pal
 32: Test oil tank
7. Attach the front left cover.
8. Check the ll level in the test oil tank after an injec‐
tor test. If necessary, top up the test oil.
---Separator---
5.2.3 Changing the test oil lter
---Separator---
5.2.3.1 Removing the test oil lter
1. End all computer applications.
2. Shut down the Windows operating system.
3. Switch off the DCI 700 at the main switch (2).
4. Remove the front left cover (1).
1
2
458922_03_Pal
 33: Preparing to change the test oil
5. Release the two wing screws (1) and (4). Do not re‐
move the wing screws.
6. Use the two handles (2) and (3) to pull the test oil
tank out of the test bench.
1
4
2
3
458922-04_Pal
 34: Test oil tank
7. Place a collecting container (2) under the test oil l‐
ter.
8. Loosen the test oil lter (1) by turning it clockwise
with the aid of a strap wrench.
9. Unscrew the test oil lter (1) . Collect the draining
test oil in the collecting container (2) .
458922-25_Pal
2
1
 35: Removing the test oil lter
10. Dispose of the test oil and test oil lter (see  26
"Disposal" ).
---Separator---
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5.2.3.2 Installing the test oil lter
1. Make sure that the sealing surface on the new test
oil lter is clean.
2. Lubricate the sealing ring and threads of the test oil
lter with test oil.
3. Fill the test oil lter with fresh test oil.
4. Attach the test oil lter to the lter connection by
turning it counterclockwise until its seal presses
against the sealing surface of the socket.
5. Tighten the test oil lter by an additional 3/4 turn
manually.
458922-27_Pal
 36: Tightening the test oil lter
6. Use the handles (2) and (3) to push the test oil tank
into the test bench.
7. Tighten the two wing screws (1) and (4).
1
4
2
3
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 37: Test oil tank
8. Switch on DCI 700 at the main switch.
9. In the DCI software: select "Maintenance."
10. Select the "System test" tab.
11. Select "Test oil lter change," and use <Start> to
start the bleeding process.
12. Follow the instructions and perform system bleed‐
ing.
13. After checking the level in the test oil tank, attach
the front left cover.
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5.2.4 Changing the test oil lter in the inlet lter
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5.2.4.1 Removing the inlet lter
DANGER
Hot components can cause burns immediately
after the test.
Allow DCI 700 to cool before starting on the
work steps.
Wear protective gloves.
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en | 20 | DCI 700