Bosch DCI 700 Repair Instructions
  1. Manuals
  2. Brands
  3. Bosch Manuals
  4. Diagnostic Equipment
  5. DCI 700
  6. Repair instructions

Bosch DCI 700 Repair Instructions

Common-rail injector test bench
Hide thumbs Also See for DCI 700:
Table of Contents

Advertisement

Quick Links

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

Advertisement

Table of Contents
loading

Related Manuals for Bosch DCI 700

Summary of Contents for Bosch DCI 700

  • Page 1 DCI 700 Common-rail injector test bench Repair instructions Common-rail injector test bench...

  • Page 2: Table Of Contents

    | 2 | DCI 700 User instructions............................Symbols used in the documentation....................... Warnings in the documentation........................Target group..............................Safety instructions............................Other applicable documents........................... Opening the DCI 700 Help Center...
  • Page 3 ..........................Calibrating the rail sensor B80........................Troubleshooting............................After the DCI 700 is switched on the screeen remains dark and the operating display does not light up on monitor..............................Touchscreen not responding.........................

  • Page 4: User Instructions

    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‐ fied by unauthorized individuals.

  • Page 5: Opening The Dci 700 Help Center

    DCI 700 | 5 | en • 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...

  • Page 6: 1.10 Disposal

    | 6 | DCI 700 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. filters) are hazardous to water and the environment. Sub‐...
  • Page 7 DCI 700 | 7 | en  2: Rear view of DCI 700 (1) Cover for heat exchanger compartment and test oil area (2) Hydraulics compartment cover  3: Test area (1) Storage tray (2) Storage compartment with holders for the accessories...
  • Page 8 | 8 | DCI 700  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...
  • Page 9 DCI 700 | 9 | en  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...
  • Page 10 | 10 | DCI 700  7: Motor compartment and electronics compartment open (1) Front cover of electronic control (2) Drive motor (3) Counterweight (4) Electrical cabinet 1 689 975 289 | 2020-05-06 Robert Bosch GmbH...

  • Page 11: Component Overview

    DCI 700 | 11 | en  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...

  • Page 12: Electronic Control

    | 12 | DCI 700 (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 –...
  • Page 13 DCI 700 | 13 | en (2) Port X101 (RJ45) – Communication to frequency converter A1 (3) USB port X103 – Communication to processor unit 1 2 3 4 5 6 7 8 9 10111213141516 458929-13_Pal  12: LED overview (1) V49 –...

  • Page 14: Measurement Block Return A-B

    | 14 | DCI 700 3.1.3 Measurement block return A-B  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...

  • Page 15: Measurement Block Return C-D

    DCI 700 | 15 | en 3.1.4 Measurement block return C-D  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...

  • Page 16: Processor Unit

    | 16 | DCI 700 (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 3.1.6...

  • Page 17: Swivel Mechanism

    DCI 700 | 17 | en ATX12V1 Battery USB2_3 LVDS1 COM6 COM4 RJ-45 RJ-45 COM Port1 COM Port3 Mouse Line USB 2.0 USB 3.0 USB1 USB1 COM Port2 VGA1 USB0 USB0 Mic.In Keybo. 458929-17_Pal  18: Connections and jumper settings for motherboard A3...

  • Page 18: High-Pressure Unit

    | 18 | DCI 700 3.1.8 High-pressure unit  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 3.1.9 High-pressure rail  21: High-pressure rail (1) Pressure-control valve K20 –...

  • Page 19: Modes

    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 insufficient test oil in the test oil tank.

  • Page 20: Removing The Cover For Motor Compartment And Electrical Compartment

    Removing the cover 5.1.3 Removing the protective doors Voraussetzungen: Before removing the protective door, disconnect the DCI 700 at the main switch and secure against reactiva‐ tion. 1. Open the protective door (3). The door contact for the safety switch must be located outside the switch box for door monitoring (1).

  • Page 21: Removing The Pump Plate

    DCI 700 | 21 | en  27: Removing the protective door 3. Place the protective door on a clean and soft surface. 5.1.4 Removing the pump plate 1. Swivel the high-pressure rail to position "P". and 5). Always loosen pressure line fittings at the adapter nut.
  • Page 22 | 22 | DCI 700  28: Loosening the coupling 8. Remove 4 Torx screws (2) and spring washers. and 3) into the pump plate. 9. Screw 2 M5 screws and 3) alternately until the two spacer sleeves (4) can be re‐...

  • Page 23: Removing The High-Pressure Pump

    DCI 700 | 23 | en 5.1.5 Removing the high-pressure pump  30: Removing the pump plate 1. Remove hex nut (1) and lock washer (2). Insert a 10 mm round rod into the hole in the pump drive plate and hold the pump drive plate securely while loosening the hex.

  • Page 24: Assembling The High-Pressure Pump

    | 24 | DCI 700 5.1.6 Assembling the high-pressure pump  32: Removing the pump plate 1. Remove the high-pressure pump from the packaging and place it aside. Do not remove the sealing plugs. 2. Place the pump plate (5) on the high-pressure pump (6).

  • Page 25: Attaching The Pump Plate

    DCI 700 | 25 | en  33: Attaching the pump drive plate 10. Remove all sealing plugs from the high-pressure pump. 5.1.7 Attaching the pump plate 1. Check whether the thrust rings (1) have been tightened on both pressure lines (left-hand thread). Remove the adapter nuts and turn the thrust rings counterclockwise as far as possible.
  • Page 26 | 26 | DCI 700 458929-38_Pal  35: Attaching the pump plate 4. Place the two spacer sleeves (2) between the pump drive plate (1) and coupling (3). If the spacers sleeves can‐ not be inserted because there is not enough space between the pump drive plate (1) and coupling (3), move the pump plate a bit farther away from the rotating frame.

  • Page 27: Installing The Protective Doors

    2. Lift the protective door slightly and tilt forwards until the top guide roller can be set on the rail.  38: Installing the protective door 5.1.9 Leak tightness test Connecting and testing injectors (see DCI 700 Help Center). Robert Bosch GmbH 1 689 975 289 | 2020-05-06...

  • Page 28: Installing The Cover For The Motor Compartment And Electrical Compartment

    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. 1 689 975 289 | 2020-05-06...

  • Page 29: Removing The Cover From The Hydraulics Compartment

    DCI 700 | 29 | en 5.2.2 Removing the cover from the hydraulics compartment The cover is secured by means of a retaining device and cannot be tilted backwards. The cover must be removed by 2 people. and 3). The square box wrench is included in the 1.

  • Page 30: Removing The Flow Meter

    | 30 | DCI 700  42: Removing the upper cover from the hydraulics compartment 5.2.4 Removing the flow meter Make sure that the surroundings and air are clean when replacing the flow meter. When performing repairs, make sure no other work is in progress which could emit particles into the air. If these requirements are not satisfied, then replace the flow meter at a clean workplace that has an extraction device.
  • Page 31 DCI 700 | 31 | en  43: Quantity measurement block with fan assembly 4. Remove the connection cable (2) from the flow meter (1).  44: Flow meter with connection cable 5. Remove both fastening screws. 6. Remove the flow meter (1) and both O-rings from the spacer plate (2).

  • Page 32: Installing The Flow Meter

    | 32 | DCI 700  45: Replacing the flow meter 7. Do not leave the measurement block open for long without the flow meter installed. Install the new flow meter immediately. 5.2.5 Installing the flow meter The flow meter must be installed immediately after the blind plugs have been removed (risk of contamina‐...
  • Page 33 DCI 700 | 33 | en  47: Replacing the flow meter 7. Attach connection cable to the flow meter. 8. Using a wrench (1), loosen the hex nut on the plug. Do not remove the hex nut. 9. Turn and align the connection cable (2). The connection cable must point down.

  • Page 34: Entering The Calibration Values

    12. Connect both connection cables from the fan assembly to connection cables M6 and M7. 5.2.6 Entering the calibration values 1. Switch on the DCI 700 at the main switch. 2. Start the DCI software. 3. If a mouse is not connected, connect a mouse to an unused USB port of the processor unit, 4.
  • Page 35 DCI 700 | 35 | en  51: Rear view of DCI 700 - Arrangement of the flow meters (1) Flow meter T22 for injector D return (2) Flow meter T21 for injector C return (3) Flow meter T14 for injector D quantity...

  • Page 36: Final Steps

    | 36 | DCI 700 5.2.7 Final steps Connecting and testing injectors (see DCI 700 Help Center). WARNING Risk of injury from spraying test oil!  Wear safety goggles. WARNING Risk of trapping in rotating parts!  Maintain a sufficient distance from rotating parts.

  • Page 37: Installing The Cover On The Hydraulics Compartment

    5.3.1 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. Robert Bosch GmbH 1 689 975 289 | 2020-05-06...

  • Page 38: Removing The Cover For Motor Compartment And Electrical Compartment

     After switching off the unit, wait 5 minutes to allow the charged capacitors in the frequency converter to discharge.  Before beginning work, make sure the DCI 700 and devices are not live. Removing the protective cover 1. Remove the Torx screws (1) and with washer.
  • Page 39 DCI 700 | 39 | en  57: Opening the electrical cabinet Removing the mounting panel and placing it aside 1. Slide 2 rectangular wooden strips measuring 59 x 59 350 mm (4) under the mounting panel (1) and rest them on the beams of the test bench frame.

  • Page 40: Removing Frequency Converter A1

    | 40 | DCI 700 458929-43_Pal  59: Mounting panel resting on wooden strips 5.3.4 Removing frequency converter A1 1. Disconnect all connection cables from the frequency converter A1 (3). 2. Remove circuit board A6 (2). 3. Remove the 4 Torx screws (1).
  • Page 41 DCI 700 | 41 | en  61: Frequency converter A1 4. Set frequency converter A1 on the mounting panel. Make sure that no cables are pinched or damaged. 5. Fasten frequency converter A1 to the mounting panel with 4 Torx screws (1) and washers.

  • Page 42: Installing The Mounting Panel

    | 42 | DCI 700  63: Protective conductor connection on the frequency converter 10. Connect voltage supply to frequency converter A1 (refer to circuit diagram): — Connect wire from contactor Q2/2 (T1) to connection L1 of the frequency converter A1.
  • Page 43 DCI 700 | 43 | en 458929-49_Pal  65: Fastening the mounting panel 6. Use 2 Torx screws M6 x 16 mm and washers to secure cover (1) to the mounting panel. 458929-50_Pal  66: Fastening the cover 7. Use Torx screws M6 x 16 mm (3 and 5) and washers to secure protective cover (4). While attaching it, make sure the protective conductor is connected to the cover.

  • Page 44: Installing The Cover For The Motor Compartment And Electrical Compartment

    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. 1 689 975 289 | 2020-05-06...

  • Page 45: Removing The Cover From The Electronics Compartment

    DCI 700 | 45 | en 5.4.2 Removing the cover from the electronics compartment 1. Close the protective door. 2. Use a square box wrench to open the locking mechanisms (1). The square box wrench is included in the scope of delivery of DCI 700.

  • Page 46: Removing The Upper Cover From The Hydraulics Compartment

    | 46 | DCI 700  70: Opening the cover 2. With the aid of a second person, raise the cover, detach it, and remove it by lifting it.  71: Removing the cover 5.4.4 Removing the upper cover from the hydraulics compartment 1.

  • Page 47: Removing Circuit Board A3

    DCI 700 | 47 | en  72: Removing the upper cover from the hydraulics compartment 5.4.5 Removing circuit board A3 Take note of the ESD handling instructions in EDIS, and remove components with care. Extreme bending may damage the circuit board.
  • Page 48 | 48 | DCI 700  73: Removing the circuit board cover 4. Remove the protective conductor on the front circuit board cover (2). 5. Remove the 2 cylinder head screws (1) and washers. 6. Lift the front circuit board cover (2), and carefully pull it up and out.

  • Page 49: Installing Circuit Board A3

    DCI 700 | 49 | en  75: Removing circuit board A3 5.4.6 Installing circuit board A3 Take note of the ESD handling instructions in EDIS, and remove components with care. Extreme bending may damage the circuit board. When installing the circuit board, take care not to slide it across a sheet metal edge of the test bench. This may cause components on the circuit board to get detached or damaged.
  • Page 50 | 50 | DCI 700  77: Installing circuit board A3 5. Connect all connection cables to circuit board A3 (see circuit diagram). 6. Carefully, insert the front circuit board cover (2) below the guide at an angle and set it down. Make sure not to detach or pinch any cables.

  • Page 51: Installing The Cover On The Hydraulics Compartment

    DCI 700 | 51 | en  79: Installing the circuit board cover 12. Attach the protective conductor to the rear circuit board cover (2). 13. Check the protective conductor in accordance with DGUV A3. 5.4.7 Installing the cover on the hydraulics compartment 1.

  • Page 52: Installing The Cover On The Hydraulics Compartment

    2. Press cover against the test bench frame. and 3). The square box wrench is included 3. Using a square box wrench, close the two electrical cabinet locks in the scope of delivery of the DCI 700.  82: Opening the cover 5.4.9...

  • Page 53: Final Steps

    Installing the cover on the electronics compartment 5.4.10 Final steps 1. Connect the power supply cable to the mains voltage system. 2. Switch on DCI 700 at the main switch. 3. Start the "DCI" software.  57 "Updating the firmware").
  • Page 54 7. Seal high-pressure connections A to C with threaded plugs. Tightening torque: 25 Nm – 30 Nm. 8. Select <Start>.  The DCI 700 starts and the first pressure point is approached. 9. Once the measured value in the Reference [MPa] field is stable and <Next> is active, save the measured value and approach the next pressure point by pressing <Next>.

  • Page 55: Troubleshooting

    After the DCI 700 is switched on the screeen remains dark and the operating display does not light up on the monitor After the DCI 700 is switched on, the screen remains dark and the operating display does not light up on the monitor.

  • Page 56: Software And Firmware

    ---Separator--- System recovery If the current software version causes problems or if the DCI 700 is to be sold, reset the DCI 700 to factory set‐ tings. System recovery will delete all data and settings from the DCI 700, e.g. licensing information, log files, user settings, protocols, images.

  • Page 57: Updating "Dci" Software

    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 instructions). 4. Select the "Subscription" (Licensing) tab.
  • Page 58 | 58 | DCI 700 3. Select Status from the header. 4. In the line "Firmware version," check the status.  If there is a green checkmark, the firmware version is up to date. No further steps are required. If there is an orange exclamation point, a new firmware version is available for installation.
  • Page 60 15V SL6/3 Bolzen Monitorbefestigung (nur 220/230V) SL6/4 Bolzen Umhausung Trafo (nur 220/230V) DCI 700- 380-440V * T1 & F1 = DCI 700 - 220/230V Datum 29.01.2016 Robert Bosch GmbH NETZANSCHLUSS / ANTRIEB 1 680 S01 935 06.04.2020 hah2bue Bearb.
  • Page 61 4 sensor 1 sensor 2 sensor 3 sensor 4 (optional) (optional) (optional) (optional) Datum 29.01.2016 Robert Bosch GmbH SENSORBOARD_1 1 680 S01 935 06.04.2020 hah2bue Bearb. wog2pl DCI700 1 680 S01 868 05.12.2019 hah2bue Stromlaufplan 1689 911 532 Gepr.
  • Page 62 3 channel 3 channel 3 channel 4 channel 4 channel 4 channel 4 channel 4 channel 4 Datum 29.01.2016 Robert Bosch GmbH SENSORBOARD_2 1 680 S01 935 06.04.2020 hah2bue Bearb. wog2pl Stromlaufplan 1689 911 532 DCI700 1 680 S01 868 05.12.2019...
  • Page 63 X14_1 X11_2 X13_2 X12_2 X14_2 X11_3 X13_3 X12_3 X14_3 SCHIRM_1 SCHIRM_3 SCHIRM_2 SCHIRM_4 Datum 06.10.2004 Robert Bosch GmbH POWERBOARD_1 1 680 S01 935 06.04.2020 hah2bue Bearb. wog2pl Stromlaufplan 1689 911 532 DCI700 1 680 S01 868 05.12.2019 hah2bue Gepr. 06.04.2020 DIN A3 Änderung...
  • Page 64 Inj 1+3 Inj 1+3 Inj 1+3 Inj 1+3 discharge injector Inj 2+4 Inj 2+4 Inj 2+4 Inj 2+4 Datum 29.01.2016 Robert Bosch GmbH POWERBOARD_2 1 680 S01 935 06.04.2020 hah2bue Bearb. wog2pl DCI700 1 680 S01 868 05.12.2019 hah2bue Stromlaufplan 1689 911 532 Gepr.
  • Page 65 USB 3.0 Board COM1 COM2 HDMI SL N COM3 TOUCH Line-Out (GN) Mic-In (rs) HDMI Datum 29.01.2016 Robert Bosch GmbH PC-BOARD 1 680 S01 868 06.04.2020 hah2bue Bearb. wog2pl Stromlaufplan Stromlaufplan 1689 911 532 DCI700 1 680 S01 868 05.12.2019 hah2bue Gepr.
  • Page 66 DCI 700 | 59 | en Robert Bosch GmbH Franz-Oechsle-Str. 4 73207 Plochingen Germany www.bosch.com bosch.prueftechnik@bosch.com 1 689 975 289 | 2020-05-06 Robert Bosch GmbH 1 689 975 289 | 2020-05-06...

Table of Contents