DCI 700

Help Center

Getting started

Quick Start Guide "How do I connect injectors for a test?" (8:42 min)

Quick Start Guide "How do I connect injectors for a test?" (8:42 min)

This Quick Start Guide explains how to connect the injector types CRI, piezo CRI and CRIN.

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Quick Start Guide "Ho do I operate the DCI?" (3:19 min)

Quick Start Guide "Ho do I operate the DCI?" (3:19 min)

This Quick Start Guide explains the basic functions of the "DCI" software.

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Overview of DCI 700

Overview of DCI 700

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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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Rear view of DCI 700

(1) Cover for heat exchanger compartment and test oil area

(2) Hydraulics compartment cover

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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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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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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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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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Rear of DCI 700 without cover on heat exchanger compartment and test oil area

(1) Quick-release coupling for draining the test oil

(2) Heat exchanger

(3) Test oil tank

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User interface

User interface

Diesel test equipment_de

(1) Title bar

DCI can be minimized, maximized/reduced or cancelled.

(2) Main-menu bar

Status: Display of the maintenance menu with information, e. g. about DCI 700, status messages or filter times.

User: Selecting a user. Users can be managed under: "My workshop >> Users".

Date/time: Display of the date and time. The date and time can be changed in the operating system.

Help.png: Help display (DCI Help Center).

(3) Input/output box

Box with variable content for data selection/input and information display. The arrangement of the tiles cannot be changed.

(4) Page indicator

Indicates that there is more than one page available. The pages can be selected by horizontal swiping motions or clicking the arrow.

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Other applicable documents

Other applicable documents

The current version of the technical documentation for Bosch workshop equipment can be found in the Bosch Media Library: www.downloads.bosch-auomotive.com .

In each software application, the <?> button can be used to call up the Help Center and online help.

  • 1 689 979 860 – Important information and safety instructions for Bosch diesel test equipment

  • 1 689 978 630 – DCI 700 installation instructions

  • 1 689 989 343 – DCI 700 (400 V) original instructions or
    1 689 989 473 – DCI 700 (200 V) original instructions

  • 1 689 989 415 – Original instructions for the accessory set for Bosch commercial-vehicle common-rail injectors (1 687 010 607)

  • 1 689 989 472 – Original instructions for the accessory set for Bosch commercial-vehicle common-rail injectors 4.2 (1 687 010 608)

  • 1 689 989 474 – Original instructions for the accessory set for Bosch commercial-vehicle common-rail injectors from third-party manufacturers (1 687 010 609)

  • DDM Help Center

  • Online help – Bosch QualityScan-Online

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FAQ (frequently asked questions)

General information

What injectors can I test?

What injectors can I test?

Most common-rail injectors by the manufacturers Bosch, Delphi, Denso and Siemens/VDO/Continental:

  • 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 accessories required)

  • Bosch CRIN 4.2 (special accessories required)

  • Delphi DFI, Denso Gx and Siemens/VDO/Continental PCR-I (special accessories required)

    For further information, see: Injector overview (PDF) .

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What accessories are available for the DCI 700?

What accessories are available for the DCI 700?

  • 1 687 010 607: accessory set for testing Bosch commercial-vehicle common-rail injectors (CRIN 1x, CRIN 2x, CRIN 3x)

  • 1 687 010 608: accessory set for testing Bosch commercial-vehicle common-rail injectors (CRIN 4.2)

  • 1 687 010 609: accessory set for common-rail injectors from third-party manufacturers (Delphi DFI, Denso 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 configuring your test and repair equipment: https://component-test.bosch-automotive.com/en/en/sharedActions/countrySelector .

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Can I use Bosch Connected Repair (CoRe)?

Can I use Bosch Connected Repair (CoRe)?

Currently, Bosch Connected Repair (CoRe) is not supported by the DCI 700.

The Bosch Connected Repair (CoRe) software makes it possible to exchange customer and vehicle information as well as protocols within the workshop. For this, the diagnostic devices (CoRe clients) are connected to a central computer (CoRe server) via the computer network.

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What is Bosch QualityScan (BQS)?

What is Bosch QualityScan (BQS)?

Test and repair of Bosch injection components with proof of quality. The test can only be performed by authorized Bosch Diesel Centers and Bosch Diesel Services. This requires the "DCI" software installed on the test bench, a hand scanner, a thermal printer, a label dispenser as well as repair ID labels and repair ID clips to mark repaired Bosch injection components.

The information concerning the repaired Bosch injection components (e.g. end of warranty, IMA code, contact details) is saved on the Bosch Quality Scan server and can be accessed via the website Bosch QualityScan-Online or via the Bosch "QualityScan" app.

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What do I need to do for a Bosch QualityScan?

What do I need to do for a Bosch QualityScan?

  • Internet connection required

  • Bosch QualityScan login information (user name and password)

  • Bosch QualityScan is activated under: "Settings >> Subscriptions >> BQS"

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DCI 700: testing injectors and preparing protocols

  1. Clean the injector.

  2. Repair the injector.

  3. Use a heat-resistant touch-up applicator to conceal the existing IMA identifier.

  4. Attach a repair ID to the injector.

    If scanning is difficult with the components installed, we recommend attaching repair ID labels and repair ID clips only after the injectors have been tested.

  5. Connect the injector for the test.

  6. Perform the test.

  7. Create the protocol by selecting <Result>.

    The data will be entered into the protocol.

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Creating a repair file and uploading it to the Bosch QualityScan server

Only components that have passed the test can be used for Bosch QualityScan.

  1. Select the BQS tab.

  2. Enter the injector data, e.g. the repair ID, by using the hand scanner or keyboard.

    The 10-digit repair ID consists of upper-case letters (no special characters such as umlauts) and/or digits from 2 to 7.

    When entering the repair ID, it must be ensured that the tested and repaired Bosch injection components are not mixed up and that the correct repair ID is assigned to the test result.

  3. Use <Upload> to upload the injector data to BQS.

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Website "Bosch QualityScan-Online": showing repair files and printing packaging labels

The information stored on the Bosch QualityScan server can be called up on the website "Bosch QualityScan-Online". Packaging labels can be printed.

  1. Open the website Bosch QualityScan-Online .

  2. Enter your user name and password.

  3. Select <Log in>.

  4. Select a closed repair file.

  5. Use <Packaging label> to print a packaging label.

  6. Place the injector in the packaging intended for that purpose.

  7. Attach the packaging label to the front face of the package.

    The injector repair with Bosch QualityScan is complete.

    The data for the repaired component are accessible on the internet.

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Bosch "QualityScan" app: showing repair files

The Bosch "QualityScan" app can be used to access repair information on Bosch common-rail injectors and Bosch injection pumps stored on the Bosch QualityScan server.

The app is available from the Apple App Store and the Google Play Store.

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What is the meaning of the symbols in the "DCI" software?

What is the meaning of the symbols in the "DCI" software?

  • ITEM

    Open the context menu with additional functions

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  • ITEM

    Open the context menu with additional functions and additional dialog boxes

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  • ITEM

    Firmware update required. Go to the system overview to update the firmware

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  • ITEM

    The injector can be selected

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  • ITEM

    The injector cannot be selected because there is no license or the serial number of the DCI 700 does not match (e.g. due to test plan imports)

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  • ITEM

    Pictogram

    Actual value

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  • ITEM

    Pictogram

    Setpoint

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  • ITEM

    Pictogram

    Minimum value

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  • ITEM

    Pictogram

    Maximum value

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  • ITEM

    Start of loop. Several test steps are repeated in a loop

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  • ITEM

    End of loop. Several test steps are repeated in a loop

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  • ITEM

    Symbol indicating that an arrangement can be changed, e.g. the sequence of test steps or the order in which measured values displayed

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  • ITEM

    Symbol indicating that a menu (e.g. a test step) can be moved to a different position

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  • ITEM

    Quantity injected

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  • ITEM

    Injector return quantity

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  • ITEM

    Return pressure

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  • ITEM

    Injector return quantity (pressure booster)

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  • ITEM

    Return pressure (pressure booster)

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  • ITEM

    Sum of return quantities (injection nozzle and pressure booster)

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What is the workshop management system?

What is the workshop management system?

"Workshop management system" is a function in DCI. Injector data (e.g. type party number, serial number, date of manufacture, repair ID, IQA code) centrally stored as an XML file by a workshop management system can be used across all DCI 700s available in the computer network. This way, injectors can be identified prior to testing by the workshop management system and test results can be managed centrally. To increase workflow automation, other applications can be included in the network, e.g. a laser device for marking injectors (IQA identifier).

Further information can be obtained from your customer service agent (e.g. dealer).

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  • Workshop management system creating XML files with injector data

  • XML file with a structure readable by DCI, e.g.:

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Enabling the "workshop management system" function

  1. "DCI" software: log in a user with the expert user role.

  2. "Settings >> General >> Workshop management system."

  3. Select the option Switch on the interface for the workshop management system.

  4. Specify the directory to which the workshop management system is to save the injector data.

  5. Select <Save>.

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Identifying the injector

  1. "DCI" software: select <Test>.

    The injector selection will be displayed.

  2. Optional: limit the number of injectors displayed by selecting a tab, e.g. "Bosch CRI piezo."

  3. Highlight the injector, or enter the part number (e.g. 0445116001) or some of the part number (e.g. 001).

  4. Select <Next>.

    The injector has been identified.

  5. Activate the injector position.

  6. Select the injector from "Workshop system data."

    The injector data will be displayed.

  7. Select <Next>.

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Test

  1. Test the injector.

  2. Save the test result.

    The test result will be included in the XML file. The XML file will be overwritten, e.g.:

    The "Result_Test" and "Result_Value" tags describe the test result for the injector tested.
    "Result_Test": "OK" (test successful) or "NOK" (test unsuccessful).
    "Result_Value": the value "5" indicates that the test was successful. Any other value indicates that the test was unsuccessful.

User settings

How do I set up a printer?

How do I set up a printer?

  • The printer is configured in the operating system

  1. Connect the printer (e.g. 1 687 001 850) to the DCI 700 by means of the USB connecting cable, or use a network printer.

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    (1) USB 3.0 ports

    (1) USB 2.0 ports

  2. Switch on the printer.

  3. "DCI" software: select "Settings >> Printer."

    "Microsoft Print to PDF" can be used to save protocols as PDF files. This way, protocols can be transferred to another computer, e. g. by USB stick, and printed from there.

  4. Select the printer.

  5. Select <Save>.

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How can I add, delete and edit users?

How can I add, delete and edit users?

Some of DCI 700's functions are only available to users with the expert role, e.g. "Settings >> General >> Workshop management system."

After a restart of DCI, there will be a password prompt if no password has been entered for the most recently selected user.

  1. "DCI" software: select "My workshop >> Tester."

  2. Optional: use <New> to add a user. Then, edit the new user, e.g. by changing the user name or password or by selecting a user role or profile image.

  3. Use to open the context menu.

  4. Select "Edit" or "Delete."

  5. Edit the user, e.g. by changing the password or selecting a user role or profile image.

  6. Select <Apply>.

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How can I change the company information and company logo that appears on the test protocols?

How can I change the company information and company logo that appears on the test protocols?

  1. "DCI" software: Select "My workshop >> My workshop".

  2. Select <Edit>.

  3. Enter company data.

  4. Select <Apply>.

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How do I activate/deactivate the virtual keyboard?

How do I activate/deactivate the virtual keyboard?

  1. "DCI" software: Select "Settings >> Regions".

  2. Activate/deactivate the option Use virtual keyboard.

  3. Press <Save>.

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How can I change the keyboard layout?

How can I change the keyboard layout?

  1. "DCI" software: Select "Settings >> Regions".

  2. Select country.

    The language and keyboard layout are set on a country-specific basis.

  3. Change the language and keyboard layout (optional).

  4. Press <Save>.

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How can I change the order in which the measured values are displayed?

How can I change the order in which the measured values are displayed?

  1. In the "Test" window, select the Details tab.

  2. Select .

  3. Select the Rearrange tiles tab.

  4. Arrange the measured value tiles (e.g. tank temperature) in the order you wish.

  5. Select <Apply>.

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Can I change the arrangement of the DCI control elements?

Can I change the arrangement of the DCI control elements?

No, the arrangement of the control elements (e.g. the tiles on the start screen of DCI) cannot be changed.

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Prerequisites

Does the DCI 700 need an internet connection?

Does the DCI 700 need an internet connection?

Yes, an Internet connection is needed, for instance, for licensing and regular license verification, for downloading updates, for Bosch QualityScan (BQS) and for display of the Help Center.

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Do I need an antivirus program and firewall?

Do I need an antivirus program and firewall?

We recommend using an up-to-date antivirus program and firewall. These have already been installed and configured by Windows.

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Licensing

What licensing models are available for the DCI 700?

What licensing models are available for the DCI 700?

Additional licenses can be used for a second or additional DCI 700.

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  • DCI-CRI – 1687P15090999

  • DCI-CRI (1 year) – 1687P15091999

  • DCI-CRI (3 years) – 1687P15093999

  • DCI-CRI (4 years) – 1687P15094999

  • DCI-CRI additional license – 1687P15095999

  • DCI-CRI additional license (1 year) – 1687P15096999

  • DCI-CRI additional license (3 years) – 1687P15098999

  • DCI-CRI additional license (4 years) – 1687P15099999

  • DCI-CRIN – 1687P15100999

  • DCI-CRIN (1 year) – 1687P15101999

  • DCI-CRIN (3 years) – 1687P15103999

  • DCI-CRIN (4 years) – 1687P15104999

  • DCI-CRIN additional license – 1687P15105999

  • DCI-CRIN additional license (1 year) – 1687P15106999

  • DCI-CRIN additional license (3 year) – 1687P15108999

  • DCI-CRIN additional license (4 year) – 1687P15109999

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How do I obtain licenses for DCI and BQS?

How do I obtain licenses for DCI and BQS?

  • Internet connection required

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DCI

  1. Select "Settings >> Subscriptions >> DCI ."

  2. Select <Extension to license>.

  3. Enter your user name and password.

    Your user name (customer number) and password can be found in your welcome e-mail. If you lose your user name or password, please contact the ESI[tronic] Serviceline.

  4. Select <Next>.

    License information will be displayed.

  5. If you have several agreements, select the desired agreement.

  6. Select <Apply>.

    DCI has been licensed.

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BQS (Bosch QualityScan)

  1. Select "Settings >> Subscriptions >> BQS."

  2. Select <Log in>.

  3. Enter the BQS user name and password.

    An e-mail with your BQS user name and password was sent to you on the conclusion of the agreement. If you lose your password, you can request a new one from the website Bosch QualityScan-Online . If you lose your user name, please contact the Bosch QualityScan team (for contact information, see the menu item "Contact" in the header of the website Bosch QualityScan-Online ).

  4. Select <Next>.

    The BQS has been licensed.

    License information will be displayed.

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How do I renew the license for DCI?

How do I renew the license for DCI?

If used under a limited-term license, DCI requires a new license at the end of the year.

License information (e.g. license status, scope and expiry date) can be displayed under: "Settings >> Subscription >> DCI ."

  • The message DCI license expired or DCI license in extension period is displayed

  • Internet connection required

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  1. "DCI" software: select "Settings >> Subscription >> DCI ."

  2. Select <Renew license>.

  3. Enter your user name and password.

    Your user name (customer number) and password can be found in your welcome e-mail. If you lose your user name or password, please contact the ESI[tronic] Serviceline.

  4. Select <Next>.

    License information will be displayed.

  5. If there are multiple contracts: select the contract assigned to this DCI 700.

  6. Select <Apply>.

    DCI has been licensed.

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Do I need to license the operating system (Windows 10)?

Do I need to license the operating system (Windows 10)?

No, the DCI 700 operating system does not need to be licensed at either initial commissioning or when restoring the system (recovery). Internet connection required.

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Updates

Do I need to perform updates (e.g. during initial commissioning)?

Do I need to perform updates (e.g. during initial commissioning)?

Yes, during initial commissioning an update must be performed via "DDM" (Diagnostics Download Manager). We recommend keeping the DCI 700 connected to the internet permanently so that new functions, content and product improvements can be installed. After a software update, check if a firmware update is available.

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What is DDM?

What is DDM?

The "DDM" (Diagnostics Download Manager) software makes it possible to easily install and update Bosch workshop applications, e.g. ESI[tronic] and DCI.

As soon as the DCI 700 is online, "DDM" will regularly check for available updates and download them from the Bosch server in the background. We recommend keeping the DCI 700 connected to the internet permanently so that new functions, content and product improvements can be installed. After a software update, check if a firmware update is available.

The "DDM" software was automatically installed during initial commissioning of the DCI 700.

For further information, see "DDM Help Center" (open the "DDM" software: double-click in the task bar).

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How do I update DCI 700?

How do I update DCI 700?

Downloads of software updates are performed automatically in the background, which has no impact on the performance of your DCI 700. Interrupted downloads will resume automatically at the next available opportunity.

Checks for software updates can be performed automatically at specified intervals or manually. Software updates will only be installed after confirmation.

  1. Open the "DDM" software: click in the task bar.

  2. Select "Updates."

    For further information, see "DDM Help Center".

  3. After the software update, check if a firmware update is available.

    "DCI" software: select "Status" from the main-menu bar.

    If the message New firmware version available. is displayed: select .

    In the line "Test bench firmware," select <Update> or <Repair>.

    Highlight the highest firmware version.

    Use <Download> to install the firmware.

    Read and follow the instructions on the screen.

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Do I need to update the operating system?

Do I need to update the operating system?

No, the operating system does not need to be updated manually. If required, Microsoft makes updates available automatically, e.g. for the virus scanner.

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Preparation for testing

How do I import test sequences?

How do I import test sequences?

You can obtain test sequences for CRIs and piezo CRIs by Denso, Delphi and Siemens/VDO/Continental from the information provider "REFDAT," for example. These test sequences can be imported into DCI.

The information provider is responsible for the accuracy of the test values. Robert Bosch GmbH will not accept any liability for the test sequence and data.

For further information, see: www.refdat.net

REFDAT test sequences are specific to certain test benches and therefore cannot be used for other DCI 700s. If a REFDAT test sequence has been imported into a DCI 700 under a different serial number, the symbol will be displayed and the test cannot be performed.

  1. "DCI" software: Select "My test plans."

  2. Select <Import>.

  3. Select the test plans' directory (XML file).

    The test plans available will be shown.

  4. <Import all> can be used to import all test plans from the directory selected, or "Import >" can be used to import individual test plans.

  5. Select <Next>.

    The test plans will be imported.

  6. Select <Next>.

    The XML file has been imported. Imported test plans are displayed under "My test plans."

    Added injectors can be selected from the injector selection.

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How do I clean injectors?

How do I clean injectors?

Do not clean the nozzle cone with a brass brush, steel brush or the like as this would damage the injection orifices. Do not clean injection orifices with the nozzle cleaning tool 0 986 611 140. Do not clean the electrical connection of the injector with cold cleaning agent.

  1. Also heed the additional cleaning information in the ESI[tronic] component repair instructions.

  2. Seal the inlet connection, test oil return connection and nozzle cone of the injector with protective caps or cover over.

  3. Use a plastic brush to remove any coarse dirt on the injector.

  4. Pre-clean the injector with cold cleaning agent.

    For ultrasonic cleaning, use the intensive cleaner TICKOPUR TR 13 or a comparable corrosion- and coke-dissolving cleaning agent.

  5. Remove the protective cap from the nozzle cone.

  6. Attach the injector to a suitable holding device and immerse it in the ultrasonic bath until the nozzle retaining nut is completely covered by the cleaning agent.

  7. Set a cleaning temperature of 60 °C to 70 °C.

  8. After approx. 15 minutes, take the injector out of the ultrasonic bath and blow dry with compressed air.

  9. To prevent subsequent contamination (e.g. fluff, metal chips), place the injectors in a clean, closed container after cleaning.

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How do I change the adapter nut so that I can attach the injector to the high-pressure rail?

How do I change the adapter nut so that I can attach the injector to the high-pressure rail?

The high-pressure connections have replaceable adapter nuts which must be changed depending on the thread size of the high-pressure port on the injector (see Help Center).

  1. Swivel the high-pressure rail to position "P".

    458922-50_Pal.svg
    Swivel fixture

    (1) Swivel fixture with high-pressure rail

    (2) Locking lever

    (3) Scale plate

  2. Remove the injector or screwed drain plug from the high-pressure connection on the high-pressure rail.

  3. Turn the adapter nut counterclockwise (1) to unscrew and remove it from the hexagon socket head bolt (2) .

    458922-45_Pal.svg
    Reduziermutter entfernen

    (1) Adapter nut

    (2) Hex nut

  4. Check whether the thrust ring is (2) tight (left-hand thread).

  5. Turn the adapter nut (1) clockwise to attach it to the hexagon socket head bolt (3). Do not tighten the adapter nut.

    458922-46_Pal.svg
    Reduziermutter montieren

    (1) Adapter nut

    (2) Thrust ring

    (3) Hexagon socket head bolt

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Which adapter cable do I need to use, and how do I connect it?

Which adapter cable do I need to use, and how do I connect it?

During the test, the injectors are actuated electrically by way of the adapter cables. One adapter cable is needed for each injector.

Adapter cable 1 684 465 848 / new: 1 684 465 890

For Bosch CRI 1, CRI 2x and CRI piezo and CRIN with CRI connection features.

458922-51_Pal.svg
Adapter cable 1 684 465 890

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Adapter cable 1 684 465 849

For Bosch CRIN.

458930-03_Pal.svg
Adapter cable 1 684 465 849

  1. Plug the connector (2) into the injector actuation port (1), and lock it.

  2. Attach the sockets (3) to the contacts (4) of the Bosch CRIN (5). It is not necessary to observe any particular sequence of polarity.

    458930-02_Pal.svg
    Electrical connection of Bosch CRIN A

    (1) Injector A actuation port

    (2) Plug

    (3) Sockets

    (4) Contacts

    (5) Bosch CRIN

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Adapter cable 1 684 465 865

For Bosch CRI piezo 3-25 and 3-27.

458922-52_Pal.svg
Adapter cable 1 687 465 865

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Adapter cable 1 684 465 867

For Bosch CRIN 4.2.

458931-08_Pal.svg
Adapter cable 1 684 465 867

Per testing procedure, a maximum of 2 Bosch CRIN 4.2s can be clamped in and tested.

Always refer to the designation plates on the adapter cable while making connections. If the plugs are plugged in the wrong way, the DCI 700 will detect reverse polarity and the screen will display a message for the user.

  1. For Bosch CRIN A: plug the A/C plug (2) into the injector A actuation port (1), and lock it.
    For Bosch CRIN C: plug the A/C plug (2) into the injector C actuation port, and lock it.

  2. For Bosch CRIN B: plug the B/D plug (4) into the injector B actuation port (3), and lock it.
    For Bosch CRIN D: plug the B/D plug (4) into the injector D actuation port, and lock it.

  3. Attach the connector (5) to the Bosch CRIN contacts. The contacts of the Bosch CRIN are staggered. While making the connection, make sure to insert the connector (5) in the right position. The connector's coding (6) must face forward.

    Connection cables with a damaged connector (5) are exempt from liability claims for material defects.

    458931-09_Pal.svg
    Electrical connection of Bosch CRIN A

    (1) Injector A actuation port

    (2) A/C plug (nozzle needle actuation)

    (3) Injector B actuation port

    (4) B/D plug (pressure booster actuation)

    (5) Connector

    (6) Coding

    (7) Bosch CRIN

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Adapter cable 1 684 465 884

Adapter cable 1 684 465 884 for actuating Denso CRIs and Denso piezo CRIs during testing.

458935-03_Pal.svg
Adapter cable 1 684 465 884

---Separator---

Adapter cable 1 684 465 885

Adapter cable 1 684 465 885 for actuating Delphi CRIs during testing.

458935-04_Pal.svg
Adapter cable 1 684 465 885

---Separator---

Why do I need return adapter 1 687 016 138, and how do I connect it?

Why do I need return adapter 1 687 016 138, and how do I connect it?

Return adapter for adaptation to the test oil return connection on Siemens/VDO/Continental piezo CRIs.

458935-07_Pal.svg
Return adapter 1 687 016 138

(1) Return adapter 1 687 016 138

(2) O-ring Ø3.5 x 1.25 mm

---

Return adapter 1 687 016 138 connection and removal

458935-01_Pal.svg
Return adapter 1 687 016 138

(1) Return adapter 1 687 016 138

(2) Test oil return connection

(3) Spring clip

  1. Check the O-ring of the return adapter (1). Replace the O-ring if it is defective or brittle.

    WARNING – Fragments from the O-ring can remain in the injector and make their way into the vehicle's fuel system.

  2. Plug the return adapter (1) into the test oil return connection (2) of the Siemens/VDO/Continental piezo CRI.

  3. Use the spring clip (3) to secure the return adapter. The spring clip is supplied with the Siemens/VDO/Continental piezo CRI.

  4. Connect hose assembly (test oil return) 1 680 712 382 to the return adapter.

  5. For removal of the return adapter, perform the connection steps in reverse order.

---

Why do I need return adapter 1 687 016 215, and how do I connect it?

Why do I need return adapter 1 687 016 215, and how do I connect it?

Return adapter for adaptation to the test oil return connection on the injector. For most Bosch CRIs.

458922-54_Pal.svg
Rücklaufadapter 1 687 016 215

(1) Return adapter 1 687 016 215

(2) O-ring (9.5 x 2 mm)

(3) Spring clip 0 986 612 893

  1. Check the O-ring (2) of the return adapter (1). Replace the O-ring if it is defective or brittle.

    WARNING – Fragments from the O-ring can remain in the injector and make their way into the vehicle's fuel system.

  2. Insert the return adapter (1) into the test oil return connection of the injector.

  3. Secure the return adapter with the spring clip (3). The spring clip is supplied with the injector.

  4. Connect hose assembly 1 680 712 382 for return quantities to the return adapter.

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Why do I need return adapter 1 683 356 137, and how do I connect it?

Why do I need return adapter 1 683 356 137, and how do I connect it?

The included cover caps can be used to keep the return adapters dust-free during storage.

---

Return adapter for adaptation to the test oil return connection on Delphi CRIs.

458935-06_Pal.svg
Return adapter 1 683 356 137

(1) Return adapter 1 683 356 137

(2) O-ring Ø3.5 x 1.25 mm

---

Return adapter 1 683 356 137 connection and removal

458909-03_Pal.svg
Return adapter 1 683 356 137

(1) Return adapter 1 683 356 137

(2) Test oil return connection

(3) Tab

  1. Check the O-ring of the return adapter (1). Replace the O-ring if it is defective or brittle.

    WARNING – Fragments from the O-ring can remain in the injector and make their way into the vehicle's fuel system.

  2. Plug the return adapter (1) into the test oil return connection (2) of the Delphi CRI.

  3. Secure the return adapter (1) by pressing the tab (3) down.

  4. Connect hose assembly 1 680 712 249 to the return adapter (1).

  5. Connect the other end of hose assembly 1 680 712 249 to hose assembly (test oil return) 1 680 712 382.

  6. To remove it, pull up the tab (3) and pull the return adapter (1) out of the test oil return connection (2).

---

Why do I need return adapter 1 683 356 138, and how do I connect it?

Why do I need return adapter 1 683 356 138, and how do I connect it?

The included cover caps can be used to keep the return adapters dust-free during storage.

---

Return adapter for adaptation to the test oil return connection on Delphi CRIs.

458935-05_Pal.svg
Return adapter 1 683 356 138

(1) Return adapter 1 683 356 138

(2) O-ring Ø3.5 x 1.25 mm

---

Return adapter 1 683 356 138 assembly and removal

458909-04_Pal.svg
Return adapter 1 683 356 138

(1) Return adapter 1 683 356 138

(2) Test oil return connection

(3) Tab

  1. Check the O-ring of the return adapter (1). Replace the O-ring if it is defective or brittle.

    WARNING – Fragments from the O-ring can remain in the injector and make their way into the vehicle's fuel system.

  2. Plug the return adapter (1) into the test oil return connection (2) of the Delphi CRI.

  3. Secure the return adapter (1) by pressing the tab (3) down.

  4. Connect hose assembly 1 680 712 249 to the return adapter (1).

  5. Connect the other end of hose assembly 1 680 712 249 to hose assembly (test oil return) 1 680 712 382.

  6. To remove it, pull up the tab (3) and pull the return adapter (1) out of the test oil return connection (2).

---

Why do I need the hose assembly hose assembly 1 683 351 066 and how do I connect it?

Why do I need the hose assembly hose assembly 1 683 351 066 and how do I connect it?

Hose assembly for adaptation to the test oil return connection of the injector. For Bosch CRI 2.18 and 2.20.

458922-55_Pal.svg
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

  1. Check both O-rings (1) and (2). Replace defective or brittle O-rings.

    WARNING – Fragments of the O-ring can remain in the injector and then find their way into the vehicle's fuel system.

  2. Loosen the knurled nut (3) until the O-ring (2) is no longer tensioned.

  3. Insert the hose assembly for adaptation into the test oil return connection of the injector.

  4. Hold the hose assembly in position and tighten the knurled nut (3) by hand.

  5. Check that the hose is firmly attached.

  6. Also attach hose assembly 1 680 712 382 for the return quantities to the hose assembly.

---Separator---

Why do I need hose assembly 1 680 712 249, and how do I connect it?

Why do I need hose assembly 1 680 712 249, and how do I connect it?

Hose assembly for adaptation to the test oil return connection on Delphi CRIs.

458935-13_Pal.svg
Hose assembly 1 680 712 249

(1) Screw clamp Ø6–16 mm

(2) Hose assembly 1 680 712 249

Hose assembly 1 680 712 249 connection and removal

458935-10_Pal.svg
Hose assembly 1 680 712 249 connection

  1. Connect hose assembly 1 680 712 249 to the test oil return connection of the Delphi CRI.

  2. Tighten the screw clamp.

  3. Connect hose assembly (test oil return) 1 680 712 382 to the hose assembly.

  4. For removal of the hose assembly, perform the connection steps in reverse order.

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Why do I need hose assembly 1 680 712 250, and how do I connect it?

Why do I need hose assembly 1 680 712 250, and how do I connect it?

Hose assembly for adaptation to the test oil return connection on Delphi CRIs.

458935-12_Pal.svg
Hose assembly 1 680 712 250

(1) Spring clamp

(2) O-ring Ø4 x 1.5 mm

Hose assembly 1 680 712 250 connection and removal

458935-11_Pal.svg
Hose assembly 1 680 712 250 connection

  1. Check the O-ring. Replace the O-ring if it is defective or brittle.

    WARNING – Fragments from the O-ring can remain in the injector and make their way into the vehicle's fuel system.

  2. Plug hose assembly 1 680 712 250 into the return bore of the Delphi CRI. The spring clamp is intended to secure the hose assembly.

  3. Connect hose assembly (test oil return) 1 680 712 382 to the hose assembly.

  4. For removal of the hose assembly, perform the connection steps in reverse order.

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Why do I need hose assembly 1 680 712 253, and how do I connect it?

Why do I need hose assembly 1 680 712 253, and how do I connect it?

Hose assembly for adaptation to the test oil return connection with the screw connection M8 x 1 on Delphi CRIs.

458935-14_Pal.svg
Hose assembly 1 680 712 253

(1) Copper gasket A8 x 11 mm

(2) Hose assembly 1 680 712 253

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Hose assembly 1 680 712 253 connection and removal

458935-09_Pal.svg
Hose assembly 1 680 712 253 connection

  1. Screw in and tighten hose assembly 1 680 712 253 with the gasket on the test oil return connection of the Delphi CRI.

  2. Connect hose assembly (test oil return) 1 680 712 382 to the hose assembly.

  3. For removal of the hose assembly, perform the connection steps in reverse order.

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Why do I need hose assembly 1 680 712 312, and how do I connect it?

Why do I need hose assembly 1 680 712 312, and how do I connect it?

Hose assembly for adaptation to the test oil return connection on Denso CRIs.

458935-15_Pal.svg
Hose assembly 1 680 712 312

(1) O-ring Ø4 x 1.5 mm

(2) Lever for hose retainer

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Hose assembly 1 680 712 312 connection and removal

458935-08_Pal.svg
Hose assembly 1 680 712 312 connection and removal

  1. Push the lever.

  2. Plug hose assembly 1 680 712 312 into the test oil return connection of the Denso CRI.

  3. Release the lever. The hose retainer must engage with the groove of the test oil return connection.

  4. Connect hose assembly (test oil return) 1 680 712 382 to the hose assembly.

  5. For removal of the hose assembly, perform the connection steps in reverse order.

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Why do I need the hose assembly hose assembly 1 680 712 315 and how do I connect it?

Why do I need the hose assembly hose assembly 1 680 712 315 and how do I connect it?

Hose assembly for adaptation to the test oil return connection of the injector. For Bosch CRI piezo.

458922-56_Pal.svg
Hose assembly 1 680 712 315

  1. Check the O-ring at the test oil return connection of the injector. Replace the O-ring if it is defective or brittle.

  2. Attach the terminal connector to the test oil return connection of the injector.

    458922-57_Pal.svg
    Schlauchleitung aufstecken

  3. The terminal connector must snap onto the test oil return connection.

    458922-58_Pal.svg
    Schlauchleitung einrasten

  4. Push the locking sleeve down.

    458922-59_Pal.svg
    Schlauchleitung verriegeln

---Separator---

Removing the hose assembly

  1. Pull the locking sleeve up.

  2. Carefully remove the terminal connector from the test oil return connection.

    458922-60_Pal.svg
    Schlauchleitung entfernen

---Separator---

What do I need hose assembly 1 680 712 396 for, and how do I connect it?

What do I need hose assembly 1 680 712 396 for, and how do I connect it?

Hose assembly 1 680 712 396 for connecting to the connector on connection adapter Ax1.

458931-17_Pal.svg
Connection with hose assembly 1 680 712 396

(1) Hose assembly 1 680 712 396

(2) Pressure booster return quantity connection (DV)

(3) Connection adapter

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What do I need connection adapter Ax1 for, and how do I connect it?

What do I need connection adapter Ax1 for, and how do I connect it?

Connection adapter for accepting Bosch CRINs for testing.

The hold-down (1) is used to insert the Bosch CRIN into the connection adapter and to pull it out of the connection adapter during disassembly. The hose assembly 1 680 712 396 is to be connected to the pressure booster return quantity connection (DV) (2). The hose assembly for return quantity 1 680 712 382 is to be connected to the solenoid valve return quantity connection (3).

458931-07_Pal.svg
Connection adapter Ax1

(1) Hold-down

(2) Pressure booster return quantity connection (DV)

(3) Solenoid valve return quantity connection (DMV)

Hydraulic connection

458931-11_Pal.svg
Hydraulic connection CRIN 4.2

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How do I adapt the injection chamber to the various nozzle diameters?

How do I adapt the injection chamber to the various nozzle diameters?

Depending on the diameter of the injection nozzle (7 mm or 9 mm) of the injector, the O-ring insert (3) with the O-rings and the knurled nut (1) on the injection chamber must be changed. The O-ring inserts and the knurled nuts are marked with D7 for nozzle diameter 7 mm and D9 for nozzle diameter 9 mm.

  1. Turn the knurled nut (1) counterclockwise and remove it from the injection chamber (5).

  2. Remove the O-ring insert (3) from the injection chamber.

  3. Select O-ring insert (7 mm or 9 mm) (3).

  4. Insert the appropriate O-rings (2) and (4) into the O-ring insert (3).

  5. Place the O-ring insert with the O-rings into the injection chamber (5).

  6. Select the appropriate knurled nut (7 mm or 9 mm) (1).

  7. Turn the knurled nut (1) clockwise to attach it to the injection chamber (5). Do not tighten.

    458922-38_Pal.svg
    O-Ringeinsatz und Rändelmutter montieren

    (1) Knurled nut 7 mm (D7) or 9 mm (D9)

    (2) O-ring (7 x 4 mm for O-ring insert 7 mm or O-ring 9 x 3 mm for O-ring insert 9 mm)

    (3) O-ring insert (7 mm for knurled nut D7 or 9 mm for knurled nut D9)

    (4) O-ring 12 x 2 mm

    (5) Injection chamber

---Separator---

How do I fasten the injection chamber to the injector?

How do I fasten the injection chamber to the injector?

  • The injector must be positioned vertically to attach the injection chamber.

---Separator---

  1. Turn the locking knob (3) counterclockwise and loosen the attachment (4).

  2. Adjust the attachment (4) and injection chamber (2) until the injection chamber can be pushed onto the nozzle tip of the injector (1).

  3. Push the injection chamber (2) all the way onto the nozzle tip of the injector.

    458922-41_Pal.svg
    Einspritzkammer montieren

    (1) Nozzle tip of an injector

    (2) Injection chamber

    (3) Locking handle for securing the attachment

    (4) Attachment

  4. Turn the locking handle(2) clockwise and secure the attachment (3) .

  5. Turn the knurled nut (1) clockwise to tighten it by hand.

    Do not tighten the knurled nut to the point where it comes into contact with the body of the injection chamber. The thermal expansion of the injection chamber would then make it difficult to loosen the knurled nut.

    458922-42_Pal.svg
    Einspritzkammer befestigen

---Separator---

Conducting the test

How do I test injectors?

How do I test injectors?

Heed 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 observed.

  • Pictogram DANGER

    • Warning

    • Do not delete this line.

      • Touching hot injectors and hot test equipment (e.g. the injection chamber) may cause severe burns.

      • Allow injectors and test equipment to cool down.

      • Put on protective gloves before removing the injection chamber.

      • Wear protective gloves.

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Preparation for testing

  1. Clean the injectors. ( How do I clean injectors? )

  2. Identify the injector. ( How do identify an injector? )

    The connection adapters will be displayed.

  3. Connect the injectors. ( How do I connect injectors for the test? )

  4. Attach the injection chamber for the injector quantity test to the injector.

  5. Close the protective door.

  6. Select <Next>.

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Conducting the test

  1. In the "Injector selection" window, select <Next>.

  2. Use On to activate the injector positions at which injectors are connected.

  3. Enter the injector data, e.g. the serial number.

    The IQA identifier (IQA = injector quantity adjustment) is an identifier affixed to IQA-coded components for the calibration of fuel injectors. Once the test is finished, the IQA identifier entered will be confirmed or a new IQA identifier will be generated and indicated in the protocol.
    When testing injectors, use the IQA identifier indicated in the imprint. For injector repairs, a new IQA identifier must be generated.

  4. Select <Next>.

  5. Optional: edit the test sequence, e.g. change the sequence of test steps.

  6. In the "Test" window, select <Start>.

    The test will start.

  7. Monitor the test.

    In the event of a malfunction, use <Stop> to interrupt the test.

  8. Use <Result> to display the test result.

  9. Add the customer.

  10. Use <Save> to save the test result.

  11. Use "Protocols >> Print" to print the protocol.

  12. Optional: use "Protocols >> BQS" to transfer the data to Bosch QualityScan. ( What do I need to do for a Bosch QualityScan? )

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How do identify an injector?

How do identify an injector?

Identifying the injector

  1. "DCI" software: select <Test>.

    The injector selection will be displayed.

  2. Optional: limit the number of injectors displayed by selecting a tab, e.g. "Bosch CRI piezo."

  3. Highlight the injector, or enter the part number (e.g. 0445116001) or some of the part number (e.g. 001).

  4. Optional: use to add the injector to favorites.

  5. Select <Next>.

    The injector has been identified.

    For many injectors, clamping information such as the IQA identifier's position on the injector are indicated in the tab "Injector details."

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Reading the serial number on the injector

The type part number, date of manufacture and serial number are located on the plastic collar on the top end of Bosch CRIs and CRINs:

  • Type part number: 10-digit number starting with 0 445 (some CRINs do not have a number like that)

  • Date of manufacture: e.g. a 5-digit or 6-digit number (sometimes hyphenated)

  • Serial number: e.g. a 4-digit number

    The description applies to most Bosch CRIs and CRINs. On some Bosch CRIs and CRINs, the information is indicated differently. The figures shown are examples. For further information, see: Bosch "ESI[tronic]" diagnostic software.

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CRI (0 445 110 xxx)

1 IQA identifier of the injection valve

2 Type part number

3 Serial number

4 Date of manufacture

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CRIN (0 445 120 xxx)

1 IQA identifier of the injection valve

2 Type part number

3 Serial number

4 Date of manufacture

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How can I add an injector to favorites?

How can I add an injector to favorites?

  1. "DCI" software: select <Test>.

    The injector selection will be displayed.

  2. Optional: limit the number of injectors displayed by selecting a tab, e.g. "Bosch piezo CRI."

  3. Highlight the injector, or enter the part number (e.g. 0445110002) or some of the part number (e.g. 002).

  4. Use to open the context menu.

  5. Select "Add to favorites …."

    The injector will appear in the Favorites tab.

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How do I connect injectors for the test?

How do I connect injectors for the test?

  • Use only clean connection equipment

  • Observe the requirements in the "DCI" software for connection equipment specific to the injector.

    Diesel test equipment_de

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Connecting the injector

  1. Swivel the high-pressure rail to position "P."

  2. Attach the specified adapter nut (M12 x 1.5 or M14 x 1.5) to the high-pressure rail. ( How do I change the adapter nut so that I can attach the injector to the high-pressure rail? )

  3. Attach the injector to the high-pressure connection of the high-pressure rail, and align it. Tightening torque: 25–30 Nm.

  4. Seal unused high-pressure connections with threaded plugs. Tightening torque: 25–30 Nm.

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Attaching the adapter cable to the DCI 700

  • Attach the adapter cable to the injector actuation port. ( Which adapter cable do I need to use, and how do I connect it? )

    458922-49_Ju.svg

    (1) Injector A actuation port

    (2) Injector B actuation port

    (3) Injector C actuation port

    (4) Injector D actuation port

    Per testing procedure, a maximum of 2 Bosch CRINs 4.2 can be clamped in and tested (injector positions A and C).

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Attaching the adapter cable and hose assembly to the injector

  1. Use the swivel mechanism to swivel the injectors to a vertical position.

  2. Attach the adapter cable to the injector.

    Observe the specifications for assigning the adapter cables to the injectors A, B, C and D.

    Injectors will get hot during the test and may damage cables as a result.

    Position the cables in such a way that they do not touch the injectors.

  3. Attach the connection adapter to the injector.

  4. Attach test oil return hose assembly 1 680 712 382 to the connection adapter.

    Observe the specifications for assigning the hose assemblies to the injectors A, B, C and D.

    458922-53_Pal.svg
    Test oil return connection with return adapter 1 687 016 215

    (1) Test oil return hose assembly 1 680 712 382

    (2) Return adapter 1 687 016 215

    (3) Test oil return connection of injector

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Fasten the injection chamber for the injector quantity test to the injector

  • The injector must be positioned vertically to attach the injection chamber.

---Separator---

  1. Turn the locking knob (3) counterclockwise and loosen the attachment (4).

  2. Adjust the attachment (4) and injection chamber (2) until the injection chamber can be pushed onto the nozzle tip of the injector (1).

  3. Push the injection chamber (2) all the way onto the nozzle tip of the injector.

    458922-41_Pal.svg
    Einspritzkammer montieren

    (1) Nozzle tip of an injector

    (2) Injection chamber

    (3) Locking handle for securing the attachment

    (4) Attachment

  4. Turn the locking handle(2) clockwise and secure the attachment (3) .

  5. Turn the knurled nut (1) clockwise to tighten it by hand.

    Do not tighten the knurled nut to the point where it comes into contact with the body of the injection chamber. The thermal expansion of the injection chamber would then make it difficult to loosen the knurled nut.

    458922-42_Pal.svg
    Einspritzkammer befestigen

---Separator---

How do I fit Bosch CRINs 4.2?

How do I fit Bosch CRINs 4.2?

Damaged Bosch CRINs may damage the connection adapter.

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Defective O-rings on the Bosch CRIN may not form a proper seal. Leakage may lead to observational errors.

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  1. Clean the Bosch CRIN as specified by Bosch.

  2. Check the Bosch CRIN for damage. Do not install a Bosch CRIN if it is visibly damaged.

  3. Check both O-rings on the Bosch CRIN. Replace any damaged O-rings.

  4. Check the O-ring (2) of the connection adapter (1) for damage and proper placement. Replace the O-ring if it is damaged.

    458931-16_Pal.svg
    Connection adapter with O-ring

  5. Release the screw (1), and remove the hold-down (2).

    458931-15_Pal.svg
    Removing the hold-down

  6. Slide the Bosch CRIN into the hold-down (1).

  7. Use the hold-down to insert the Bosch CRIN into the connection adapter (2), and position it in such a way that the screw (3) is aligned with the threaded hole.

    458931-13_Pal.svg
    Installing the Bosch CRIN

  8. Screw in the screw (1) until the hold-down (2) is resting on the connection adapter.

    458931-14_Pal.svg
    Securing the Bosch CRIN

For removal, perform the steps in reverse order.

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Fitting a CRIN 4.2

Removing a CRIN 4.2

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How do I fit connection adapters for CRIN?

How do I fit connection adapters for CRIN?

Connection adapters are used to supply CRIN with internal connections via the inlet connector with test oil. In the software "DCI", the required test accessories are displayed after selecting the CRIN, e.g. injector-specific connection adapter, inlet connectors.

(1) CRIN

(2) Connection adapter

(3) Inlet connector

  1. Select the connection adapter (2).

  2. Check the O-ring in the connection adapter for damage (e.g. cracks).

  3. Slide the CRIN (1) into the connection adapter. When doing so, the inlet bore must be aligned with the hole for the inlet connector (3).

  4. Turn the CRIN until the high-pressure inlet bore is visible in the hole for the inlet connector.

    It is essential to comply with the specified torque when tightening the inlet connector. An excessive tightening torque will result in damage and breakage of the inlet connector on testing.

  5. Screw the inlet connector into the coonection adapter and tighten (tightening torque: 20 Nm – 25 Nm).

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Can I test different injector types at the same time?

Can I test different injector types at the same time?

No, only injectors that have the same type-part number can be tested during a test.

---Separator---

How do I enter customer data?

How do I enter customer data?

  1. "DCI" software: Select "My customers".

  2. Select <New>.

  3. Enter customer data.

  4. Select <Apply>.

---Separator---

Can I create new test sequences?

Can I create new test sequences?

No. Test sequences are already specified and can be edited, e.g. the sequence of the test steps can be changed. ( How can I edit a test sequence? )

---Separator---

How can I edit a test sequence?

How can I edit a test sequence?

  1. In the "Test" window, select the Details tab.

  2. Select .

  3. Select the Re-arrange the list tab.

  4. Optional: move the test steps to place them in the desired order.

    For piezo CRIs, the "Back Pressure" test step must be performed so flow measuring will be possible.

  5. Optional: edit the test step.

    Use to open the context menu.

    Select the desired function, e.g. Delete test step.

  6. Select <Apply>.

    In the Overview tab of the "Test" window, individual test steps can be deactivated or loops can be defined (start of loop and end of loop ).

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Where can I get test sequences for injectors from third-party manufacturers?

Where can I get test sequences for injectors from third-party manufacturers?

You can obtain test sequences for CRIs and piezo CRIs by Denso, Delphi and Siemens/VDO/Continental from the information provider "REFDAT," for example. For further information, see: www.refdat.net and " How do I import test sequences? ".

The information provider is responsible for the accuracy of the test values. Robert Bosch GmbH will not accept any liability for the test sequence and data.

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What do the test step names refer to?

What do the test step names refer to?

Back Pressure

"Back Pressure" test step

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BAL S

"Ballistic" test step

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Clean run

"Clean run" test step

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EM

"Emission point" test step

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IMA calculation

"IMA calculation" test step

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Isolation

"Isolation" test step

---

Leak test

"Leak test" test step

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Idle

"Idle" test step

---

Resistance

"Resistance" test step

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Start up

"Start up" test step

---

TL B

"Boot part load" test step

---

TL S

"Square part load" test step

---

VE

"Distributor fuel injection" test step

---

VE o

"Distributor fuel injection without booster" test step

---

FL

"Full load" test step

---

VL B

"Boot full load" test step

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Warm up

"Warm up" test step

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How do I remove injectors after the test?

How do I remove injectors after the test?

  • Pictogram DANGER

    • Warning

    • Do not delete this line.

      • Touching hot injectors and hot test equipment (e.g. the injection chamber) may cause severe burns.

      • Allow injectors and test equipment to cool down.

      • Put on protective gloves before removing the injection chamber.

      • Wear protective gloves.

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  1. Remove the injection chamber.

  2. Remove the adapter cable.

  3. Remove the hose assembly.

    Do not detach the hose assembly along with the return adapter from the injector to prevent test oil from leaking out. Emptying the valve blocks will extend the test duration.

  4. Remove the return adapter.

  5. To prevent test oil from leaking out, swivel the high-pressure rail to the "P" position.

  6. Remove the injector from the high-pressure rail.

  7. Seal the high-pressure connections with threaded plugs.

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How do I stop the DCI 700 in the event of a fault?

How do I stop the DCI 700 in the event of a fault?

  1. In the event of a malfunction, use <Stop> to interrupt the test.

    Injector actuation will be stopped.

    The drive motor will shut down in a controlled manner.

    The pressure in the high-pressure rail will be released.

  2. Rectify the malfunction.

  3. Restart the test.

    Switch off the DCI 700 by the main switch only in cases of extreme emergency. Switching off by the main switch while a test is being conducted may damage the processor unit or the operating system.

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Maintenance

When do I need to perform the various maintenance tasks?

When do I need to perform the various maintenance tasks?

  • Pictogram DANGER

    • Warning

    • Do not delete this line.

      • Risk of electric shock from hazardous voltage!

      • Work on electrical systems or equipment must only be performed by qualified electricians or trained personnel under the guidance and supervision of an electrician.

      • Before opening the DCI 700, switch it off and disconnect it from the mains voltage system.

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For further information, see the original operating instructions DCI 700 (1 689 989 343).

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.

Use-dependent

If the DCI 700 detects a fouled inlet filter or test oil filter, the user is informed by a message.

  • Change the test oil filter in the inlet filter.

  • Change the test oil filter.

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Once a day

  • Checking the high-pressure rail, injection chambers and test connections for leaks. Eliminate leaks immediately.

  • Inspect the adapter nuts and sealing surfaces at the high-pressure connections of the high-pressure rail for damage. Replaced damaged adapter nuts. Have damaged 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 immediately.

  • Inspect the protective cover for porous spots, cracks and dents. If the protective cover is damaged, change it immediately.

  • Check the fan on the heat exchanger for unusual noises. In the event of loud or scraping noises from the fan, notify customer service.

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Once a week

  • Drain contaminated oil in the test area.

  • Clean the test area and metal shelves in the work area. Heed the cleaning instructions.

  • Clean the protective insert in the protective door. Heed the cleaning instructions.

  • Clean the work area lights. Heed the cleaning instructions.

  • 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.

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Every 2 months or after 1500 injector tests

  • Change the test oil.

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Once a year

  • Inspect all hoses and hose assemblies for cracks and scuff marks. Replace damaged hoses or hose assemblies immediately.

  • Inspect the electrical cables on the rotating frame for scuff marks and bare spots. Replace damaged electrical cables or components immediately.

    DANGER! – Danger of electric shock. Disconnect the DCI 700 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 discolored power supply cable immediately.

    DANGER! – Danger of electric shock. Disconnect the DCI 700 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. Disconnect the DCI 700 from the mains voltage system.

  • Inspect the electrical connection in the junction box of the drive motor, on the power supply, on the frequency inverter and at the main switch for loose attachment. Tighten loose connections.

    DANGER! – Danger of electric shock. Disconnect the DCI 700 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 electronics 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 fins 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 accuracy.

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Every 8 years

  • Change the protective insert in the protective door.

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How can I reset maintenance cycles?

How can I reset maintenance cycles?

After maintenance work, e.g. changing the test oil or filter, the maintenance time must be reset.

  • Maintenance is complete

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  1. "DCI" software: select "Maintenance >> Service interval."

  2. Select "Status" from the main-menu bar.

    The Maintenance cycle tab will be displayed.

  3. Use to open the context menu of the tile (e.g. the most recent test oil change).

  4. Select "Reset."

  5. Use <OK> to confirm the reset.

    The current date and number of days until the next maintenance will be shown.

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How do I create data backups (back up data and settings)?

How do I create data backups (back up data and settings)?

We recommend performing regular data backups.

The storage location should be on a different computer or an external data storage device with sufficient storage space. The data backup includes the settings, results, users, customer data and workshop data stored on the DCI 700.

Before restoring saved data, we recommend that you perform a data backup, as the existing data will be overwritten during the restoring process.

  1. "DCI" software: select "Backup."

    Previous data backups will be displayed.

  2. Select <New data backup>.

  3. Select the storage location.

  4. Optional: enter a comment.

  5. Select <Start>.

    A data backup will be performed.

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How do I restore a data backup?

How do I restore a data backup?

  1. "DCI" software: select "Backup."

    Previous data backups will be displayed.

  2. Select <Restore>.

  3. Select the storage location.

  4. Highlight the data backup.

  5. Select <Next>.

  6. Optional: deselect unwanted components, e.g. settings.

  7. Select <Start>.

    The data will be restored.

  8. Restart the DCI 700.

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How do I calibrate DCI 700? (for customer service only)

How do I calibrate DCI 700? (for customer service only)

  • Reference pressure sensor 1 681 032 095

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Calibrate DCI 700 after replacement of the rail pressure sensor:

  1. Connect the reference pressure sensor to DCI 700 via a USB connection.

  2. "DCI" software: Select "Calibration >> High pressure".

  3. Attach the reference pressure sensor to the high-pressure connection of the high-pressure rail. Tightening torque: 25 Nm – 30 Nm.

  4. Once the measured values are stable, perform a zero point calibration with <Zero point calibration>.

  5. Seal unused high-pressure connections with screwed drain plugs. Tightening torque: 25 Nm – 30 Nm.

    If the measured values are not stable, replace the screwed drain plugs with injectors.

  6. Approach the first pressure point with <Start>.

  7. Once the measured value is stable, save the measured value and approach the next pressure point with <Continue>.

  8. Perform a calibration for the other positions.

  9. Press <Save>.

    Calibration is performed.

    If the calibration is canceled, the original calibration can be restored with <Read from the database>. Then select <Save>.

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Support

How can I contact support, e.g. in case of questions, instructions or faults?

How can I contact support, e.g. in case of questions, instructions or faults?

Further information can be obtained from your customer service agent, e.g. dealer.

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Faults

After the injector has been removed, a large amount of test oil emerges from the injection chamber

After the injector has been removed, a large amount of test oil emerges from the injection chamber

After the injector has been removed, a large amount of test oil emerges from the injection chamber.

The check valve in the hose assembly for the injected fuel quantity no longer closes properly.

  • Replace the hose assembly for the injected fuel quantity.

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Test oil emerges at the knurled nut on the injection chamber during the test.

Test oil emerges at the knurled nut on the injection chamber during the test.

Test oil emerges at the knurled nut on the injection chamber during the test.

Wrong O-ring insert was selected or the O-ring in the O-ring insert is defective.

  1. Use the appropriate O-ring insert with O-ring.

  2. Replace defective O-ring in the O-ring insert.

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The values for the amount of test oil are too high when injectors are tested.

The values for the amount of test oil are too high when injectors are tested.

The values for the amount of test oil are too high when injectors are tested.

There is too much air in the system.

  • Perform a test at the full-load step several times until the air has been purged out of the system.

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The values for the amount of test oil are too low when injectors are tested

The values for the amount of test oil are too low when injectors are tested

The values for the amount of test oil are too low when injectors are tested.

There could be a leak in the system.

  • Check for leaks. Eliminate leaks immediately.

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No amounts of test oil are measured when injectors are tested

No amounts of test oil are measured when injectors are tested

No amounts of test oil are measured when injectors are tested.

Injectors are not connected properly.

  • Check whether the injectors are connected properly electrically and hydraulically.

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PDF files, e.g. the injector overview, is not displayed

PDF files, e.g. the injector overview, is not displayed

On the DCI 700, not PDF files are displayed, e.g. the injector overview in the Help Center or in the DCI 700 release notes of the software "DDM" (Diagnostics Download Manager).

No PDF viewer like Adobe Acrobat Reader is installed.

  1. Open the website https://get.adobe.com/reader .

  2. Read and follow the installation instructions.

    Adobe Reader is now installed.

    The PDF files will be displayed.

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No license can be obtained for the DCI 700

No license can be obtained for the DCI 700

After a limited-term license has expired or after the DCI 700 has been sold, it might not be possible to obtain a license for DCI.

Malfunction in the CodeMeter Control Center

  1. Contact the ESI[tronic] Serviceline (), and have the contract unassigned from the DCI 700.

  2. Back up data and settings. ( How do I create data backups (back up data and settings)? )

    The system recovery will delete all data and settings from the DCI 700, e.g. licensing information, user settings, protocols and images.

  3. Perform a system recovery. ( Performing a recovery )

  4. Reload the backed-up data and settings ( How do I restore a data backup? ).

  5. Obtain a new license for DCI and BQS ( How do I obtain licenses for DCI and BQS? ).

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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 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.

No voltage supply.

  1. Check whether power supply cable is connected correctly.

  2. Turn on the main switch.

  3. Press the on/off button on the monitor.

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On switching on the DCI 700, the message "Missing Operating System" is displayed

On switching on the DCI 700, the message "Missing Operating System" is displayed

On switching on the DCI 700, the message Missing Operating System is displayed.

A USB stick is plugged into one of the processor unit's USB ports

  • Remove the USB stick.

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The Windows message "Low disk space" is displayed

The Windows message "Low disk space" is displayed

The Windows message Low disk space is displayed.

Temporary files take up space on the hard drive

  • Admin permission is required for the computer

  1. Start the Microsoft application "Disk Cleanup."

  2. Select the "Windows (C:)" drive.

  3. Select <OK>.

  4. Select the file types to be removed.

  5. Select <Clean up system files>.

  6. Select <OK>.

    Disk cleanup will be performed.

    Further information can be obtained from your administrator or the Microsoft documentation.

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Touchscreen not responding

Touchscreen not responding

Touchscreen not responding.

The USB connecting cable from the monitor to the computer unit is not connected or is defective.

  1. Check whether the USB connecting cable is connected to both the monitor and the computer unit.

  2. At the computer unit, unplug the USB connecting cable from the monitor and connected to a different USB port.

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The message "Disconnected" is displayed in "DDM"

The message "Disconnected" is displayed in "DDM"

The message Disconnected is displayed in "DDM."

The Internet connection has been interrupted, and the "DDM" (Diagnostics Download Manager) software cannot establish a connection to the DDM server.

  1. Check if the network cable is intact and connected properly.

  2. For additional information, see "DDM Help Center."

  3. Download and install the latest DDM version.

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No internet connection

No internet connection

The DCI 700 has no connection to the internet, which means, among other things, that no updates can be downloaded and that the Help Center cannot be displayed.

Internet connection interrupted

  • Check if an internet connection is available: open any website in the browser.

  • Try again later.

Incorrect proxy settings

  • Configure the internet connection.

    "DCI" software: log in a user with the expert user role.

    Select "Settings >> General >> Network proxy settings."

    Check the proxy settings.

    No proxy: establish an internet connection without a proxy server.
    Detect proxy settings automatically: establish an internet connection via a specific proxy server.
    Manual proxy settings: establish an internet connection via a specific proxy server. The host address and port number can be obtained from your administrator. Host = main computer in a computer network. Port = part of a network address for distinguishing between multiple connections.

    Further information can be obtained from your administrator.

  • Should the malfunction persist, advise customer service.

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Performing a recovery

Performing a recovery

If the current software version causes problems or if the DCI 700 is to be sold on, reset the DCI 700 to factory settings.

The system recovery will delete all data and settings from the DCI 700, e.g. licensing information, log files, user settings, protocols, images.

  • Recovery USB stick (1 688 400 654)

  • Internet connection

  • Keyboard

  • Customer number and password for login to DDM

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Resetting the DCI 700 to factory settings

  1. Back up data and settings. ( How do I create data backups (back up data and settings)? )

  2. Remove the cover from the processor unit.

  3. Insert the recovery USB stick into an unused USB port, (1) or (2), on the processor unit.

    458922-66_Pal.svg
    USB ports

  4. If no keyboard is connected, connect the keyboard to an unused USB port on the processor unit.

  5. Close all running applications.

  6. Shut down the Windows operating system.

  7. Switch off the DCI 700 by the main switch.

  8. After 30 seconds, switch on the DCI 700 by the main switch.

    The processor unit will boot up.

    The recovery will commence (duration: approx. 30 min).

  9. Read and follow the instructions on the screen.

  10. When prompted, remove the recovery USB stick.

  11. Shut down the processor unit by pressing any key on the keyboard.

    The processor unit will shut down.

  12. Switch off the DCI 700 by the main switch.

    The DCI 700 is now reset to the factory settings.

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Installing the operating system

  1. After shutting down, wait 30 s before switching the DCI 700 back on.

  2. Switch on the DCI 700 by the main switch.

    The processor unit will boot up.

    The language selection will be displayed.

  3. Read and follow the instructions on the screen.

  4. In the "Sign in with Microsoft" window, use / create a Microsoft e-mail address or proceed without an e-mail address by using <Domain join instead>.

    You will be prompted to specify a name and password. Entering a name is required. The password is not necessary to operate the 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) software will be started.

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Setting up the "DDM" software

  1. Select a country and language in the "License Agreement" window.

  2. Enable the option I accept the agreement.

  3. Select <Next>.

  4. In the Login tab, enter your customer number and password.

  5. Select <Test login>.

    The following message will be displayed: Successful.

    Should the message Login failed be displayed, correct the user name and/or password and try the login information again.

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Installing the "DCI" software

  1. In the "DDM" software, select the Updates tab.

    If the "DDM" software finds a new update version, the "DDM" software will immediately start the download and retrieve 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: Download completed.

  3. Use <Install now> to install the "DCI" software.

    The DCI 700 must not be switched off while an update 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 now installed.

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Setting up and obtaining a license for 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. Reload the backed-up data and settings ( How do I restore a data backup? ).

    If no data backup is available, all settings must be made again (see the DCI 700 installation instructions).

  4. Select "Settings >> Subscriptions."

  5. If necessary, perform the licensing process for DCI and BQS ( How do I obtain licenses for DCI and BQS? ).

    The "DCI" software is now set up.

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Additional information

Bosch Workshop World

Bosch Workshop World

Website of Bosch Automotive Service Solutions for information on the products and services for Bosch workshop equipment: www.boschaftermarket.com .

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Test bench configurator

Test bench configurator

Website of Bosch Automotive Service Solutions for configuring your test and repair equipment: https://component-test.bosch-automotive.com/en/en/sharedActions/countrySelector .

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Bosch Media Library

Bosch Media Library

Bosch Automotive Service Solutions website for downloading technical documentation and software for Bosch workshop equipment: www.downloads.bosch-auomotive.com .

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Glossary

Glossary

BAL S

"Ballistic" test step

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BDC

Bosch Diesel Center

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BDS

Bosch Diesel Service

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Bosch CRI

Bosch common-rail injector for passenger cars

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Bosch piezo CRI

Bosch common-rail injector for passenger cars with piezo actuator

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Bosch CRIN

Bosch common-rail injector for commercial vehicles

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BQS

BQS (Bosch QualityScan). Test and repair of Bosch injection components with proof of quality. This service can only be performed by authorized Bosch Diesel Centers and Bosch Diesel Services. This requires the "DCI" software installed on the test bench, a hand scanner, a thermal printer, a label dispenser as well as repair ID labels and repair ID clips to mark repaired Bosch injection components.

The information concerning the repaired Bosch injection components (e.g. end of warranty, IMA identifier, contact details) is saved on the Bosch QualityScan server and can be accessed via the website Bosch QualityScan-Online or via the Bosch "QualityScan" app.

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Clean run

"Clean run" test step

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DCI

"DCI" (Diagnostic Component Injector) software. Software for the DCI 700.

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DCI 700

Common-rail injector test bench from Robert Bosch GmbH for testing common-rail injectors from Bosch, Delphi, Denso and Siemens/VDO/Continental.

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DDM

The "DDM" (Diagnostics Download Manager) software makes it possible to easily install and update Bosch workshop applications, e.g. ESI[tronic] and DCI. Updates are downloaded from the download server in the background without disrupting your workflow – the workshop applications can be used as usual while downloads are active.

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Delphi DFI

Delphi common-rail injector for passenger cars

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Denso Gx

Denso common-rail injector for passenger cars

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EM

"Emission point" test step

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IMA identifier

The IMA identifier (IMA = injector quantity adjustment) is an identifier affixed to IMA-coded components for calibration of fuel injectors. Once the test is finished, a new IMA identifier will be generated and displayed in a specific color in the test protocol (black = same IMA identifier, red = modified IMA identifier).

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Injector

Common-rail injector

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Leak test

"Leak test" test step

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Idle

"Idle" test step

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Commercial vehicle

Commercial vehicle

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Passenger car

Passenger car

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Repair ID

The repair ID (repair identification number) uniquely identifies repaired Bosch injection components and is stated on the repair ID labels and repair ID clips. The repair ID can be entered in the "DCI" software or at the "Bosch QualityScan-Online" website. The 10-digit repair ID consists of upper-case letters (no special characters such as umlauts) and/or digits from 2 to 7.

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Siemens/VDO/Continental PCR-I

Siemens/VDO/Continental piezo common-rail injector for passenger cars (PCR = piezo common-rail system)

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Start up

"Start up" test step

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TL B

"Boot part load" test step

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TL S

"Square part load" test step

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VE

"Distributor fuel injection" test step

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VE o

"Distributor fuel injection without booster" test step

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FL

"Full load" test step

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VL B

"Boot full load" test step

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Warm up

"Warm up" test step

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Corporate information

Legal notice

Data protection policy

symbol description

4/16/2021

Robert Bosch GmbH 2021, all rights reserved