Bosch illustrates how its DCI 700 diesel test bench helps with the process of testing and repairing commercial vehicle injectors, and how it can prepare the sector for future challenges.
Due to current emission standards and future guidelines, efficient testing of common rail injectors in modern commercial vehicle diesel engines has become more important than ever.
Since Bosch released the first common rail system, more than two decades of research and development have contributed to constant modernisation. This has resulted in a huge variety of systems coexisting in the market. However, all of these require regular maintenance or repairs to be carried out by commercial vehicle workshops and diesel specialists.
Thanks to its new measuring system, the DCI 700 can be used to test all generations of Bosch injectors, including IMA/NIMA coding and those equipped with the latest control systems such as ‘Pressure Amplification’ (CRIN4), ‘Needle Closing Control’ (NCC), or ‘Valve Closing Control’ (VCC).
For these latest technologies, an electronic control loop ensures high accuracy of fuel delivery from the injector throughout its service life; which ensures compliance with global emission limits. Third party injectors also have similar systems and functions.
Workshops looking to purchase a diesel test bench usually base their decision on the ability to quickly and accurately test both current and future technologies. The DCI 700 test bench is the only test bench currently on the market capable of testing VCC and NCC technologies to OE factory specification.
In order to comply with the time pressures of the diesel repair market, the DCI 700 features a very short mounting/dismounting – injectors can be fitted and removed in less than five minutes. Couple this with a test routine that, on average, takes 12 minutes, and this means a set of injectors can be tested within 20 minutes from start to finish.
Simplifying the process
Ergonomic workflow and intuitive operating increases the efficiency even further. It allows the operator to stand upright in front of the test bench without having to bend over to connect injectors. This is achieved by tapering the frame of the DCI 700 backwards, allowing the operator to position themselves closer to the test bench.
For operation, there is a touch screen monitor, a keyboard, and a mouse. The reflection-free display screen can be turned, pivoted, and adjusted in height to cater for the operator’s eye level, allowing the user to always keep an eye on the test routine.
The workspace lighting is bright, dazzlefree and easy on the operator’s eyes. When it comes to software and test plans, updates are provided online for quick download. A rotating high pressure rail with direct connection to the injectors removes the need for high pressure hoses, which keeps maintenance costs to a minimum.
The quality of a Bosch Diesel Network repair can be demonstrated with the Bosch QualityScan concept, which is used by workshops and vehicle owners to determine an authorised repair versus a non-authorised repair.
Only an authorised Bosch Diesel Centre or Bosch Diesel Service company can add data about repaired diesel injectors to the Bosch QualityScan database. For this authorisation, a diesel specialist must possess Bosch vehicle diagnostic capability, certified Bosch test equipment and repair tools, specially trained Bosch technicians complying with the latest Bosch repair concept methods, and the use of genuine Bosch spare parts.
Once the Bosch Diesel Network’s qualified expert has repaired and tested the injector, a special ‘repair ID label or clip’ is attached to provide a record of the repair. This information can be accessed quickly and easily using the free Bosch QualityScan app (available for Android and iOS smartphones).
Scanning the QR code on the injector will show all of the component data available on the Bosch QualityScan database, such as the IMA/NIMA code, the date of repair, and even the contact details of the Bosch diesel specialist who carried out the repair.
The repaired diesel injectors are subject to a stringent quality check complying with Bosch specifications before they are identified with the Bosch QualityScan repair ID. In addition, the injectors documented in the Bosch QualityScan database are delivered in special Bosch packaging with a guarantee on the performed repair.
That way, the workshop and vehicle owner can be sure that the repaired injectors received are of the highest quality and comply fully with the Bosch specifications.
There are over 3,500 Bosch Diesel workshops worldwide who are specialists in the repair of all diesel injection systems, from diagnosis and component repair to specialised technical services.