Bacharach 67-7622 Installation & Operation Instruction Download Page 46

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Bacharach, Inc.

Instructions 67-9319

OPERATION

INJECTOR CALIBRATOR CD3

15. Make sure the O-rings are in position in the

manifold block connectors.

3.2.4.6 Fuel Inlet

16. Disconnect the fuel inlet hose from the fuel arm

at the quick disconnect.

17. Swing the fuel inlet arm back toward console.

18. Connect hose to the fuel inlet connector at the

manifold INLET.

3.2.4.7 Injector Clamping

19. Push and hold the HOLD TO OPERATE button

with left hand.

20. While holding down the HOLD TO OPERATE

button, move the CLAMP/UNCLAMP lever to

the CLAMP position with right hand.

The maximum clamping force shown on CLAMP

MONITOR/TIMING PLUNGER TO BODY gauge

will be in the green segment of the dial and the

PLUNGER TO BODY timing light will be lit.

21. Wait until the PLUNGER TO BODY timing

light goes out (after about 3 seconds).

22. Release the HOLD TO OPERATE button

first

and

then

the CLAMP/UNCLAMP lever. The

lever will return to the center position.

For clamping to occur correctly, you must follow

this sequence carefully.

The gauge reading will decrease from the green

segment of the dial to a lower reading (red seg-

ment) immediately after the CLAMP/UNCLAMP

valve lever is returned to the center position.

The injector is now ready for testing (Section 3.2.7).

Figure 3-42. Injector Clamping

Figure 3-43. Timing Light & Clamp Monitor

CLAMP

HOLD TO OPERATE

Plunger to Body

Clamp Monitor

Plunger to Body

Timing Light

Summary of Contents for 67-7622

Page 1: ...TOR CD3 Part Number 67 7622 to 67 7627 Installation Operation Maintenance Rev 8 January 1999 Bacharach Inc 621 Hunt Valley Circle New Kensington PA 15968 7074 Phone 724 334 5000 FAX 724 334 5001 Web www bacharach inc com Printed in U S A ...

Page 2: ...ment of this Product or parts thereof that are defective in title The warranty set forth in paragraph 1 does not apply to parts the Operating Instructions designate as having a limited shelf life or as being expended in normal use THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF i ANY AND ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED...

Page 3: ... Injectors 3 1 3 1 1 Quick Reference Chart 3 1 3 1 2 Changing Speed 3 2 3 1 3 Changing Cams 3 3 3 1 4 Inserting the Cummins Discharge Head 3 4 3 1 5 Mounting Cummins Type PTD Cylindrical Injectors 3 5 3 1 6 Mounting Cummins Types PTB and PTC Cylindrical Injectors 3 8 3 1 7 Mounting Flanged Injectors 3 11 3 1 8 Testing 3 13 3 1 9 Unclamping 3 44 3 1 10 Removing Injectors and Shutting Down Calibrato...

Page 4: ...ing Pulley cover Interlock 4 11 4 3 4 Adjusting Optical Detector on Camshaft 4 11 4 3 5 Motor Starter Overload Relay Setting 4 11 4 3 6 Changing Drive Belt 4 11 4 3 7 Replacing Push Rod Shear Pin 4 13 5 0 ILLUSTRATED PARTS LIST 5 1 5 1 Console Front and Side Views 5 2 5 2 Console Rear View 5 4 5 3 Cabinet Front View Left Side View 5 5 5 4 Cabinet Top View 5 7 5 5 Operator s Table 5 9 5 6 Optical D...

Page 5: ...state control 104 F 1 F factory setting Cooling by cold tap water Heating by two 500 watt immersed electric heaters Instrumentation Controls Injector Supply Rail Pressure Gauge 4 Dial Scale 0 200 psi Calibration Fluid Temperature Gauge 4 Dial Dual Scale 40 140 F 5 60 C Supply pressure regulator Clamping pressure regulator Main drive start stop switches Measurement system start switch Measurement S...

Page 6: ... 3 60 Hz 24 33 67 7623 460 VAC 3 60 Hz 12 17 67 7624 208 VAC 3 60 Hz 26 38 67 7625 220 VAC 3 50 Hz 25 35 67 7626 380 VAC 3 50 Hz 15 20 67 7627 440 VAC 3 50 Hz 13 18 Air Pressure 80 120 psi 2 CFM Water Cold tap approximately 1 2 GPM 4 5 liter min Accessories Accessories are available for mounting and testing of all Cummins injectors mechanical and injectors mechanical manufactured by Diesel Technol...

Page 7: ...plunger to body Discharge head Cummins performance Accuracy with Detroit Diesel DD master injectors These can be checked and recalibrated if necessary by a qualified service technician using precision equipment available from Bacharach in an Audit Kit part number 67 7707 See Appendix A 1 1 Calibrator Features INSTRUMENT CONSOLE FEATURES Refer to Fig 1 2 Feature Operation __________________________...

Page 8: ...to the green segment of the dial clamping force is TO BODY gauge 380 lb 10 lb Plunger to Body Clamp Lights for about 3 seconds during clamping operation Timing Indicator light START MAIN Applies power to main drive motor Starts camshaft rotation DRIVE Button and the injector supply pump HEATER ON When lit indicates power is being applied to calibration fluid Indicator reservoir heater TEMPERATURE ...

Page 9: ...FT OPERATOR S TABLE FEATURES Feature Operation _____________________________________________________________________ On Off Switch For switching the control circuit power on and off When switched on starts the clamp pump motor which then runs constantly Also turns on the calibration fluid automatic temperature control and hour meter STOP Button Shuts down main drive motor BODY TO SEAT Applies air ...

Page 10: ...unger to body clamp This is part of the two hand safety operation system _____________________________________________________________________ Figure 1 4 Right Table Features RIGHT OPERATOR S TABLE FEATURES Feature Operation ___________________________________________________________________ A Clamps body to seat Will operate only when flywheel BODY TO SEAT is in a certain angular position and the...

Page 11: ... e l y 1 2 Accessories Figure 1 5 Accessories The accessories for the CD3 come in three different sets 1 The Basic Accessories not shown supplied with 2 Accessories for the Cummins Injectors 3 Accessories for the DD Injectors A lists of all parts in the accessories kits are given in Chapter 5 Accessories for testing Cummins or DD injectors are supplied if ordered separately They come with hooks fo...

Page 12: ...o has a dipstick and two drain valves Injector clamping Injectors are clamped using a hydraulic cylinder The cylinder is locked mechani cally at all times An air driven hydraulic pump called an intensifier provides the high pressure required to unlock the clamp cylinder Pneumatic clamping Two double acting air cylinders are used in clamping the Cummins injectors body to seat Circulating and clamp ...

Page 13: ...e separate circuits a The clamp and unclamp circuit which also provides continuous circulation of calibration fluid for close temperature control b The injector supply circuit rail pressure c The flowmeter circuit injector output a Clamping Circuit Plunger to Body Figure 1 11 For plunger to body clamping of Cummins and clamping of DD injectors a double acting hydraulic cylinder 8 is used The hydra...

Page 14: ...mounted filter 2 fluid to the cylinder through a relief valve 4 and across a 4 way selector valve 5 A lever on operator s table marked CLAMP UN CLAMP B controls selector valve A back pressure regulator 7 is in the line to maintain pressure to produce a clamping force of 380 10 pounds NOTE Do not disturb the setting of this regulator it was set by the factory and should be adjusted only with the us...

Page 15: ...enter toggle clamp For the Cummins flanged and DD injectors the fuel arm is bypassed When lever B on the operator s table is in the UNCLAMP position fluid is directed into the rod side of the cylinder to retract it for unclamping During cylinder retraction and when the piston reaches the end of its travel the relief valve 4 dumps the fluid to the reservoir The same pressure is also used for the pi...

Page 16: ...urned to the reservoir The metering system uses a patented positive displacement type flowmeter Fluid drives a piston in a reciprocating motion controlled by two 3 way solenoid valves Motion of the piston mechanically connected to a linear measurement device produces signals which represent displaced volume These signals and signals generated by camshaft rotation are elec tronically computed Deliv...

Page 17: ...stem shop air pressure at 95 125 psi is reduced to 90 psi by the Primary Air Pressure Regulator and 60 psi 4 1 bar by the Secondary Air Pressure Regulator complete with water trap filter and gauge The correct air pressure settings are made at the factory and must be monitored by the operator The Primary Air Pressure Regulator controls force exerted by the air cylinders for body to seat clamping of...

Page 18: ...Page 1 12 Bacharach Inc Instructions 67 9319 INTRODUCTION INJECTOR CALIBRATOR CD3 Figure 1 14B Pneumatic System Figure 1 14A Intensifier Assembly ...

Page 19: ...s shown with the labels on the photos refer to step num bers on the following instructions 1 Open the left side hinged door and remove the panel in the rear of the console 2 At the left side of the calibrator loosen the top nuts on the motor mounting plate spring 3 Remove the two shipping blocks from between the motor plate and the frame 4 Adjust the spring tension to 3 3 4 inches 5 Remove the two...

Page 20: ...If there is no fluid in the reservoir at this time do not allow Clamp circulating pump or main drive motor to run more than a few seconds to check rotation 4 After wiring jog the main drive motor turn On Off Switch ON and OFF quickly to check that the direction of rotation is the same as shown by the arrow on the motor 5 If the motor direction is wrong switch any two wires and check again The moto...

Page 21: ...t both drains of the calibration fluid reservoir are closed 2 Through the dipstick port fill reservoir to the F mark on the dipstick with new fluid Use Bacharach part number 67 5598 SAE J967 3 After a few minutes check for leaks 4 Place a tag on the reservoir giving date it was filled Cambox The cambox is filled with lube oil at the factory However if filling is necessary 5 Make sure cambox drain ...

Page 22: ...not operate the calibrator until all items on the check list in Section 2 6 have YES re sponses 2 6 Initial Checks Before operating the calibrator for the first time after installation complete the following checklist ALL RESPONSES SHOULD BE YES PRE OPERATION CHECKLIST CONDITION YES NO _______________________________________________ 1 The On Off Switch is in the _____ _____ OFF position 2 The elec...

Page 23: ...e Regulator _____ _____ gauge Inside lower rear panel indicates 90 5 psi Secondary Air Pressure Regulator must read 60 psi 4 1 bar 5 0 psi Reset if necessary NOTE Air pressure regulators were set at the factory 7 Both drain valves are closed on_____ _____ the calibration fluid reservoir 8 The calibration fluid reservoir _____ _____ is filled to the F mark on the dipstick Use Calibration Fluid P N ...

Page 24: ...he calibrator to ON The POWER indicator the HEATER indicator and the red dot on the display will be lit and the circulating and clamp cylinder pump will be running 2 Allow the calibrator to warm up until the CAL FLUID TEMPERATURE gauge indicates 104 F 1 F 40 C This usually takes about 15 to 20 minutes depending on the ambient tempera ture The HEATER indicator light will be lit while the heater is ...

Page 25: ...nting plate 6 Tighten the main drive motor mounting spring until the motor is secure 7 Place 5 8 x 7 8 x 11 1 2 inch wooden blocks under each side edge of the console 8 Use a 3 4 inch long 1 4 20 hex head cap screw in the center of each edge of the console to hold the console securely to the cabinet 9 Install shipping blocks under the flowmeter transducer 10 Use two 3 4 inch long 1 4 20 bolts nuts...

Page 26: ...Page 2 8 Bacharach Inc Instructions 67 9319 INSTALLATION INJECTOR CALIBRATOR CD3 NOTES ...

Page 27: ...tting of the adjusting screw on the discharge head The discharge head was adjusted at the factory for proper flow characteristics and leakage and can be adjusted only by using the Audit Kit See Appendix A A push rod extension is used for all Cummins in jectors This extension fits between the end of the push rod and the injector link It incorporates a plug and a shear pin for safety in case the lin...

Page 28: ...roper cam installation Section 3 1 3 ____________________________________________________________________________________ Cummins Accessory Part Number or Identification ____________________________________________________________________________________ Push Rod Drain Locating Injector Type Adapter Link Connection Pin Cam Flanged H NH H NH J C H NH 67 6580 189 Flanged J C H NH J C J C 67 6580 189...

Page 29: ...d the push rod when the cam is being removed NOTE Failure to do so can lead to disengagement of follower parts and subsequent early failure of cambox 6 Using a 1 1 8 in box wrench unscrew and remove the nut washer and cam 7 Select proper cam for the injector to be tested Using Cummins service publications as a guide Cam Part No Cam Identification 67 6370 189 67 6369 310 67 6861 230 67 6870 169 77 ...

Page 30: ...tion 2 Connect the tubing from the console to the discharge head 3 Make sure spring loaded lever on the quick connect is locked 4 For all injectors except the PTD type slide push rod extension 67 5706 over the push rod extending from the cambox so that the cut off portion faces up Cummins injectors come in three general styles each require specific accessories and procedures Type PTD cylindrical S...

Page 31: ...7 6997 K HVT PTD STC 77 0891 STC The PTD L 10 and PTD K HVT adapters do not appear in the photo of Cummins accessories see Section 5 14 2 With adapter slot facing down and the injector inlet orifice facing up align injector body drain hole with corresponding hole in the adapter 3 Insert locating pin 67 6519 4 Insert link 67 5703 into injector 5 Hold these parts in two hands and lower them into the...

Page 32: ...and clamp the injector 11 Release BODY TO SEAT CLAMP button when the BODY TO SEAT monitor turns green 3 1 5 3 Clamping Plunger to Body CAUTION Clamping force influences fuel delivery Follow these instructions carefully 12 Continue to hold the HOLD TO OPERATE button with left hand 13 While holding down the HOLD TO OPERATE button move the CLAMP UNCLAMP lever to the CLAMP position with right hand Max...

Page 33: ... arm This can be done by using a small mirror If it is necessary to disassemble fuel arm see Trouble shooting Guide Section 4 16 Make sure that the inlet fuel connector round knurled knob is tightly secured to the fuel arm assembly 17 Swing the fuel arm into place over the injector 18 Lower the connector tube over the inlet orifice by moving the toggle clamp fully forward toward you so it locks 19...

Page 34: ...16 PTB PTC PTC 5 16 large 67 6602 5 16 PTB PTC radius link 3 Align the injector with the socket screw head in the adapter 4 Reinstall the plunger with the spring into the injector from the opposite end of the adapter 5 Insert the PTB C or the PTC lg rad link into the plunger 6 Hold these parts in two hands and lower them into the carrier plate making sure that a The adapter slot aligns with the pr...

Page 35: ...n the HOLD TO OPERATE button 11 Press the BODY TO SEAT CLAMP button The air cylinders will retract and clamp the injector 12 Release the BODY TO SEAT CLAMP button when the BODY TO SEAT monitor turns green 3 1 6 3 Clamping Plunger to Body CAUTION Clamping force influences fuel delivery Follow these instructions carefully 13 Continue to hold the HOLD TO OPERATE button with left hand 14 While holding...

Page 36: ...arly style PTB and PTC injectors may have to be reworked to provide for the button head inlet orifice Unless reworked they cannot be tested with these accessories 17 Make sure that the inlet fuel connector round knurled knob is tightly secured to the fuel arm assembly 18 Swing the fuel arm into place over the injector 19 Lower the connector tube over the inlet orifice by moving the toggle clamp fu...

Page 37: ...unger Injector Part No Ident Flanged H NH 67 6575 H NH Flanged J C 67 6576 J C 4 Hold these parts in two hands and lower them into the carrier plate making sure that a The adapter slot aligns with the protruding 3 8 in pin b The adapter rests against the semicircular area of the carrier plate c The link rests on top of the push rod exten sion 3 1 7 2 Clamping Body to Seat 5 Lift the pulley cover t...

Page 38: ... on the CLAMP MONITOR TIMING PLUNGER TO BODY gauge will be in the green segment and the timing light will be lit 13 Wait until the PLUNGER TO BODY timing light goes out after about 3 seconds 14 Release the HOLD TO OPERATE button first and then the CLAMP UNCLAMP lever The lever will return to the center position For clamping to occur correctly you must follow this sequence The gauge reading will de...

Page 39: ...o allow the main drive motor to operate 2 Wait until trapped air escapes from the dis charge head through the plastic tubing leading to the meter Rapid chattering indicates that air is trapped in the tubing 3 Check fuel pressure on the RAIL PRESSURE gauge It must be exactly 100 psi If the RAIL PRESSURE is above or below 100 psi adjust it by turning the Rail PRESSURE REGULATOR and relocking the nut...

Page 40: ...h button and allow the CLAMP UNCLAMP lever to return to its center position 5 Press the BODY TO SEAT RELEASE button and hold down until the BODY TO SEAT green indicator retracts 3 1 10 Removing Injectors Shutting Down 1 Disconnect the fuel inlet hose from the injector holder or manifold 2 Remove injector and accessories from the calibrator 3 Replace accessories on inside cabinet door 4 Disconnect ...

Page 41: ...camshaft speed must be 2000 RPM To change speed see Section 3 2 2 For DD injectors rail pressure must be 35 psi 3 2 2 Changing Speed The CD3 calibrator is shipped with the drive belt disengaged To change the speed setting to test DD injectors 1 Open the flywheel sheave cover to expose the upper pulleys Figure 3 32 DD Injector Accessories Detroit Diesel Accessory Part Number or Identification _____...

Page 42: ...hanging Cams The cam is secured in place on the tapered end of the camshaft by a 3 4 in hex nut and a 3 4 in plain washer and is locked to the shaft by a key When shipped from the factory the calibrator has Cam 189 67 6370 installed used for most Cummins injectors To change the cam 1 Switch the power On Off Switch to OFF 2 Raise hinged lids of the cambox and flywheel 3 Insert barring tool into one...

Page 43: ... does not wobble on the camshaft If wobble exists dress the camshaft where required as applicable 9 Secure the cam with the washer and hex nut 10 Remove pushrod lock The calibrator is now ready for mounting DD Injectors Procedures for mounting DD injectors vary according to the style of the injector Type 53 71 92 or 92 M Section 3 9 Type 149 Section 3 10 Type 8 2 liter Section 3 11 Follow the moun...

Page 44: ...medium standoffs are for 92 Marine injectors and the short standoffs are for high crab injectors 3 2 4 1 Manifold 1 Slide the manifold block assembly 77 0613 over the dowel pins with the inlet port face up The return port with the barbed elbow should be on the far side in a horizontal position 2 Install correct standoffs in the manifold block Long standoffs Low crab injectors Medium standoffs 92 M...

Page 45: ... TO OPERATE button 9 Press the BODY TO SEAT CLAMP button The air cylinders will retract and clamp injector 10 Release the BODY TO SEAT CLAMP button when the BODY TO SEAT monitor turns green 3 2 4 4 Tubing 11 Push one end of the two foot plastic tubing over the fill tube 67 5292 and the other end over the barbed elbow at the OUTLET port on the manifold The plastic tubing and fill tube are part of t...

Page 46: ...CLAMP MONITOR TIMING PLUNGER TO BODY gauge will be in the green segment of the dial and the PLUNGER TO BODY timing light will be lit 21 Wait until the PLUNGER TO BODY timing light goes out after about 3 seconds 22 Release the HOLD TO OPERATE button first and then the CLAMP UNCLAMP lever The lever will return to the center position For clamping to occur correctly you must follow this sequence caref...

Page 47: ...st time wet O ring with calibration fluid for easier installation 6 Insert the flowmeter tubing with the quick connect plug into the discharge head 3 2 5 3 Body to Seat Clamp NOTE The body to seat air clamping is not needed for DD injectors To keep them out of the way activate the air cylinders and leave them in clamped position during testing 7 Lift the pulley cover to expose the camshaft pulleys...

Page 48: ...19 While holding down the HOLD TO OPERATE button move the CLAMP UNCLAMP lever to the CLAMP position with right hand Maximum clamping force shown on the CLAMP MONITOR TIMING PLUNGER TO BODY gauge will be in the green segment of the dial and the PLUNGER TO BODY timing light will be lit 20 Wait until the PLUNGER TO BODY timing light goes out after about 3 seconds 21 Release the HOLD TO OPERATE button...

Page 49: ...d for easier installation 3 Insert the flowmeter tube with the quick connect plug into the discharge head 3 2 6 3 Body to Seat Clamp NOTE The body to seat air clamping is not needed for 8 2 Liter injectors To keep them out of the way activate the air cylinders and leave them in clamped position during testing 4 Lift the pulley cover to expose the camshaft pulleys and flywheel 5 Rotate flywheel by ...

Page 50: ...the injector holder 14 Attach the flexible plastic tubing to the barbed elbow at the bottom of the injector holder 15 Insert the other end of the tubing into the hole of the drain pan 3 2 6 6 Injector Clamping 16 Push and hold the HOLD TO OPERATE button with left hand 17 While holding down the HOLD TO OPERATE button move the CLAMP UNCLAMP lever to the CLAMP position with right hand Maximum clampin...

Page 51: ...ration injectors please read the following IMPORTANT NOTE It was recognized that testing unit injectors manufactured by Diesel Technology Corporation for Detroit Diesel Corporation DDC engines the results can be different from those obtained on other makes and models of calibrators In particular it has been determined that Master Injectors marketed by Kent Moore all read higher on the Bacharach CD...

Page 52: ...pped air escapes from the dis charge head through the plastic tubing leading to the meter Rapid chattering indicates that air is trapped in the tubing 3 Check the fuel pressure on the RAIL PRES SURE gauge It should be about 35 psi 4 Set the STROKE selector on 100 5 Press START METER on the console The light in the button will come on The MM3 STROKE delivery display will show cumulative readings un...

Page 53: ...P position to extend clamp ing cylinder until the injector holder butts against the angle spacers next to cambox Injector will pop out of injector holder d Repeat steps 3 4 again 3 2 9 Removing Injectors Shutting Down 1 Disconnect the fuel inlet hose from the injector holder or manifold 2 Remove injector accessories from calibrator 3 Return accessories on inside cabinet door 4 Disconnect flowmeter...

Page 54: ...Page 3 28 Bacharach Inc Instructions 67 9319 OPERATION INJECTOR CALIBRATOR CD3 NOTES ...

Page 55: ...___________________________________________ 1 Calibration fluid 2 Filters 3 Flowmeter transducer strainer 4 Cambox oil ____________________________________________ This schedule is only a guideline maintenance will depend a great deal on the working environment and the cleanliness of the injectors See the following sections for these procedures 4 1 2 Changing Calibration Fluid and Filters Calibrat...

Page 56: ...n a tag to the reservoir giving the date the fluid was changed 6 Unscrew the suction filter cartridge from its bracket and throw it away 7 Replace the filter cartridge with a new one NOTE Before installation fill the filter cartridge with calibration fluid 8 Using a wrench remove the bolt from the top of the final stage filter 9 Remove the old filter and install a new one NOTE Before installation ...

Page 57: ...Lubricating The CD3 calibrator will remain in good working condition with just ordinary cleaning procedures It is important however to avoid spilling or dropping contaminants into the drain tray where they can mix with the calibration fluid For the same reason injectors should be cleaned before being tested The calibrator s mechanical parts are largely self lubricating and therefore no special lub...

Page 58: ...lator and make sure that solenoid valve is operative Clamp force not 1 Air may be in clamp system because of low oil level in the intensifier reservoir repeating a Bleed air at bleed port Section 8 2 b Fill intensifier reservoir Section 4 c Make sure all fittings and hoses leading from the reservoir to the clamp pump are tight 2 Faulty clamp pressure regulator replace Pressure drops in Pressure re...

Page 59: ...r solenoid may be defective Replace 6 Calibration fluid in reservoir may be low Increase fluid level 7 Temperature Sensor may be defective Replace 8 Thermometer may be defective Replace 9 Cooling water supply may be absent Connect and turn on water supply Body to seat clamp 1 Fuse F 1 2 Amp may have blown Replace Section 4 2 5 inoperative 2 Relay K 2 part no 04 5298 may be defective Replace 3 Fuse...

Page 60: ...id flow past the loosened plug 7 Allow air to escape through port until oil flows freely 8 While oil flows tighten plug Release the button 9 Replenish oil in the reservoir immediately after bleeding TROUBLESHOOTING CHART FOR ELECTRICAL PROBLEMS cont Fault Possible Cause and Remedy _________________________________________________________________________________ Flowmeter displays 1 Connector to ma...

Page 61: ...estigate why the motor was overloaded Resetting Flowmeter Limit Switches If the flowmeter displays all zeros or will not display flow readings the limit switches may be tripped 1 Disconnect power to the flowmeter by switching the On Off Switch left side panel to OFF 2 Remove console rear cover 3 Reposition the flowmeter piston so that the adapter block is centered in the cavity 4 Reconnect main po...

Page 62: ...ndicator Red ON HEATER Indicator Amber ON or OFF LED Display Red Dot OFF blank A Body to Seat Clamp inoperative Main Drive Start ON Flowmeter Transducer piston inoperative F 3 F 4 4 Amps Both fuses F 3 and F 4 are for special voltage options 380 and 460 VAC operation These fuses control input to Transformer T 3 If either fuse blows the operator console will indicate the following All power OFF F 5...

Page 63: ...r 4 5 VDC Defective transducer 8 and 7 0 or 4 5 VDC Defective transducer 8 and 9 5 5 or 6 0 VDC Defective main P C Board 8 and 14 with cam 4 5 to 5 VDC Defective main P C Board top dead center 8 and 14 with cam 0 VDC Defective main P C Board bottom dead center 8 and 5 4 5 to 5 VDC Defective K1 relay ________________________________________________________________________________ Movement of the fl...

Page 64: ...correct pressure for unlocking the hydraulic cylinder If for any reason it is necessary to change this setting 1 The Primary Air Pressure Regulator should be set at 90 5 psi the Secondary Air Pressure Regulator must be set at 60 5 0 psi 4 1 bar The air pressure regulators are behind the lower rear panel See Section 2 3 CAUTION HIGH PRESSURE CAN DAMAGE AIR REGULATOR Shop air supply must be less tha...

Page 65: ...r wheel rides through the center of the slot 4 3 5 Motor Starter Overload Relay Setting 1 Find the operating volts located on the nameplate of the test stand 2 Locate the FLA Full Load Amps and SF Service Factor for the corresponding voltage step 1 which can be found on the main drive motor 3 The minimum dial setting on the Motor Starter Overload Relay is equal to the FLA value 4 The maximum dial ...

Page 66: ...gs thus provided and over the large diameter pulley on top and the small diameter pulley below 11 Reassemble the optical detector on the cross bar being careful to align it as per Section 4 3 4 12 Reassemble the gear pump to the end of the motor shaft 13 Lower the motor to its original position 14 Adjust the motor mounting plate spring tension for 3 3 4 inches 15 If required slide the motor block ...

Page 67: ...everywhere 22 Run the calibrator to check that the belt is running smoothly 23 After the first 50 hours of operation Check the belt tension 24 If necessary readjust the belt tension steps 14 to 18 4 3 7 Replacing Push Rod Shear Pin applies to Cummins Injector testing To replace a broken shear pin 67 5702 in the push rod extension 67 5706 1 Extract plug with a 10 32 screw sleeve washer and nut 2 Pu...

Page 68: ...Page 4 14 Bacharach Inc Instructions 67 9319 MAINTENANCE AND TROUBLESHOOTING INJECTOR CALIBRATOR CD3 NOTES ...

Page 69: ...e Views 5 2 5 2 Console Rear View 5 4 5 3 Cabinet Front Left Side View 5 5 5 4 Cabinet Top View 5 7 5 5 Operator s Table 5 9 5 6 Optical Detector 5 11 5 7 Cambox Assembly 5 12 5 8 Calibration Fluid Plumbing System 5 13 5 9 Pneumatic and Hydraulic Plumbing Systems 5 14 5 10 Calibrator Wiring Harness 5 15 5 11 Electrical Control Panel 5 18 5 12 Electrical Power System 5 20 5 13 Standard Calibrator A...

Page 70: ...board assembly 67 5690 display parts toggle switch 104 0348 display board 67 5689 LED red Fairchild FLU510 204 2451 LED 7 segment display Fairchild 204 2452 205 hour meter 0 99 999 230V 60 hz 04 3795 206 hour meter 0 99 999 230V 50 hz 04 3796 207 neon lamp 250 VAC DC amber lens 04 3585 208 neon lamp 250 VAC DC red lens 04 3584 209 lamp incandescent 28V 04 3520 213 lamp neon amber lens with bezel 0...

Page 71: ...Instructions67 9319 Bacharach Inc Page 5 3 INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5 1 Console Front and Side Views Cont ...

Page 72: ..._________________ 120 orifice 67 2395 155 lube oil SAE 30 06 2553 179 grommet rubber 05 4618 216 fuse 5 amp 250 V buss mda 5 04 2715 217 fuse 3AG slow blo 0 4 amp 250 V 04 2649 238 strainer 03 4254 240 valve solenoid 8320 B132 24 50 50Hz 03 4220 241 valve solenoid 8320 B132 24 60 60Hz 03 4213 ___________________________________________________________ based on drawing 67 7622S13R86 ...

Page 73: ...temperature sensor 350 C max 67 6141 116 tank heater 500W 67 5426 199 motor 3 hp 220 380 440 VAC 3 phase 50 Hz 04 4098 5 hp 220 VAC 3 phase 50 Hz 04 4117 5 hp 380 VAC 3 phase 50 Hz 04 4116 5 hp 440 VAC 3 phase 50 Hz 04 4118 200 motor 3 hp 230 460 VAC 3 phase 60 Hz 04 4097 5 hp 230 460 VAC 3 phase 60 Hz 04 4114 201 motor 3 hp 208 VAC 3 phase 60 Hz 04 4096 5 hp 208 VAC 3 phase 60 Hz 04 4115 202 moto...

Page 74: ...Page 5 6 Bacharach Inc Instructions67 9319 PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5 3 Cabinet Front Left View cont ...

Page 75: ...tud 65 0309 131 connector stud 65 1177 143 filter final stage with hardware 07 1621 filter cartridge Fram C1110PB 07 1640 144 filter element replacement 07 1618 185 Coupling Sleeve 3 Flange 05 3450 186 flexible coupling TB Woods 33 05 3400 191 timing belt 1 2 pitch 60 Hz 05 2114 192 timing belt 1 2 pitch 50 Hz 05 2113 233 coupling 2 way shut off plug 03 5352 236 hose low pressure 03 5108 237 regul...

Page 76: ...Page 5 8 Bacharach Inc Instructions67 9319 PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5 4 Cabinet Top View cont ...

Page 77: ...ly 67 6472 62 switch push button red S 4 104 0540 63 switch push button yel S 8 104 0533 64 switch push button grn S 7 10 104 0534 88 directional control valve 67 6416 94 clamp cylinder 67 6405 121 stem block knob assembly 67 2082 stem block knob assembly parts O ring 05 5110 145 cylinder pneumatic double acting 07 0982 175 O ring Teflon 05 5446 227 hose low pressure 6 black 03 6013 248 quick conn...

Page 78: ...Page 5 10 Bacharach Inc Instructions67 9319 PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5 5 Operator s Table cont ...

Page 79: ...CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5 6 Optical Detector Item Description Part __________________________________________________ 136 optical detector assembly 60 7000 __________________________________________________ based on drawings 67 7622S10R86 ...

Page 80: ...4 3 spring lower seat 67 5713 4 cam follower sleeve assembly 67 5716 5 cambox 67 6374 8 push rod guide 67 6417 9 tappet assembly 67 6418 10 spring 67 6419 11 spring upper seat 67 6420 19 hex nut 3 4 16 02 3159 20 plain washer 3 4 02 4158 23 dowel pin 1 4x3 4 02 5532 24 bearing taper roller 05 1102 43 woodruff key 91 05 4516 ______________________________________________ based on drawings 67 7619S2...

Page 81: ...met rubber 05 4620 194 grommet rubber 05 4615 226 hose low pressure 6 black 03 5106 227 hose low pressure 6 clear 03 6013 232 insert quick connect 1 4 O D 03 5400 236 hose low pressure 03 5108 255 polyflo tubing 3 8 03 2940 256 polyurethane tubing 1 4 x 062 03 2920 257 tubing flexible nylon 03 2913 258 tubing flexible nylon 1 4 x 10 03 2912 284 tubing 1 4 nylon 03 6355 ____________________________...

Page 82: ...Hydraulic Plumbing Systems Item Description Part _________________________________________________ 255 polyurethane tubing 3 8 03 2940 256 polyflo tubing 1 4x 062 03 2920 258 tubing flexible Nylon 1 4 x 10 03 2912 _________________________________________________ based on drawing 67 7622S18R86 order by the foot ...

Page 83: ...el S 8 104 0533 64 switch push button grn S 7 10 104 0534 65 switch push button S 6 104 0524 66 potentiometer 3W 6 Ohm R1 204 4593 67 relay K 1 04 5187 79 relay time delay K 1 04 5254 109 temp controller 85 130 F 67 6142 112 display Board Assy calibrator 67 5690 207 neon lamp 250VAC DC amber 04 3585 209 lamp incandescent 28V 04 3520 213 lamp neon amber 04 3591 412 transformer 115 230V 50 60 Hz 104...

Page 84: ...Page 5 16 Bacharach Inc Instructions67 9319 PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5 10 Calibrator Wiring Harness cont ...

Page 85: ...Instructions67 9319 Bacharach Inc Page 5 17 INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5 10 Calibrator Wiring Harness cont ...

Page 86: ...V 50 60hz 104 1946 7 transformer pri 230 460V 50 60hz 104 1944 8 transformer pri 240 480V 60hz 104 1906 9 transformer pri 240 480V 50 60hz 104 1913 16 circuit breaker 04 1308 41 starter 3 hp motor 208 60 220 50 230 60 104 0089 5 hp motor 208 60 220 50 230 60 104 0097 42 starter 3 hp motor 380 50 440 50 460 60 104 0090 5 hp motor 380 50 440 50 460 60 104 0089 _______________________________________...

Page 87: ...Instructions67 9319 Bacharach Inc Page 5 19 INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5 11 Electrical Control Panel cont ...

Page 88: ...Page 5 20 Bacharach Inc Instructions67 9319 PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5 12 Electrical Power System ...

Page 89: ...Instructions67 9319 Bacharach Inc Page 5 21 INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5 12 Electrical Power System cont ...

Page 90: ...Page 5 22 Bacharach Inc Instructions67 9319 PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5 12 Electrical Power System cont ...

Page 91: ...Instructions67 9319 Bacharach Inc Page 5 23 INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5 12 Electrical Power System cont ...

Page 92: ...___________________________________________ 1 Barring tool 67 6469 2 Fill tube 67 5292 3 Key Woodruff 91 1 4x3 4 spare 05 4516 4 O rings Teflon ARP 568 111 05 5446 5 O rings 145 ID x 9 32 OD 05 5018 6 Tubing vinyl 1 4 ID x 1 16 W 03 6063 7 Lock push rod 67 5712 8 Touch up paint azure blue 77 0568 9 Touch up paint midnight blue 77 0569 ______________________________________________ based on drawing...

Page 93: ...6 adapter 3 8 PTD 67 6348 7 adapter 5 16 PTD 67 6350 8 adapter K PTD 67 6351 9 adapter PTD TS 67 6349 10 adapter L 10 TS not shown 77 0825 11 push rod N NH 67 6575 12 push rod J C 67 6576 13 push rod PTB PTC 67 6577 14 push rod PTC LG RAD 67 6574 15 push rod link for PTD K PTD 67 5703 16 drain connection H NH J C 67 6580 17 locating pin 67 6519 18 cam 310 67 6369 19 cam 169 67 6870 20 cam 230 67 6...

Page 94: ...613 2 manifold block 149 67 7643 3 front support 53 71 92 67 6606 4 front support 149 67 6605 5 injector holder assembly 8 2L 67 8525 6 discharge head 53 71 92 67 5696 7 discharge head 149 67 5700 8 cam 53 71 92 77 0610 9 cam 149 67 6372 10 push rod extension 67 5708 11 O rings 05 5109 12 O rings 05 5113 13 seal spare for 53 71 92 67 2431 14 seal spare for 149 67 5697 15 quick connect plug 103 540...

Page 95: ...used to check gear pump pressure and test discharge head performance Viscor Cup Used to check the viscosity of the calibration fluid Each cup is serialized and calibrated by the calibration fluid manufacturer Dummy Injector Assembly Simulates the injector for setting the exact inlet pressure using the dead weight tester lt is also used to check the discharge head performance Digital Indicator Indi...

Page 96: ...Page A 2 Bacharach Inc Instructions 67 9319 APPENDIX INJECTOR CALIBRATOR CD3 NOTES ...

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