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Bacharach INJECTOR CALIBRATOR CD3, Installation & Operation Instruction

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Bacharach INJECTOR CALIBRATOR CD3 Installation & Operation Instruction Download Page 1

INSTRUCTION 67-9319

INJECTOR CALIBRATOR 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.

Summary of Contents for INJECTOR CALIBRATOR CD3

Page 1: ...OR 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 ww...

Page 2: ...ent 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...

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...

Page 4: ...ng 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...

Page 5: ...tate 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 C...

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...

Page 7: ...lunger 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...

Page 8: ...o 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...

Page 9: ...T OPERATOR S TABLE FEATURES Feature Operation _____________________________________________________________________ On Off Switch For switching the control circuit power on and off When switched on st...

Page 10: ...nger to body clamp This is part of the two hand safety operation system _____________________________________________________________________ Figure 1 4 Right Table Features RIGHT OPERATOR S TABLE FEA...

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 Accessor...

Page 12: ...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 intensi...

Page 13: ...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 flowm...

Page 14: ...ounted 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...

Page 15: ...nter 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...

Page 16: ...rned 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 pis...

Page 17: ...tem 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...

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: ...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 cal...

Page 20: ...f 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...

Page 21: ...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...

Page 22: ...ot 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 fol...

Page 23: ...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 th...

Page 24: ...e 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 unt...

Page 25: ...ting 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 h...

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

Page 27: ...ting 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 Appendi...

Page 28: ...oper cam installation Section 3 1 3 ____________________________________________________________________________________ Cummins Accessory Part Number or Identification _______________________________...

Page 29: ...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 th...

Page 30: ...ion 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...

Page 31: ...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 fa...

Page 32: ...nd 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 instr...

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 se...

Page 34: ...6 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...

Page 35: ...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 gr...

Page 36: ...rly 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 conne...

Page 37: ...nger 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...

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...

Page 39: ...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 t...

Page 40: ...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 Injecto...

Page 41: ...amshaft 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 chan...

Page 42: ...anging 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 calibrato...

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 mou...

Page 44: ...edium 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 fac...

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 Tub...

Page 46: ...LAMP 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...

Page 47: ...t 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...

Page 48: ...9 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 b...

Page 49: ...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 injec...

Page 50: ...he 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...

Page 51: ...ation 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 resu...

Page 52: ...ped 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 ga...

Page 53: ...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 Injecto...

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 mai...

Page 56: ...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 instal...

Page 57: ...ubricating 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...

Page 58: ...ator 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...

Page 59: ...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...

Page 60: ...d 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 TR...

Page 61: ...stigate 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 th...

Page 62: ...dicator 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...

Page 63: ...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...

Page 64: ...orrect 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...

Page 65: ...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 Serv...

Page 66: ...s 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 Reas...

Page 67: ...verywhere 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...

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

Page 69: ...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 Plu...

Page 70: ...oard 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 2...

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...

Page 73: ...emperature 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...

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: ...ud 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...

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

Page 77: ...y 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 ste...

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

Page 79: ...ALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5 6 Optical Detector Item Description Part __________________________________________________ 136 optical detector assembly 60 7000 _____________________________...

Page 80: ...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...

Page 81: ...et 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 poly...

Page 82: ...ydraulic 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...

Page 83: ...l 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 controll...

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: ...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...

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...

Page 93: ...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 P...

Page 94: ...13 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 ca...

Page 95: ...sed 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 manuf...

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

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