INSTRUCTION 67-9319
INJECTOR CALIBRATOR CD3
Part Number 67-7622 to 67-7627
Installation/Operation/Maintenance
Rev. 8 – January, 1999
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.
Bacharach, Inc.
WARRANTY
Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from
defects in material and manufacture and will conform substantially to Bacharach Inc.’s
applicable specifications. Bacharach’s liability and Buyer’s remedy under this warranty are
limited to the repair or replacement, at Bacharach’s option, of this Product or parts thereof
returned to Seller at the factory of manufacture and shown to Bacharach Inc.’s reasonable
satisfaction to have been defective; provided that written notice of the defect shall have been
given by Buyer to Bacharach Inc. within one (1) year after the date of delivery of this Product
by Bacharach, Inc.
Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach’s
liability and Buyer’s remedy under this warranty of title are limited to the removal of any
title defects or, at the election of Bacharach, to the replacement 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 WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND (ii) ANY
OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT,
WHETHER OR NOT ARISING FROM BACHARACH’S NEGLIGENCE, ACTUAL OR
IMPLIED. The remedies of the Buyer shall be limited to those provided herein to the
exclusion of any and all other remedies including, without limitation incidental or
consequential damages. No agreement varying or extending the foregoing warranties,
remedies or this limitation will be binding upon Bacharach, Inc. unless in writing, signed by
a duly authorized officer of Bacharach.
NOTE: Fuses and gaskets are expendable items and are excluded from the terms of this
warranty.
A
Bacharach, Inc. Instruction 67-9319
TABLE OF CONTENTS
1.0 INTRODUCTION ............................................................................................................. 1-1
1.1 Calibrator Features .................................................................................................. 1-1
1.2 Accessories ................................................................................................................ 1-5
1.3 Construction .............................................................................................................. 1-6
1.4 Calibration Fluid System ........................................................................................ 1-7
1.5 Calibration Fluid Temperature Control System ................................................... 1-10
1.6 Pneumatic System .................................................................................................. 1-11
1.7 Electrical System .................................................................................................... 1-11
2.0 INSTALLATION ............................................................................................................... 2-1
2.1 Selecting the Site ...................................................................................................... 2-1
2.2 Hold Downs ............................................................................................................... 2-1
2.3 Utility Connections ................................................................................................... 2-2
2.4 Filling Reservoirs ...................................................................................................... 2-3
2.5 Pre-operation Checks ................................................................................................ 2-4
2.6 Initial Checks ............................................................................................................ 2-4
2.7 Start-up ..................................................................................................................... 2-6
2.8 Repacking for Shipping ............................................................................................ 2-7
2.9 Shipping and Storage ............................................................................................... 2-7
3.0 OPERATION ..................................................................................................................... 3-1
3.1 Cummins 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 Calibrator ................................... 3-14
3.2 Detroit Diesel (DD) Injectors .................................................................................. 3-15
3.2.1 Quick Reference Chart ................................................................................ 3-15
3.2.2 Changing Speed ........................................................................................... 3-15
3.2.3 Changing Cams ........................................................................................... 3-16
3.2.4 Mounting DD Injector Types 53, 71, and 92 ............................................... 3-18
3.2.5 Mounting DD Injector Type 149 ................................................................. 3-21
3.2.6 Mounting DD Injector Type 8.2 Liter ......................................................... 3-23
3.2.7 Testing ......................................................................................................... 3-25
3.2.8 Unclamping .................................................................................................. 3-27
3.2.9 Removing Injectors and Shutting Down Calibrator................................... 3-28
Instruction 67-9319 Bacharach, Inc. i
TABLE OF CONTENTS (cont.)
4.0 MAINTENANCE & TROUBLESHOOTING ................................................................... 4-1
4.1 Maintenance .............................................................................................................. 4-1
4.1.1 Schedule ......................................................................................................... 4-1
4.1.2 Changing Calibration Fluid and Filters ....................................................... 4-1
4.1.3 Changing Cambox Oil ................................................................................... 4-3
4.1.4 Cleaning and Lubricating ............................................................................. 4-3
4.1.5 Checking Flowmeter Cavity .......................................................................... 4-3
4.2 Troubleshooting ........................................................................................................ 4-4
4.4.1 Charts............................................................................................................. 4-4
4.4.2 Hydraulic System .......................................................................................... 4-6
4.4.3 Replacing O-ring in Fuel Arm ....................................................................... 4-7
4.4.4 Resetting Switches ........................................................................................ 4-7
4.4.5 Changing Fuses ............................................................................................. 4-8
4.4.6 Checking Main PC Board .............................................................................. 4-9
4.3 Adjustments ............................................................................................................ 4-10
4.3.1 Calibration Fluid Temperature Adjustment .............................................. 4-10
4.3.2 Air Pressure Regulator Adjustment ........................................................... 4-10
4.3.3 Adjusting 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 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 Accessories ............................................................................ 5-24
5.14 Accessories for use with Cummins Injectors ......................................................... 5-25
5.15 Accessories for use with DD Injectors .................................................................... 5-26
APPENDIX A Calibrator Audit Kit
ii Bacharach, Inc. Instruction 67-9319
TECHNICAL DATA AND FEATURES
• Synchronous drive motor
• Digital fuel measurement
• Floor standing unit; full welded frame construction
• Operating speeds: 1050 RPM (Cummins), 2000 RPM (DD)
• Cast iron cambox with tapered roller bearings and quick change cam capability
• Injector clamping: hydraulic
• Calibration fluid reservoir capacity: 8 U.S. Gallons (30 liters)
• Filtration:
- Primary filter (spin-on type): 10 micron
- Final stage filter: 3 micron
- Flowmeter transducer: screen
• Calibration fluid temperature control:
- Solid 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 System:
- Positive displacement Flowmeter (U.S. Patent No. 4141243)
- Measurement Units - mm3/str.
- Digital display resolution - 0.1 mm3/str.
- Measurement sampling - 50 or 100 strokes
- Stroke counter - electronic/optical
- Accuracy: + . 75% of reading or 1 mm3/str. whichever is greater
Instruction 67-9319 Bacharach, Inc. iii
TECHNICAL DATA AND FEATURES (Continued)
• Indicator Lights:
- Power (red) - Heat/Cool (amber) - Clamping (amber).
• Accessibility: Two front and one upper left hand side hinged doors. All other panels have quick
turn fasteners for easy removal.
• Dimensions: 50"W (1.27m) x 30"D (.76m) x 56" H (1.42m)
• Weight (Dry): 1150 lbs. (521 kg)
• Utilities Required:
- Electrical:
ELECTRICAL OPTIONS
Part # Voltage Phase Freq. 3 HP Motor 5 HP Motor
Amps Amps
67-7622 230 VAC 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 Technology Corporation for engine models 53, 71, 92, 92 marine,
149, and 8.2L. These accessories must be ordered separately.
- Provision for hanging all accessories on pegboard inside lower doors.
iv
Bacharach, Inc. Instruction 67-9319
INJECTOR CALIBRATOR CD3 INTRODUCTION
y
1.0 INTRODUCTION
Bacharach Model CD3 Injector Calibrator provides fast, accurate and safe calibration of mechanical unit
injectors manufactured by Cummins Engine Company and Diesel Technology. The calibrator will accommodate the Cummins H-NH, J, and C flanged injectors, plus all cylindrical types, as well as injectors
manufactured for Detroit Diesel (DD) engine model numbers 53, 71, 92, 92 Marine, 149, and 8.2L.
F u e l D e l i v e r y D i s p l a y
I n j e c t o r F u e l S u p p l
C l a m p
I n j e c t o r C r a d l e
Figure 1-1. CD3 Injector Calibrator
The CD3 was tested at the Bacharach factory with high precision instruments and calibrated for:
• Injector supply pressure
• Calibration fluid temperature
• Flowmeter and calibrator accuracy
• Correct clamping forces (body-to-seat and 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
_________________________________________________________________________________________________
RAIL PRESSURE 0 to 200 psi, accurate to ± 1/4%, has a 4-1/2 in. dial, and a mirror scale
Gauge to avoid parallax. Calibrated at the factory and offset to indicate true
CALIBRATION FLUID 40° to 140°F (5° to 60°C) has a 3-1/2 in. dial, accurate to ± 1°F (caliTEMPERATURE Gauge brated at the factory to indicate the true temperature at the injector
Instructions 67-9319 Bacharach, Inc. Page 1-1
pressure at injector inlet.
inlet).
INTRODUCTION INJECTOR CALIBRATOR CD3
S T R O K E S S e l e c t o r
S w i t c h
H O U R S M e t e r
L A M P M O N I T O R / T I M I N G
L U N G E R T O B O D Y G a u g e
P O W E R
I n d i c a t o r
3
M M / S T R O K E
D i s p l a y
S T A R T M E T E R
C A L I B R A T I O N F L U I D
T E M P E R A T U R E G a u g e
P l u n g e r t o b o d y c l a m p
t i m i n g i n d i c a t o r
S T A R T M A I N
D R I V E
H E A T E R
I n d i c a t o r
T E M P E R A T U R E
A d j u s t m e n t
C L A M P M O N I T O R
B O D Y T O S E A T
Figure 1-2. Console Features
Feature Operation
_____________________________________________________________________
R A I L P R E S S U R E
G a u g e
P R E S S U R E
R E G U L A T O R
START METER Button Switches on flowmeter. Lights while meter is running.
(Flowmeter)
MM3 / STROKE Four-digit LED display with resolution of 0.1 mm3/stroke (Red
Display (Flowmeter) flashing dot indicates update in LED display).
STROKES Selector Selects 50 or 100 strokes per reading.
Switch (Flowmeter)
POWER “ON” When lit, indicates that the On/Off Switch is closed, and the pump
Indicator (light) for circulating calibration fluid and providing clamping pressure is
operating.
HOURS Meter 0 to 9999 hours (counts total hours while On/Off Switch is on).
CLAMP MONITOR/ Factory set to indicate proper plunger-to-body clamp force. When
TIMING, PLUNGER pointer points 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 Permits manual setting of calibration fluid temperature.
Adjustment
(Potentiometer)
Page 1-2 Bacharach, Inc. Instructions 67-9319
INJECTOR CALIBRATOR CD3 INTRODUCTION
Feature Operation
_____________________________________________________________________
CLAMP MONITOR Monitors the injector body-to-seat clamping force. When clamping
BODY-TO-SEAT force is low, the indicator shows black. When clamping force is
(Cummins) correct, the indicator shows green.
PRESSURE Precision diaphragm-type pressure regulator allows the pressure of
REGULATOR the calibration fluid supply to the injector to be set as indicated on
RAIL PRESSURE gauge the (Injector Supply).
H o l e P r o v i d e d t o
K e e p B a r r i n g T o o l
H O L D T O O P E R A T E
" A " O R " B "
B O D Y T O S E A T R E L E A S E
S T O P S w i t c h
O n / O f f S w i t c
h
Figure 1-3. Left Table Features
LEFT 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 pressure to the two clamping cylinders that
RELEASE Button drive the body to seat clamp cylinders to the full,
HOLD TO OPERATE Unlocks the main clamp cylinder. Functions only when
Instructions 67-9319 Bacharach, Inc. Page 1-3
extended (release) position.
main drive motor is OFF.
INTRODUCTION INJECTOR CALIBRATOR CD3
Feature Operation
___________________________________________________________________
“A” OR “B” Button There is no physical movement of the clamping mechanism
when this button is pressed but it must be held down to
operate the body to seat clamp or plunger 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
___________________________________________________________________
B O D Y T O S E A T C L A M P
" A "
" B "
P l u n g e r t o B o d y C L A M P
“A” Clamps body to seat. Will operate only when flywheel
BODY TO SEAT is in a certain angular position and the HOLD TO
CLAMP Button OPERATE “A” or “B” button is held down.
“B” Clamps plunger to injector body. Will operate only
Clamp/Unclamp lever when the HOLD TO OPERATE “A” or “B” button is
(4-way selector valve) held down.
Page 1-4 Bacharach, Inc. Instructions 67-9319
INJECTOR CALIBRATOR CD3 INTRODUCTION
s
1.2 Accessories
B a r r i n g T o o l D r a i n H o s e
C u m m i n s A c c e s s o r i e
( O r d e r S e p a r a t e l y )
D D A c c e s s o r i e s
( O r d e r S e p a r a t e l y )
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 for hanging them inside the front doors.
Instructions 67-9319 Bacharach, Inc. Page 1-5
INTRODUCTION INJECTOR CALIBRATOR CD3
x
r
1.3 Construction
Cabinet: The frame is of welded steel 1-1/4 inch
square tubing and angle iron. The upper left side
and both front doors are easily accessible for
I n s t r u m e n t C o n s o l e O p e r a t o r s T a b l e H y d r a u l i c C y l i n d e
changing speed, storing accessories, and performing
routine maintenance through hinged doors. All
other external panels are secured with 1/4-turn
fasteners for easy removal. Rotating parts are
protected with a hinged cover, safety interlocked
with the main drive motor.
Console and operator’s table: The instrument
console is mounted to the operator’s table with
vibration absorbing mounts for the controls and
gauges. Vibration absorbing leveling pads are
provided for easy leveling of the unit.
Calibration Fluid Reservoir: The calibration
fluid is stored in a 8 U.S. gallon (30 liter), thermostatically controlled reservoir which is used in
common by the injector test fuel supply and the
C i r c u l a t i n g a n d C l a m p i n g
M o t o r a n d P u m p
C a l i b r a t i o n
F l u i d R e s e r v o i r
clamping circuits. Contained in the reservoir are
two 500-watt electric heaters and a cooling coil. The
reservoir also has a dipstick and two drain valves.
Figure 1-6. Cabinet, Console, Operators Table,
Reservoir & Clamping
Injector clamping: Injectors are clamped using a
hydraulic cylinder. The cylinder is locked mechanically at all times. An air driven hydraulic pump
called an intensifier provides the high pressure
required to unlock the clamp cylinder.
P u l l e y s C a m b o
F l y w h e e l
( h i d d e n )
Pneumatic clamping: Two double-acting air
cylinders are used in clamping the Cummins
injectors body to seat.
Circulating and clamp cylinder pump: A 1/3
HP electric motor drives the gear pump supplying
fluid to the double-acting hydraulic cylinder which
clamps and unclamps the injector. The motor and
pump run continuously which keeps the calibration
fluid circulating to stabilize fluid temperature.
Main drive motor: The calibrator is powered by
an1800 RPM synchronous speed electric motor
operated by a starter with overload protection. This
motor drives the camshaft which in turn activates
the plunger in the injector being tested. The motor
also drives the injector supply pump.
Pulleys: A pulley arrangement between the main
motor drive shaft and the cam shaft offers two
speed settings. The motor is mounted on a hinged
plate and a barring tool inserted into the yoke
permits quick speed change over from CUM (1050
RPM) to DD (2000 RPM) or vice versa.
M a i n D r i v e M o t o r
Figure 1-7. Main Motor, Pulleys, Flywheel, &
Cambox
Page 1-6 Bacharach, Inc. Instructions 67-9319
INJECTOR CALIBRATOR CD3 INTRODUCTION
F l o w m e t e r T r a n s d u c e r
Flywheel: A flywheel is mounted on the driven
end of the camshaft for uniform rotation. An
encoder wheel, also mounted on the camshaft in
conjunction with an optical pickup, counts strokes.
Cambox: The cambox is constructed of cast iron
and contains a 1-1/2 inch diameter camshaft
supported by heavy duty tapered roller bearings.
The cam is mounted to one end of the shaft on a
non-locking taper, secured by a nut and washer.
The driving torque is transmitted by a key and
keyway which allows quick and easy cam changes.
The rotating cam dips and splashes to lubricate the
cam, bearings, tappet, roller, and pusher rod.
Flowmeter transducer: For measuring fuel
output of the injector, the calibrator uses a positive
displacement flow measuring device with a digital
C a m s h a f t N u t a n d W a s h e r L u b r i c a t i n g O i l
readout.
Figure 1-8. Cambox Parts
1.4 Calibration Fluid System (Figure 1-10)
The calibration fluid system consists of three
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 hydraulic cylinder is mechanically locked
under normal operating conditions by an interference fit between the sleeve and the piston. To allow
the cylinder to move for clamping or unclamping an
injector, an intensifier assembly applies high
hydraulic pressure to the sleeve.
Figure 1-9. Flowmeter Transducer
The intensifier assembly (Fig. 1-14A) consists of an
air driven hydraulic pump, reservoir, 3-way air
solenoid valve, and a 2-way hydraulic air release
valve. With power on, under normal operating
conditions, the 2-way hydraulic air release valve is
open so that pump output is vented back to the
reservoir.
Instructions 67-9319 Bacharach, Inc. Page 1-7
INTRODUCTION INJECTOR CALIBRATOR CD3
INJECTOR SUPPLY DIAGRAM
Figure 1-10A. Calibration Fluid System Schematic
When a clamp or unclamp operation is desired
(initiated by pressing HOLD TO OPERATE A or B),
the 3-way air solenoid valve is energized and the
2-way hydraulic air release valve closes. Air is
admitted to air-driven hydraulic pump, generating
high pressure to unlock the hydraulic cylinder. As
long as the button is held down, this pressure is
applied so the cylinder piston is free to move.
To move cylinder piston, a clamp pump (3) driven
by a 1/3 horsepower electric motor supplies (from
reservoir) (1), and externally 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/UNCLAMP “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
CLAMPING &
CIRCULATION
DIAGRAM
Figure 1-10B. Calibration Fluid System
Schematic
should be adjusted only with the use of precision equipment. This equipment is available from Bacharach in Audit Kit (67-7707).
When lever “B” on the operator’s table is in the
CLAMP position, fluid is directed to the blind side
of the cylinder to extend it for injector clamping.
Page 1-8 Bacharach, Inc. Instructions 67-9319
INJECTOR CALIBRATOR CD3 INTRODUCTION
Figure 1-11. Clamping Circuit
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 pilot to open
the check valve (6) which helps to accelerate the
piston retraction.
During retraction, fluid from the blind side of the
cylinder is displaced through the selector valve and
the pilot operated check valve to the reservoir.
When lever “B” on operator’s table is in “neutral”
(normal) position, all calibration fluid is routed to
the reservoir so it can be kept at a stable
temperature.
(b) Injector Supply Circuit (Rail Pressure)
(Fig. 1-12)
The injector supply and the clamping circuits share
the suction filter. All three circuits share a thermostatically controlled reservoir of calibration fluid.
Calibration fluid is drawn from the reservoir (1)
through an externally mounted suction filter (2)
and is routed to the gear pump (3).
Fluid is then routed to a final stage filter (5)
through a steel capillary tube (4), which acts as a
damper to reduce the cyclic pressure variations of
the gear pump.
From the filter, the fluid is routed to a steel surge
chamber (6), which reduces pressure fluctuations
due to the injector metering cycle. A precision back
pressure regulator (7) controls pressure of the
calibration fluid.
A spring-loaded injector fuel arm (8) admits fluid
into the inlet orifice of the Cummins cylindrical
injector. The arm contains a spring loaded shutoff
valve which opens as the fuel arm is lowered onto
the injector orifice by an over-center toggle clamp.
For the Cummins flanged and DD injectors the fuel
arm is bypassed.
Instructions 67-9319 Bacharach, Inc. Page 1-9
INTRODUCTION INJECTOR CALIBRATOR CD3
Figure 1-12. Injector Supply Circuit
(c) Flowmeter Circuit (Injector Output)
(Figure 1-13)
The flowmeter circuit begins at the discharge head
which receives the injector output. Fluid passes
through a strainer & orifice, and is routed to a
3-way solenoid valve (L8) controlled by a meter
switch mounted on the control panel. When injector
is running, before the switch is actuated, injector
output is returned to the reservoir. When injector
output reading is desired, the switch is actuated,
injector output is routed through the flowmeter
before it is returned 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.
Page 1-10 Bacharach, Inc. Instructions 67-9319
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 electronically computed. Delivery is then digitally
displayed in terms of mm3/stroke.
1.5 Calibration Fluid Temperature Control
System (see Chapter 5)
Calibration fluid is supplied at the injector inlet to
104°F. Two 500 watt electric immersion heaters
mounted in the reservoir heat the fluid. Cold water
flowing through a coil of copper tubing mounted in
the reservoir cools the fluid.
INJECTOR CALIBRATOR CD3 INTRODUCTION
Figure 1-13. Flowmeter Circuit
A temperature sensor, mounted in the reservoir, is
connected to a solid-state temperature controller,
which either switches on the heaters or energizes
the water solenoid valve (L1) to admit cold water to
the cooling coil. A safety switch (S2) protects the
system from overheating should the sensor fail.
The Hour Meter (HR1) is used to monitor the time
calibration fluid has been maintained at specified
temperatures by the Temperature Control System.
Light (DS2) is “ON” during the heaters on cycle and
“OFF” during the cooling cycle. Light (DS2) when
monitored in conjunction with the CALIBRATION
FLUID TEMPERATURE gauge is used to adjust
the desired temperature with setting control R1.
Fluid temperature is kept stable through circulation provided by the continuously running gear
pump in the clamping circuit (Figure 1-11).
1.6 Pneumatic System (Figure 1-14B)
Pneumatic system operates on shop supplied compressed air. Air pressure is needed for body to seat
clamping operation and to power the intensifier.
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 Cummins injectors. The Secondary Air Pressure Regulator controls hydraulic pressure of the intensifier assembly to unlock the hydraulic cylinder. Operation of the air clamping cylinders is controlled by two solenoid valves (L4, L5).
1.7 Electrical System (See Chapter 5)
The electrical system shown in the schematics in
Chapter 5 includes the following safety interlocks:
• Motor will not start if pulley cover is not closed.
• If the operator accidently presses the “BODY
TO SEAT” (yellow) button or the “HOLD TO
OPERATE” (green) button while the calibrator
is running, no damage to the injector or the
calibrator will occur.
• If the air pressure to the calibrator is lost, the
main motor will stop.
On entering the system, 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,
Instructions 67-9319 Bacharach, Inc. Page 1-11
• Body to seat clamping will occur only if the
camshaft is in top dead center position, that is,
when the white painted area of the flywheel is
showing through the cambox cover window.
INTRODUCTION INJECTOR CALIBRATOR CD3
Figure 1-14A. Intensifier Assembly
Page 1-12 Bacharach, Inc. Instructions 67-9319
Figure 1-14B. Pneumatic System
INJECTOR CALIBRATOR CD3 INSTALLATION
5 Remove Transducer Bolt
(typical both sides)
6 Remove Console Bolt
(typical both sides)
2.0 INSTALLATION
2.1 Selecting the Site
Select an area where the calibrator will be level and
on solid footing, plus convenient to shop air, cold
water line, drain and electrical supply. Allow space
around the unit for operation and maintenance.
Allow for clearance of the cabinet doors and for easy
removal of panels. If possible, locate the unit away
from heavy vibrations and dusty or dirty
atmosphere.
2.2 Hold Downs
For security in shipment, the main motor, flowmeter and console are bolted down and the motor
mounting plate spring is completely compressed.
Figure 2-1. CD3 Dimensions
NOTE: The circled numbers shown with
the labels on the photos refer to step numbers on the following instructions.
2 Loosen Spring Nut
4 Adjust Spring to 3¾ in.
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 shipping spacers between the
transducers base and console base by removing
the two ¼-20, 3/4 long bolts, nuts and washers.
NOTE: Save all removed (shipping)
hardware for possible future moving or
shipment.
6. Remove two shipping (wooden) spacers between
the console and tabletop, located on each side of
the console, by removing the two ¼-20, 3/4 long
bolts and washers.
7. Close the front doors and reinstall the rear
panels.
Figure 2-2. Spring Tension
Instructions 67-9319 Bacharach, Inc. Page 2-1
Figure 2-3. Shipping Bolts
INSTALLATION INJECTOR CALIBRATOR CD3
2.3 Utility Connections
Electrical
1 Nameplate
4 Motor Rotation Direction
1. First, check the nameplate on the calibrator for
electrical data. The plate is located behind the
door on the left side of the calibrator to the left
(on top of frame angle) beneath the motor.
Refer to Section "Technical Data" for information
on required utilities.
2. Check that the On/Off Switch is OFF. Remove
the lower left hand side panel covering the
electrical box.
3. Wire the proper electrical power line to the
motor starter in the electrical control box after
punching appropriate hole.
CAUTION
CALIBRATOR CAN BE DAMAGED. 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 motor must rotate
counter clockwise as viewed from the drive end.
Water
6. Connect a cold water line to the fitting at the
rear of the calibrator marked WATER IN (1/4
inch NPT).
7. Connect a drain line to the fitting marked
WATER OUT (1/4 inch NPT).
NOTE: Do not install any valves, shutoffs
or other restrictions on drain line. Water
goes in under line pressure and must be free
to run out.
2 On/Off Switch
Figure 2-4. Electrical Connections
8 Air In 2 On/Off Switch
Page 2-2 Bacharach, Inc. Instructions 67-9319
7 Water Out 6 Water In 3 Electric Power Inlet
Figure 2-5. Water Connections
INJECTOR CALIBRATOR CD3 INSTALLATION
1 Close Both Drains
Air
8. Connect an air line from the shop supply (95 to
125 psi) to the fitting at the rear of the calibrator marked AIR (1/4 inch NPT).
9. Check regulator settings. 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 regulators are
behind the lower rear panel.
CAUTION:
HIGH PRESSURE CAN DAMAGE AIR
REGULATORS. Shop air supply must not
exceed 125 psi.
10. For regulator adjustments see Section 4.3.2
2.4 Filling Reservoirs
Calibration Fluid
Lift Red Ring
9 Adjust Primary Air Pressure
to 90 psi
9 Check Regulator Setting
Figure 2-6. Air Connection
8 Air in
1. Check that 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 plug is in place. Drain
plug is accessible after left-hand cab inlet door
is open.
6. Fill the cambox with SAE 30W motor oil to
bring the level up to within 3-3/4 inch from the
top (or about 1-1/2 inch from the bottom).
9 Adjust Secondary Air Pressure to 60 psi
Figure 2-7. Adjust Air Pressure
Intensifier
7. The intensifier reservoir is filled at the factory
before shipping. If additional fluid is required,
see Section 2.6.
Instructions 67-9319 Bacharach, Inc. Page 2-3
Figure 2-8. Calibration Drains
INSTALLATION INJECTOR CALIBRATOR CD3
k
Flowmeter Transducer
8. The flowmeter transducer reservoir is filled at
the factory before shipping. If additional fluid is
required, see Section 2.6.
2.5 Pre-operation Checks
Before trying to operate the calibrator for the first
time be sure to complete all the initial checks and
start-up procedures given in Section 2.6.
CAUTION
CALIBRATOR CAN BE DAMAGED. Do not
operate the calibrator until all items on the
check list in Section 2.6 have YES responses.
5 Cambox Plug
Figure 2-9. Calibration Fluid Dipstick
2 Fill to "F" Mark on Dipstic
6 Fill Cambox to 3-3/4 Inches fromTop
Figure 2-10. Checking Cambox
2.6 Initial Checks
Before operating the calibrator for the first time
3 AIR IN 4 WATER IN 1 On/Off Switch
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 electrical power supplied _____ _____*
corresponds to the data on the
nameplate inside the left side
door (See Section 2.3).
5 WATER OUT
2 Electrical Power Inlet
(terminal connections
inside left door)
2 Electrical Nameplate
(inside)
Figure 2-11. Initial Checks - Hookup
Page 2-4 Bacharach, Inc. Instructions 67-9319
INJECTOR CALIBRATOR CD3 INSTALLATION
g
CONDITION YES NO
_______________________________________________
3. The air line from the shop air _____ _____
supply is connected to the AIR
inlet at the back of the calibrator.
4. The cold water line is connected_____ _____
to the WATER IN port.
5. The drain line is connected to _____ _____
the WATER OUT port.
NOTE: Do not connect any valve,
shutoff, or other restriction in
the drain line.
Secondary
6. Inlet Air Pressure Regulator _____ _____
gauge. (Inside lower rear
panel) indicates 90 ± 5 psi.
Secondary Air Pressure
Regulator must read 60 psi
7 Reservoir
Drain Valves
Figure 2-12. Initial Checks - Air Pressure
Primary
6 Air Pressure
Re
ulator Gauges
(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. 67-5598 (SAE J967).
9. The cambox is filled with oil _____ _____
to 3-3/4 inch from the top of
cam box. If additional oil is
required, use SAE 30W motor
oil (non-detergent).
*If electrical power does not correspond to the data
on the nameplate, consult the Bacharach factory.
(Checklist continued on next page)
8 D i p s t i c k
Figure 2-13. Initial Checks - Calibration Fluid
Instructions 67-9319 Bacharach, Inc. Page 2-5
9 C a m b o x O i l
Figure 2-14. Initial Checks - Cambox Oil
INSTALLATION INJECTOR CALIBRATOR CD3
r
CONDITION YES NO
____________________________________________
10. The flowmeter cavity is filled _____ _____
with lube oil (10W30) to a
level 3/8 inch from the bottom.
Replenish if necessary.
DO NOT OVERFILL.
11. The intensifier fluid reservoir _____ _____
is filled with oil. If additional
oil is required, add SAE 10W30 motor oil.
____________________________________________
Do not proceed until all responses on the
checklist are “YES”.
2.7 Start-up
1. Switch the On/Off Switch on the left side of the
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 temperature.
The HEATER indicator light will be lit while the
heater is on. When the fluid reaches the proper
temperature, the light will go out.
3. The calibrator is now ready for testing injectors.
Follow procedures in Section 3.0 for Cummins and
DD injectors.
Figure 2-15 Initial Checks - Flowmeter Cavity
11 Intensifier Reservoi
Figure 2-16. Initial Checks - Intensifier
2 Wait Till Temperature Reaches 104°F
Page 2-6 Bacharach, Inc. Instructions 67-9319
1 Lit During Warm-up
Figure 2-17. Start-up
INJECTOR CALIBRATOR CD3 INSTALLATION
2.8 Repacking for Shipping
1. Drain the calibration fluid reservoir from both
drain valves.
2. Pack all the accessories listed in Section 5.2. Do
not ship the calibrator with its accessories
hanging on the door.
3. Disconnect all power and utilities. Drain water
and blow out water lines by applying shop air
pressure at the WATER OUT fitting. Plug both
ports.
4. Displace Drive Motor belt so that it is hanging
loose and not engaged on any pulley set.
5. Place 5/8 inch thick wooden blocks under each
end of the drive motor mounting 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 and
washers to fasten the flowmeter transducer to
the console.
11. Do not drain the fluid from the cambox.
12. Bolt the calibrator to a shipping skid.
13. Pack the calibrator in a sturdy container for
shipping.
2.9 Shipping and Storage
1. Make sure the calibrator is kept upright during
shipping and storage.
2. Do not drop or stack calibrators.
3. Store in a temperature and humidity controlled
environment.
Instructions 67-9319 Bacharach, Inc. Page 2-7
INSTALLATION INJECTOR CALIBRATOR CD3
NOTES
Page 2-8 Bacharach, Inc. Instructions 67-9319
INJECTOR CALIBRATOR CD3 OPERATION
e
3.0 OPERATION
3.1 Cummins Injectors
Cummins 189 cam (67-6370) is installed in the
cambox at the factory. Other cams are packed with
the Cummins accessories.
A complete set of Cummins Accessories is supplied
under part number 67-7633 (Figure 5-14). The
inside right front door of the calibrator has spaces
designated for hanging Cummins accessories.
Hooks are provided with the accessories.
NOTE: All parts are not shown in the
photograph, check Chapter 5 (or the
packing list) for a complete list of parts
for the Cummins Accessories set.
All Cummins injectors require the same discharge
head. This is a critical component in the measurement of injector fuel delivery. One of the main requirements of this component is that it incorporate
a reliable check valve with good sealing characteristics and the correct pressure-flow rating.
NOTE: Do not change the setting 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).
Push Rod Lock Adapters Drain Hose
Push Rods
and Links
Cams Locating
Pin
Push Rod
Extension
Discharg
Head
Figure 3-1. Cummins Injector Accessories
A push rod extension is used for all Cummins injectors. 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 link
forces are excessive for any reason. Because the
clamping cylinder rod can be locked at any position
within its stroke, it is not necessary to have a
different link for each PTD injector type.
3.1.1 Quick Reference Chart
This chart is for reference only. Use the procedures
on the following pages for preparing the calibrator,
accessories, and injectors for testing. For testing all
Cummins injectors the camshaft speed must be
1050 RPM.
To change speed refer to Section 3.1.2. All
Cummins injectors require accessories listed in the
chart, plus 67-7642 Discharge Head, and 67-5706
Push Rod Extension. For all Cummins injectors the
rail pressure must be exactly 100 psi.
Instructions 67-9319 Bacharach, Inc. Page 3-1
OPERATION INJECTOR CALIBRATOR CD3
____________________________________________________________________________________
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
PTB, PTC 3/8 3/8 PTB-PTC PTB-C —— —— 189
PTB, PTC 5/16 5/16 PTB-PTC PTB-C —— —— 189
PTC 5/16 large 5/16 PTB-PTC PTC —— —— 189
radius link LG. RAD
PTD 3/8 3/8 PTD 67-5703 —— 67-6519 189
PTD 5/16 5/16 PTD 67-5703 —— 67-6519 189
PTD-K K-PTD 67-5703 —— 67-6519 310
_______________________________________________________________________________________________
(—— means the accessory is not needed)
*THIS LIST IS A GUIDE ONLY. For cam selection, refer to the latest Cummins Injector Specfications
(Bulletin 3379664 latest issue).For a list of cams, see Section 3.1.3 and the Cummins Accessory Kit (67-7633).
Figure 3-2. Cummins Injector Accessories Chart
3.1.2 Changing Speed
The CD3 calibrator is shipped with the drive belt
disengaged. To change the speed setting to test
Cummins:
1. Open the flywheel (sheave) cover to expose the
upper pulleys.
2. Open the hinged door on the left side of the
calibrator to expose the lower pulleys.
3. Insert barring tool into roller link assembly.
4. Push down on the barring tool to raise the
motor enough to shift the drive belt from one
set of pulleys to the other.
5. For 1050 RPM speed required for running the
Cummins injectors, place drive belt over the
larger diameter pulley on camshaft (top) and
the matching pulley on motor shaft (bottom).
6. Make sure the shim (marked CUM) is under
the leveler of the motor.
5 For Cummins Use Large Pulley
Figure 3-3. Pulley
7. Lower the motor to its original position.
Next, check for proper cam installation (Section
3.1.3).
Page 3-2 Bacharach, Inc. Instructions 67-9319
INJECTOR CALIBRATOR CD3 OPERATION
)
3.1.3 Changing 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 of the radial holes
in the flywheel to hold camshaft in position.
4. Bar over flywheel until push rod is fully extended from cambox (cam at maximum lift).
5. Install push rod lock to hold 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.
5 Move to Pulley Position
3 Barring Tool
(push down)
Figure 3-4. Changing Speed
6 Shim
3 Barring Tool
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
77-0629 248
77-0823 272
77-0824 426
8. Fit the cam in place on the camshaft and make
sure key in the cam is properly seated.
NOTE: It is a good practice to check that
the cam 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.
2 Cambox Lid 6 Wrench
Figure 3-5. Changing Cams
10. Remove pushrod lock.
The calibrator is now ready for inserting the
discharge head, see Section 3.1.4.
Instructions 67-9319 Bacharach, Inc. Page 3-3
6 Washer and Nut5 Cam (Cam 189 Shown
Figure 3-6. Cam & Hardware
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