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.
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.
TABLE OF CONTENTS 1.0 INTRODUCTION ............................................................................................................. 1-1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Calibrator Features .................................................................................................. 1-1 Accessories ................................................................................................................ 1-5 Construction .....................................................................
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.
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.
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.
INJECTOR CALIBRATOR CD3 INTRODUCTION 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.
INTRODUCTION INJECTOR CALIBRATOR CD3 M M P O W E R In d ic a to r S T R O K E S S w itc h 3 /S T R O K E D is p la y C A L IB R A T IO N F L U ID T E M P E R A T U R E G a u g e S T A R T M E T E R S e le c to r H O U R S M e te r R A IL P R E S S U R E G a u g e C L A M P M O N IT O R /T IM IN G P L U N G E R T O B O D Y G a u g e P R E S S U R E R E G U L A T O R P lu n g e r to b o d y c la m p tim in g in d ic a to r S T A R T M A IN D R IV E H E A T E R In d ic a to r T E M P E R A T U
INJECTOR CALIBRATOR CD3 INTRODUCTION Feature Operation _____________________________________________________________________ CLAMP MONITOR BODY-TO-SEAT (Cummins) Monitors the injector body-to-seat clamping force. When clamping force is low, the indicator shows black. When clamping force is correct, the indicator shows green.
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.
INJECTOR CALIBRATOR CD3 INTRODUCTION 1.2 Accessories B a r r in g T o o l D r a in H o s e C u m m in s A c c e s s o r ie s ( O r d e r S e p a r a te ly ) D D A c c e s s o r ie s ( O r d e r S e p a r a te ly ) 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.
INTRODUCTION INJECTOR CALIBRATOR CD3 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 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.
INJECTOR CALIBRATOR CD3 INTRODUCTION 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.
INTRODUCTION INJECTOR CALIBRATOR CD3 INJECTOR SUPPLY DIAGRAM CLAMPING & CIRCULATION 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.
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.
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.
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.
INTRODUCTION INJECTOR CALIBRATOR CD3 Figure 1-14A. Intensifier Assembly Figure 1-14B. Pneumatic System Page 1-12 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 INSTALLATION 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.
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.
INJECTOR CALIBRATOR CD3 INSTALLATION Air Lift Red Ring 9 Check Regulator Setting 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.
INSTALLATION INJECTOR CALIBRATOR CD3 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.
INJECTOR CALIBRATOR CD3 INSTALLATION 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. 6. Inlet Air Pressure Regulator gauge.
INSTALLATION INJECTOR CALIBRATOR CD3 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.
INJECTOR CALIBRATOR CD3 2.8 INSTALLATION 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.
INSTALLATION INJECTOR CALIBRATOR CD3 NOTES Page 2-8 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 OPERATION 3.0 OPERATION Push Rod Lock Adapters Drain Hose 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.
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,
INJECTOR CALIBRATOR CD3 OPERATION 5 Move to Pulley Position 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.
OPERATION INJECTOR CALIBRATOR CD3 3.1.4 Inserting Cummins Discharge Head Push Rod Extension Cummins Discharge Head 1. For all Cummins injectors, insert discharge head (67-7642) into the clamp cylinder socket, with the quick connect socket facing up. NOTE: When discharge heads are installed for the first time, wet the O-ring with calibration fluid for easier installation. Figure 3-7. Discharge Head & Push Rod Extension 2. Connect the tubing from the console to the discharge head. 2 Tubing 3.
INJECTOR CALIBRATOR CD3 OPERATION 3.1.5 Mounting Cummins Type PTD Cylindrical Injectors Before mounting injectors, check in the cambox to be sure that the proper cam for the injector to be tested is mounted on the camshaft. (See Section 3.1.3) 1 Adapter 3 Locating Pin 1 PTD Injector Also make sure the Cummins discharge head has been installed. (See Section 3.1.4) 3.1.5.1 Inserting Injectors 4 Link 1. Insert injector into the correct PTD adapter.
OPERATION 3.1.5.2 INJECTOR CALIBRATOR CD3 13 CLAMP Clamping Body to Seat 6. Lift the pulley cover to expose the camshaft pulleys and flywheel. 7. Rotate flywheel by hand until the white painted area on the flywheel shows through the window (the barring tool inserted in a hole in flywheel can help in turning the flywheel). NOTE: If the painted area does not appear in the window, body to seat clamping can not be accomplished. 8. Close the pulley cover.
INJECTOR CALIBRATOR CD3 OPERATION 15. Release the HOLD TO OPERATE button first and then the CLAMP/UNCLAMP lever. The lever will return to the center position. 16 Inlet Fuel Connector 18 Toggle Clamp For clamping to occur correctly, you must follow this sequence. The clamp monitor reading will decrease from the green segment of the dial to a lower reading (red segment) immediately after the CLAMP/UNCLAMP valve lever is returned to the center position. 3.1.5.
OPERATION INJECTOR CALIBRATOR CD3 3.1.6 Mounting Cummins Types PTB and PTC Cylindrical Injectors 1 Plunger and Spring 1 PTB (or PTC) Injector Before mounting injectors, check cambox to be sure that the proper cam for the injector to be tested is mounted on the camshaft. (See Section 3.1.3) Also make sure the Cummins discharge head has been installed. (See Section 3.1.4) 3.1.6.1 2 Adapter Link Inserting Injectors 1. Pull out the plunger and spring from the injector. Figure 3-16.
INJECTOR CALIBRATOR CD3 3.1.6.2 OPERATION Clamping Body to Seat 11 BODY TO SEAT CLAMP 7. Lift the pulley cover to expose the camshaft pulleys and flywheel. 8. Rotate flywheel by hand until the white painted area on the flywheel shows through the window (barring tool inserted in a hole in the flywheel can help in turning the flywheel). NOTE: If the painted area does not appear in the window, body to seat clamping can not be accomplished. 9. Close the pulley cover.
OPERATION INJECTOR CALIBRATOR CD3 16. Release the HOLD TO OPERATE button first and then the CLAMP/UNCLAMP lever. The lever will return to the center position. 17 Inlet Fuel Connector 18 Fuel Arm For clamping to occur correctly, you must follow this sequence. The gauge reading will decrease from the green segment of the dial to a lower reading (red segment) immediately after the CLAMP/UNCLAMP valve lever is returned to the center position. 3.1.6.
INJECTOR CALIBRATOR CD3 OPERATION 3.1.7 Mounting Cummins Flanged Injectors Before mounting injectors, check cambox to be sure that the proper cam for the injector to be tested is mounted on the camshaft. (See Section 3.1.3) Plunger and Spring Flanged Injector Aapter Also make sure the Cummins discharge head has been installed. (See Section 3.1.4) 3.1.7.1 Inserting Injectors 1. Insert the injector into adapter H-NH, J-C (676368) so that the flanged body holes slip over the two pins. 2.
OPERATION INJECTOR CALIBRATOR CD3 9. Press the BODY TO SEAT CLAMP button. 9 BODY TO SEAT CLAMP The air cylinders will retract and clamp the injector. 10. Release the BODY TO SEAT CLAMP button when the BODY TO SEAT monitor turns green. 3.1.7.3 Clamping Plunger to Body CAUTION Clamping force influences fuel delivery. Follow these instructions carefully. 11. Continue to hold the HOLD TO OPERATE button with left hand. 8 HOLD TO OPERATE Figure 3-26. Body to Seat Clamp 12.
INJECTOR CALIBRATOR CD3 OPERATION 17. Connect the fuel inlet connector (using a Teflon O-ring) to the injector inlet port (the inlet orifice in the injector is visible). 15 Flanged Injector 16 Swing Back Fuel Arm 18. Use the drain hose connector assembly (676580) to connect to the injector return port. 19. Insert the hose into the hole of the drain pan. The injector is now ready for testing (Section 3.1.8). 3.1.8 Testing WARNING: HAZARDOUS ROTATING MACHINERY.
OPERATION INJECTOR CALIBRATOR CD3 The reading is in mm3/stroke, which is equivalent to cm3/1000 strokes (cc/1000 strokes). During a test run, if a change over is made from 50 to 100 stroke setting, or vice versa, ignore the next reading 3 UNCLAMP 7. When the test is over, press the STOP button on the left hand operator’s table. 3.1.9 Unclamping 1. Disconnect the fuel inlet. 2. Press and hold the HOLD TO OPERATE button. 3.
INJECTOR CALIBRATOR CD3 OPERATION 3.2 Detroit Diesel (DD) Injectors Front Supports Cummins 189 cam (67-6370) is installed in the cambox at the factory. Manifold Blocks Cams Injector Holder A complete set of DD accessories is supplied under part number 67-7632 (Figure 5-15). The inside left front door of the calibrator has spaces designated for hanging DD accessories (Figure 3-32). Not all of the DD accessories are shown in this photo. Hooks are provided with the accessories.
OPERATION INJECTOR CALIBRATOR CD3 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 2000 RPM setting required for running the DD injectors, move belt to the smaller diameter pulley on camshaft (top) and the matching pulley on the motor shaft (bottom). 6.
INJECTOR CALIBRATOR CD3 Injector 53, 71, 92 & 92 M 149 8.2L Cam P/N 77-0610 67-6372 77-0610 OPERATION Cam ID 53,71,92 149 53,71,92 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. 10. Remove pushrod lock. The calibrator is now ready for mounting DD Injectors.
OPERATION INJECTOR CALIBRATOR CD3 3.2.4 Mounting DD Injector Types 53, 71, 92 and 92 Marine (92M) Drain Fitting Discharge Head Manifold Block Injector Before mounting injectors, check cambox to be sure that cam 77-0610 (53, 71, 92, 92 Marine, or 8.2 L) is mounted on the camshaft. The drain fitting for the manifold block assembly (77-0613) can be positioned in either of two return ports, depending on whether the injector to be tested is offset or standard.
INJECTOR CALIBRATOR CD3 3.2.4.3 OPERATION Body to Seat Clamp 9 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 the test. 5. Lift the pulley cover to expose the camshaft pulleys and flywheel. 6. Rotate flywheel by hand (barring tool inserted in holes in the flywheel can help in turning the flywheel) until the white painted area on the flywheel shows through the window.
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. 20 CLAMP 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.
INJECTOR CALIBRATOR CD3 OPERATION 3.2.5 Mounting DD Injector Type 149 Before mounting injectors, check cambox to be sure that cam 67-6372 (149) is mounted on the camshaft. 3.2.5.1 Drain Fitting Manifold Block Discharge Head Injector Manifold 1. Place push rod extension (67-5708) over the push rod. 2. Mount manifold block (67-7643) over dowels. 3. Attach the drain hose to the return fitting on the manifold. 4. Lay the front injector support (67- 6605) over the rails.
OPERATION INJECTOR CALIBRATOR CD3 The air cylinders will retract and clamp injector. 15 Manifold Inlet 6 Flowmeter Tubing 11. Press the BODY TO SEAT CLAMP button. 12. Release BODY TO SEAT CLAMP button when the BODY TO SEAT monitor turns green. 3.2.5.4 Fuel Inlet 13. Disconnect the fuel inlet tubing from the fuel arm by unscrewing the knurled knob. 14. Swing the fuel arm back toward console. 16 Injector 15. Connect fuel inlet fitting to manifold INLET. 5 Discharge Head Figure 3-47. Injector Setup 3.
INJECTOR CALIBRATOR CD3 OPERATION Discharge Head Spacer Block Injector 3.2.6 Mounting DD Injector Type 8.2 Liter Before mounting injectors, check cambox to be sure that cam 77-0610 (53, 71, 92, 92 Marine or 8.2 L) is mounted on the camshaft. You will need injector holder assembly 67-8525 which includes the adapter, two angle spacers, a spacer block, and an injector holder with key. 3.2.6.1 Spacer Block Key 1. Attach the spacer block to the cambox over the two dowel pins on the push rod guide.
OPERATION INJECTOR CALIBRATOR CD3 8. Press the BODY TO SEAT CLAMP button. The air cylinders will retract and clamp injector. 10 Injector 8.2 12 Carriage rail 3.2.6.4 Injector 10. Install the injector into the injector holder by hand pushing until the mounting slots on both the injector and the holder are aligned. 11. Then secure with the key, straight edge towards the injector. This will prevent the injector from moving out during testing. 12.
INJECTOR CALIBRATOR CD3 OPERATION The gauge reading will decrease from the green segment of the dial to a lower reading (red segment) immediately after the CLAMP/UNCLAMP valve lever is returned to the center position. The injector is now ready for testing (Section 3.2.7). 3.2.7 Testing WARNING: HAZARDOUS ROTATING MACHINERY. Do not open cambox cover while main drive motor is running.
OPERATION INJECTOR CALIBRATOR CD3 Stamped Value 72.0 + Add Correct Value Tolerance (2%) 2.5 = 74.5 73.0 - 76.0 Therefore, for a type 71 Master injector stamped as 72.0, correct delivery value (fuel output) should be 73.0-76.0 mm³/str on a Bacharach CD3 Calibrator. From the above it follows that when calibrating and/or checking injectors in service it is necessary to add the above numbers to the limits given by the manufacturer.
INJECTOR CALIBRATOR CD3 OPERATION 3.2.8 Unclamping 3 UNCLAMP 1. Disconnect the fuel inlet. 2. Press & hold the HOLD TO OPERATE button. 3. While holding button down, move the CLAMP/ UNCLAMP lever to UNCLAMP position and let the hydraulic cylinder completely retract. 4. Release the HOLD TO OPERATE push-button and allow the CLAMP/UNCLAMP lever to return to its center position. DD Type 8.2 Liters injectors a. Lift the key from the injector holder slot. 2 HOLD TO OPERATE b.
OPERATION INJECTOR CALIBRATOR CD3 NOTES Page 3-28 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 MAINTENANCE AND TROUBLESHOOTING 4.0 MAINTENANCE & TROUBLESHOOTING 4.1 Maintenance 4.1.1 Schedule ____________________________________________ CHECK DAILY: ____________________________________________ 1. If calibration fluid is low, add enough fluid to bring the level up to the “F” on the dipstick. Use Bacharach part number 67-5598 (SAE J967). 2. If cambox oil is lower than 3-3/4 inch from the top of the cambox, add enough SAE 30W motor oil to bring the level up.
MAINTENANCE AND TROUBLESHOOTING INJECTOR CALIBRATOR CD3 At the same time the fluid is changed, change the suction and final stage filters. 1. Remove the back panels of the calibrator. 2. Drain the old fluid using the drain valves, one on each side of the reservoir. 3. Lift the lid of the reservoir and inspect its bottom. Wipe clean if necessary. 4. Close both drains of the reservoir. 5. Through the dipstick port, fill the reservoir to the “F” mark on the dipstick with new fluid.
INJECTOR CALIBRATOR CD3 MAINTENANCE AND TROUBLESHOOTING 4.1.3 Changing Cambox Oil After three months or 120 hours of operation (see hour meter), whichever occurs first, (or if the oil becomes contaminated) drain the oil from the cambox and refill using the following procedure: 1. Open drain plug on bottom of cambox and allow old oil to drain out. Drain plug is accessible after left-hand cabinet door is open. 2. Reinstall drain plug. 3.
MAINTENANCE AND TROUBLESHOOTING INJECTOR CALIBRATOR CD3 4.2 TROUBLESHOOTING 4.2.1 Charts TROUBLESHOOTING CHART FOR MECHANICAL PROBLEM Fault Possible Cause and Remedy _____________________________________________________________________________________________________ Plunger-to-body clamp faulty May lack unlocking pressure — Press HOLD TO OPERATE button and listen for valve reliefs (“putt” sound). 1. If after three putts, cylinder will still not move, there may be insufficient hydraulic pressure.
INJECTOR CALIBRATOR CD3 MAINTENANCE AND TROUBLESHOOTING TROUBLESHOOTING CHART FOR ELECTRICAL PROBLEMS Fault Possible Cause and Remedy _________________________________________________________________________________ Motor trips off 1. Overload setting may be too low – Readjust (Section 4.3.5). 2. Improper line voltage – Verify that incoming line voltage meets specifications. 3. Excessive vibration may induce interlock switches to open intermittently – Check S4, S12, S3, M1 (aux), or M1OL. 4.
MAINTENANCE AND TROUBLESHOOTING INJECTOR CALIBRATOR CD3 TROUBLESHOOTING CHART FOR ELECTRICAL PROBLEMS (cont.) Fault Possible Cause and Remedy _________________________________________________________________________________ Flowmeter displays 1. Connector to main P.C. board may be loose – Reconnect. all zeros; will not 2. Flowmeter limit switches may be tripped – Remove power and reposition piston display flow adapter block to center of cavity. readings* 3.
INJECTOR CALIBRATOR CD3 MAINTENANCE AND TROUBLESHOOTING 4.2.3 Replacing O-ring in Fuel Arm 4 O-ring If calibration fluid is leaking at the fuel arm: 1. Pull cotter pin. 2. Tilt back clamp arm. 3. Lift out fuel connector and turn over. (Do not lose spring and washer.) 4. Remove and replace O-ring. 5. Lower arm and reinstall the cotter pin. 4.2.4 Resetting Switches Figure 4-10. Fuel Arm O-Ring Resetting the Motor Reset Button In the event of a motor overload condition: 1.
MAINTENANCE AND TROUBLESHOOTING INJECTOR CALIBRATOR CD3 4.2.5 Changing Fuses F-1 (2 Amps): This fuse is in the main power circuit for all control circuits. If this fuse blows, the operator’s console will indicate the following: POWER Indicator (Red): HEATER Indicator (Amber): LED Display (Red Dot): All Clamping Functions: Main Drive Start: ON ON or OFF OFF OFF OFF F-2 (0.4 Amps): This fuse controls the flowmeter transducer circuit.
INJECTOR CALIBRATOR CD3 MAINTENANCE AND TROUBLESHOOTING 4.2.6 Checking Main PC Board Between these terminals on the main P.C. board: Voltage should be: If not, probable cause is: ________________________________________________________________________________ 15 and 16 11 to 13 VAC Defective fuse F-2 or transformer T2. 8 and 1 4.5 to 5 VDC Defective main P.C. Board. 8 and 2 3 to 5 VDC Defective optical detector #1. 8 and 2 (with detector blocked) 0 to 2 VDC Defective optical detector #1.
MAINTENANCE AND TROUBLESHOOTING INJECTOR CALIBRATOR CD3 4.3 Adjustments 4.3.1 Calibration Fluid Temperature Adjustment The CALIBRATION FLUID TEMPERATURE gauge was calibrated at the factory to indicate the fluid temperature about one inch upstream of the fuel arm. This calibration was performed at stabilized conditions using special fixtures and an electronic digital thermometer. Do not change the temperature gauge calibration without use of a special fixture and procedure.
INJECTOR CALIBRATOR CD3 MAINTENANCE AND TROUBLESHOOTING 4.3.3 Adjusting Pulley cover Interlock 1. Adjust pulley cover up or down so that when closed, the cover will push in the button on the pulley cover interlock. 2. Adjust latch, if necessary, so that cover closes completely and stays closed while calibrator is operating. 4.3.4 Adjusting Optical Detector on Camshaft The optical detector is mounted on a cross bar in the rear under the pulley cover.
MAINTENANCE AND TROUBLESHOOTING INJECTOR CALIBRATOR CD3 3. Open the hinged side door. 4. Remove the upper back panel. 5. Loosen the nuts holding the optical detector to cross bar, and remove it from the cross bar. 6. Match mark the gear pump bracket and the motor mounting plate. 7. Remove two bolts which secure the gear pump bracket to the plate. 8. Slide the pump assembly off the end of the motor shaft. 5 Encoder wheel 9.
INJECTOR CALIBRATOR CD3 MAINTENANCE AND TROUBLESHOOTING CAUTION Before turning on main drive, make sure that the injector supply hose (with quick connect) is either connected to the fuel arm or is disconnected. Any other connection (for instance - to a manifold block when no injector is installed) can cause fluid to squirt 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.
MAINTENANCE AND TROUBLESHOOTING INJECTOR CALIBRATOR CD3 NOTES Page 4-14 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5.0 ILLUSTRATED PARTS LIST These lists include most parts which may need replacing under normal operating conditions. If other parts are needed, consult the Bacharach factory. INDEX Sect. Subject Page 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5-2 5-4 5-5 5-7 5-9 5-11 5-12 5-13 5.10 5.11 5.12 5.13 5.14 5.
PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5.1 Console, Front and Side Views Item* Description Part # ________________________________________________________________ 21 51 61# 65# 105** 106** 109 112 P.C. board assembly 67-6910 gauge, clamp monitor 67-6525 switch, push button, blk.
INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5.1 Console, Front and Side Views (Cont.) Instructions 67-9319 Bacharach, Inc.
PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5.2 Console, Rear View Item* Description Part # ________________________________________________________________ 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.
INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5.
PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5.3 Cabinet, Front & Left View (cont.) Page 5-6 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5.4 Cabinet, Top View Item* Description Part # ___________________________________________________________ 22 31 gear pump 67-6902 surge chamber assembly 67-6626 surge chamber replacement parts: O-ring, 3" ID x 3-3/16 OD 05-5186 32 fuel line, .
PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5.4 Cabinet, Top View (cont.) Page 5-8 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5.5 Operator’s Table Item* Description Part # _______________________________________________ 12 fuel arm assembly 67-7638 fuel arm parts: 9 O-ring 05-5018 10 O-ring 05-5112 16 cambox assembly (see Section 5.7) 67-7619 61 injector carrier plate assembly 67-6473 62 cylinder carriage plate assembly 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.
PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5.5 Operator’s Table (cont.) Page 5-10 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5.6 Optical Detector Item* Description Part # __________________________________________________ 136 optical detector assembly 60-7000 __________________________________________________ *(based on drawings 67-7622S10R86) Instructions 67-9319 Bacharach, Inc.
PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5.
INJECTOR CALIBRATOR CD3 PARTS LISTS AND DIAGRAMS 5.8 Calibration Fluid Plumbing System Item* Description Part # _______________________________________ 28** hose assembly, 12" 67-6629 29** hose assembly, 18" 67-6628 30** hose assembly, 35" 67-6627 32** fuel line, .093x24 67-6619 38 fuel line, high pressure 67-6548 178 grommet, 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.
PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR CD3 5.9 Pneumatic and 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 5-14 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 5.10 PARTS LISTS AND DIAGRAMS Calibrator Wiring Harness Item* Description Part # ___________________________________________ 60 relay (K-2) 04-5298 61 switch, push button, blk. (S-5) 104-0524 62 switch, push button, red. (S-4) 104-0540 63 switch, push button, yel. (S-8) 104-0533 64 switch, push button, grn.
PARTS LISTS AND DIAGRAMS 5.10 INJECTOR CALIBRATOR CD3 Calibrator Wiring Harness (cont.) Page 5-16 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 5.10 PARTS LISTS AND DIAGRAMS Calibrator Wiring Harness (cont.) Instructions 67-9319 Bacharach, Inc.
PARTS LISTS AND DIAGRAMS 5.11 INJECTOR CALIBRATOR CD3 Electrical Control Panel Item* Description Part # ___________________________________________________ 3 4 6** 7 8** 9** 16 41 fuse, 2 amp, 250V (F1) 404-2709 fuse, 5 amp, 500V (F3-4) 404-2717 transformer, pri. 330/400/416V, 50/60hz 104-1946 transformer, pri. 230/460V, 50/60hz 104-1944 transformer, pri.
INJECTOR CALIBRATOR CD3 5.11 PARTS LISTS AND DIAGRAMS Electrical Control Panel (cont.) Instructions 67-9319 Bacharach, Inc.
PARTS LISTS AND DIAGRAMS 5.12 INJECTOR CALIBRATOR CD3 Electrical Power System Page 5-20 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 5.12 PARTS LISTS AND DIAGRAMS Electrical Power System (cont.) Instructions 67-9319 Bacharach, Inc.
PARTS LISTS AND DIAGRAMS 5.12 INJECTOR CALIBRATOR CD3 Electrical Power System (cont.) Page 5-22 Bacharach, Inc.
INJECTOR CALIBRATOR CD3 5.12 PARTS LISTS AND DIAGRAMS Electrical Power System (cont.) Instructions 67-9319 Bacharach, Inc.
PARTS LISTS AND DIAGRAMS 5.13 INJECTOR CALIBRATOR CD3 Basic Calibrator Accessories All accessories listed below come as a set under part number 67-6547. Item* Description Part # _____________________________________________ 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, .
INJECTOR CALIBRATOR CD3 5.14 PARTS LISTS AND DIAGRAMS Accessories for use with Cummins Injectors A complete set of Cummins accessories can be ordered under part number 67-7633. The complete set comes with pegboard hooks for hanging the accessories inside the cabinet door.
PARTS LISTS AND DIAGRAMS 5.15 INJECTOR CALIBRATOR CD3 Accessories for use with DD Injectors A complete set of DD accessories may be ordered under part number 67-7632. The complete set comes with pegboard hooks for hanging the accessories inside the cabinet door. Item Description Part # _______________________________________________ 1 manifold block (53,71,92) 77-0613 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.
INJECTOR CALIBRATOR CD3 A1.0 APPENDIX A: APPENDIX CALIBRATOR AUDIT KIT A1.1 DESCRIPTION The Calibrator Audit Kit is required for checking the critical parameters of the CD3 Calibrator in the field. This allows the user to periodically insure his unit is set to original factory specifications. This kit is calibrated at the factory using instrumentation whose accuracy is traceable to NIST (National Institute of Science and Technology). Bacharach offers recalibration service.
APPENDIX INJECTOR CALIBRATOR CD3 NOTES: Page A-2 Bacharach, Inc.
