INSTRUCTION 77-9075 INJECTOR CALIBRATOR DD5 Part Number s 77-7072 thru 77-7076 Installation/Operation/Maintenance Rev.

1 - June 1993

Bacharach, Inc. 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 Fax: 724-334-5001 Website: 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. Bacharachs liability and Buyers remedy under this warranty are limited to the repair or replacement, at Bacharachs 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. Bacharachs liability and Buyers 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, EXPRESS 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 BACHARACHS 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.

Bacharach, Inc.

Instruction 77-9075

DD5-EUI

CONTENTS DESCRIPTION

CONTENTS DESCRIPTION
This manual is designed and written to be contained into five separate chapters. Each chapter contains specific information that is designed to be read and used in a logical sequence. Information contained in each chapter is defined below. Chapter 1. Introduction - Descriptions of the unit and its controls, along with construction notes. Chapter 2. Installation - Includes unpacking, installation, and set-up, as well as repacking for shipping and storage. Chapter 3. Operation - Cam change, injector mounting, testing, and unmounting described in detail. Chapter 4. Maintenance and Adjustment - Covers maintenance, troubleshooting, and adjustments. Chapter 5. Parts List and Diagrams - Contains parts lists and diagrams of the DD5 unit.

WARNINGS AND CAUTIONS

WARNING Do not open cambox cover while main drive motor is running. Mke sure that the Flywheel has stopped turning before opening cambox cover, to prevent being splashed by hot lubricating oil.

CAUTION High shop air pressure can damage air regulator. Shop air supply must be 125 psi max.

CAUTION CALIBRATOR CAN BE DAMAGED. Do not operate the calibrator until all items on the checklist in Section 2.5 have YES responses. CAUTION Do not start Main Drive with Supply Hose connected to Manifold Block (or Injector Holder 8.2L) and with injector not clamped. This will cause calibration fluid to spray out of the block. CAUTION Do not attempt to make any adjustments or repairs to the calibrator without first disconnecting the main power line at the wall.

Instruction 77-9075

Bacharach, Inc.

TABLE OF CONTENTS

DD5

TABLE OF CONTENTS
TECHNICAL DATA AND FEATURES ........................................................................... iii 1.0 INTRODUCTION ............................................................................................................. 1-1 1.1 INSTRUMENTS, CONTROLS, AND FEATURES ................................................. 1-2 1.2 ACCESSORIES ......................................................................................................... 1-4 1.3 CONSTRUCTION ..................................................................................................... 1-5 1.4 CALIBRATION FLUID SYSTEM ............................................................................ 1-6 1.5 PNEUMATIC SYSTEM ............................................................................................ 1-8 1.6 CALIBRATION FLUID TEMPERATURE CONTROL SYSTEM ............................ 1.8 1.7 ELECTRICAL SYSTEM ........................................................................................... 1-8 2.0 INSTALLATION ............................................................................................................... 2.1 INTRODUCTION ..................................................................................................... 2.2 HOLD DOWNS ......................................................................................................... 2.3 UTILITY CONNECTIONS ....................................................................................... 2.4 FILLING RESERVOIRS .......................................................................................... 2.5 PRE-OPERATION CHECKS ................................................................................... 2.6 START-UP ................................................................................................................. 2.7 REPACKING FOR SHIPPING ................................................................................ 2.8 SHIPPING AND STORAGE .................................................................................... 2-1 2-1 2-1 2-2 2-3 2-4 2-5 2-6 2-6

3.0 OPERATION ..................................................................................................................... 3-1 3.1 INTRODUCTION ..................................................................................................... 3-1 3.2 INJECTOR MOUNTING (general) .......................................................................... 3-1 3.3 CAM CHANGE ......................................................................................................... 3-2 3.4 MOUNTING INJECTOR TYPES 53, 71, AND 92 .................................................. 3-3 3.5 MOUNTING INJECTOR TYPE 149 ........................................................................ 3-5 3.6 MOUNTING INJECTOR TYPE 8.2 LITER ............................................................ 3-7 3.7 TESTING .................................................................................................................. 3-8 3.8 UNCLAMPING INJECTORS ................................................................................ 3-10 3.9 SHUTTING DOWN CALIBRATOR ....................................................................... 3-11 4.0 MAINTENANCE AND ADJUSTMENT ........................................................................ 4-1 4.1 MAINTENANCE SCHEDULE ................................................................................ 4-1 4.2 CHANGING CALIBRATION FLUID AND FILTERS ............................................ 4-2 4.3 CHANGING CAMBOX OIL ..................................................................................... 4-3 4.4 CLEANING AND LUBRICATING .......................................................................... 4-3 4.5 REFILLING FLOWMETER CAVITY ...................................................................... 4-3 4.6 TROUBLESHOOTING CHARTS ............................................................................ 4-4 4.7 HYDAULIC SYSTEM/INTENSIFIER ..................................................................... 4-5 4.8 RESETTING SWITCHES ........................................................................................ 4-6 4.9 CHANGING FUSES ................................................................................................. 4-7 4.10 ADJUSTING AIR PRESSURE REGULATOR ........................................................ 4-8 4.11 ADJUSTING OPTICAL DETECTOR ON CAMSHAFT ......................................... 4-8 4.12 ADJUSTING FLYWHEEL COVER INTERLOCK .................................................. 4-8 4.13 REPLACING DRIVE BELT ..................................................................................... 4-9 4.14 ADJUSTING CALIBRATION FLUID TEMPERATURE ..................................... 4-10 4.15 MOTOR STARTER OVERLOAD RELAY ADJUSTMENT ................................... 4-10 4.16 FLOWMETER TRANSDUCER REPLACEMENT ................................................ 4-11 5.0 PARTS LIST AND DIAGRAMS ..................................................................................... 5.1 BASIC ACCESSORIES (77-0585) ............................................................................ 5.2 INJECTOR ACCESSORIES (77-7013) .................................................................... 5.3 SPARE PARTS LIST ................................................................................................ 5.4 ASSEMBLY DRAWING LIST .................................................................................. 5.5 DIAGRAMS ............................................................................................................... ii
Bacharach, Inc.

5-1 5-1 5-1 5-2 5-3 5-4

Instruction 77-9075

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CHARACTERISTICS

TECHNICAL DATA AND FEATURES

5HP Electric drive motor Digital fuel measurement Floor standing unit; full welded frame construction Operating speed: 2000 RPM 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 (spin-on type): 3 micron - Flowmeter transducer: screen Calibration fluid temperature control: - Solid state control - 100F + 1F (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: 0-100 psi. - Calibration Fluid Temperature Gauge, 4" Dial, Dual Scale: 40-140F (5-60C). - 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 - 100 strokes - Stroke counter - electronic/optical - Accuracy: + . 75% of reading or 1 mm3/str. whichever is greater

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CHARACTERISTICS

DD5-EUI

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: 77-7072 - 230 VAC, 3 Phase, 60 Hz. 77-7073 - 460 VAC, 3 Phase, 60 Hz. 77-7074 - 208 VAC, 3 Phase, 60 Hz. 77-7075 - 220 VAC, 3 Phase, 50 Hz. 77-7076 - 380 VAC, 3 Phase, 50 Hz.

- Air Pressure: 80-120 psi (2 CFM) - Water: Cold tap, approximately 1.2 GPM (4.5 liter/min) Accessories: - All the required accessories are included for mounting and testing Detroit Diesel 53, 71, 92, 149 and 8.2L injectors. - Provision for hanging all accessories on pegboard inside lower doors.

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Instruction 77-9075

INJECTOR CALIBRATOR DD5

INTRODUCTION

1.0 INTRODUCTION
The Bacharach Model DD5 Injector Calibrator provides fast, accurate and safe calibration of unit injectors manufactured by Detroit Diesel Allison (GM). The calibrator will test the 53, 71, 92, 149, and 8.2L MUI unit injectors. The DD5 was tested at the Bacharach factory with high precision instruments to insure:

Accurate calibration fluid temperature Flowmeter accuracy Correct clamping force Overall correlation with DDA Master Injectors

Fig. 1-1. Model DD5 Injector Calibrator

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INJECTOR CALIBRATOR DD5

1.1 INSTRUMENTS, CONTROLS, AND FEATURES Feature Operation

A. Console and Table Top (Fig. 1-2) Injector RAIL PRESSURE Gauge CALIBRATION FLUID Temperature Gauge METER START Button MM3/STROKE Fuel Delivery Display POWER Indicator Light Hour Meter (Left Side) CLAMP MONITOR Light START MAIN DRIVE Button HEATER Indicator Light 0 to 100 psi, 4 in. dial.

40 to 140F (5 to 60C) has a 4 in. dial TEMPERATURE Gauge.

Switches on flowmeter. Lights while meter is running. Four-digit LED display with resolution of 0.1 mm3/stroke (Red flashing dot indicates update in LED display). Indicates On-Off Switch/Circuit Breaker is closed, and calibration fluid system pump is operating. 0 to 9999 hours. Operates when On-Off Switch/Circuit Breaker is ON. Lights for about 1 second during clamping operation.

Applies power to 5 HP main drive motor, starts camshaft rotation.

When lit, indicates power is being applied to calibration fluid reservoir heaters. When off, water circulates through the cooling coil in the calibration fluid reservoir. Permits setting of calibration fluid temperature (Potentiometer).

TEMPERATURE Pot

B. Left Side & Operators Table (Fig. 1-3) On-Off Switch/ Circuit Breaker When switched on, starts the calibration fluid system pump motor, turns on the calibration fluid automatic temperature control, hour meter and control circuit power. Functions only when main drive motor is OFF. There is no physical movement of the clamping mechanism when this button is pressed but it must be held down to operate the clamp selector valve. This is part of the two hand safety operation system. Shuts down main drive motor and resets flow meter.

HOLD TO OPERATE Button

STOP Button

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Instruction 77-9075

INJECTOR CALIBRATOR DD5

INTRODUCTION

POWER on

Delivery Display MM3 /STROKE

CALIBRATION FLUID TEMPERATURE

Injector RAIL PRESSURE Gauge Hour Meter

METER START

HEATER on

START MAIN DRIVE

CLAMP MONITOR

TEMPERATURE Potentiometer

Fig. 1-2. Console and Table Top

Hole Provided To Keep Barring Tool HOLD TO OPERATE Switch

STOP Switch

On-Off Switch / Circuit Breaker

Fig. 1-3. Left Side & Operation Table

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Feature

Operation

C. Right operators Table CLAMP/UNCLAMP Lever (4-way valve) D. Inside Frame Rail Pressure Gauge Diaphragm type back pressure regulator regulates rail (supply) pressure to injector inlet. 2" dial, indicates clamp pressure, mounted on clamp pressure regulator. Admits, regulates, filters, and measures air pressure Clamps/Unclamps injector to support bracket. Will operate only when the HOLD TO OPERATE button is held down.

Clamp Pressure Gauge Air Pressure Filter/ Regulator/Gauge

Fig. 1-4. Right Operators Table 1.2 ACCESSORIES The DD5 is supplied with two Accessory Sets: 1. 77-0585 Basic Accessories 2. 77-7013 Accessory Set for testing 53, 71, 92, 149, 8.2L MUI injectors (Accessories contained in this set should be hung on the inside front LH door with the supplied hooks. See Section 5 for a list of parts in the sets, and Fig. 3-1 [Injector Accessories]).

Main Drive Motor Reservoir

Injector Accessories on Peg Board

Fig. 1-5. Front View With Doors Open

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Instruction 77-9075

INJECTOR CALIBRATOR DD5

INTRODUCTION

1.3 CONSTRUCTION Cabinet: The frame is welded steel 1-1/4" square tubing and angle iron. Upper left side and both front doors are hinged for ease in performing routine maintenance. Accessories are stored on the backside of the front door for accessibility. All other external panels are secured with 1/4 turn fasteners for easy removal. Rotating parts are protected with a hinged cover, and interlocked with the main drive motor for safety. Console and Operators Table: The instrument console is mounted to the operators table with vibration absorbing mounts for the controls and gauges. Vibration absorbing leveling pads at the bottom of the frame are provided for easy leveling of the unit. Hydraulic Clamp: An air driven hydraulic pump ("intensifier") provides the high pressure required to unlock the clamp cylinder.. Main Drive Motor: The calibrator is powered by a 5 HP induction motor operated by a magnetic starter with overload protection. It drives a camshaft which activates the plunger in the injector being tested. Flywheel: A flywheel is mounted on the driven end of the camshaft to provide for uniform rotation. An encoder wheel, also camshaft mounted, in conjunction with an optical pick-up, counts strokes. Cambox: The cambox is constructed of cast iron and contains a 1-" diameter camshaft supported by heavy duty tapered roller bearings. The cam is on one end of the shaft on a non-locking taper with key, secured by a nut and washer, and allows for quick & easy cam changes. Rotating cam dips and splashes to lubricate cam, bearings, tappet roller, and pusher rod. Calibration Fluid Pump: A 1 HP electric motor drives a gear pump supplying fluid to the injector and double-acting hydraulic cylinder which clamps and unclamps the injector. The motor and pump run continuously keeping the calibration fluid circulating to stabilize fluid temperature. Calibration Fluid Reservoir: Calibration fluid is stored in a 8 U.S. gallon (30 liter) reservoir which contains two 500-watt electric heaters, cooling coil, dipstick, two drain valves, and is thermostatically controlled. Flowmeter Transducer: For measuring fuel output (delivery) from the injector, the calibrator uses a positive displacement flow measuring device with a digital readout (U.S. Patent No. 4141243).
Instruction 77-9075 Bacharach, Inc.

Fig. 1-6. Cambox

Fig. 1-7. Flowmeter Transducer

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1.4 CALIBRATION FLUID SYSTEM (Fig. 1-8) The calibration fluid system consists of two circuits: (1) Injector Supply and Clamp Circuit Calibration fluid is drawn from the reservoir through an externally mounted suction filter (3) into the motor driven gear pump (5). At the same time, fluid temperature is being measured by the temperature gage (2). Fluid is routed through a free passage inside the relief valve (6) into the clamp selector valve (7), port "P". When in neutral position fluid passes thru the clamp selector valve port R and is routed to the rail pressure regulator (8) and final stage filter (9). When the gear pump operates but main drive is off, all fluid is returned to the reservoir through the rail pressure regulator at about 35 psi, set by the regulator. When the main drive START button is depressed the solenoid valve L4 (10) on the downstream side of the final stage filter opens and the fluid is routed through the injector supply hose, and quick disconnect (12), and eventually to the injector under test. At the same time fluid pressure is measured by the rail pressure gage (11). NOTE: The supply hose ends with a quick disconnect (12) that is sealed when disconnected. When clamping is required it is necessary to unlock the hydraulic cylinder (14). The hydraulic cylinder is mechanically locked under normal operating conditions by an interference fit between a sleeve and cylinder rod. To allow the cylinder to move for clamping or unclamping an injector, an air driven hydraulic pump (intensifier) assembly (see Fig. 1-10) applies high hydraulic pressure to the sleeve. The intensifier assembly consists of an air-driven hydraulic pump, reservoir, 3-way air solenoid valve L3, 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 port is vented back to the reservoir. When a clamp or unclamp operation is desired (initiated by pressing the HOLD TO OPERATE button), the 3-way air solenoid valve is energized and the 2-way hydraulic air release valve closes. Air is admitted to the air-driven hydraulic pump, generating high pressure to unlock the hydraulic cylinder. As long as the button is held down, the cylinder is free to move. When the Clamp selector valve is moved to CLAMP, fluid from port P is diverted through port 2, through the manifold (13), to the piston (clamp) side of hydraulic cylinder (14), port 2. This line is also connected through the manifold to the clamp pressure regulator (17), pilot operated check valve (POCV) #1 port C and POCV #2, port P. Maximum pressure in this line, as set by the regulator, is about 100 psi. When fluid is directed to the piston side of the cylinder, fluid trapped in the rod side of the cylinder is routed thru POCV #2 to the reservoir and also through the R port in the selector valve as well as the rail pressure regulator. When fluid pressure in the piston side of the cylinder reaches a preset pressure the pressure switch (S11, not seen in Fig. 1-8) starts a timer, and turns on the Clamp Monitor light. After about one second the power is removed from the air solenoid valve (L3) and the cylinder is automatically locked regardless of the position of the HOLD TO OPERATE button and clamp selector valve. When clamp selector valve is moved to UNCLAMP the fluid from port P is diverted to port 1 to the rod (unclamp) side of the hydraulic cylinder, port 1. On its way this line is connected to POVC #2 port C and POVC #1 port P. The maximum pressure in this line, as set by relief valve (6) is about 200 psi. When fluid is routed to the rod side of the cylinder, fluid trapped in the piston side is returned thru the manifold and the POCV #1 to the reservoir, also through the R port in the selector valve and the rail pressure regulator. The POCV operates as follows: when fluid pressure is applied to port P and no pressure is applied to port C all ports are isolated from each other. When pressure is applied to port C (in addition to port P) the valve opens and lets fluid from port P flow to port V. Port C is always isolated from ports P and V. Port V is connected to the reservoir.

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Instruction 77-9075

INJECTOR CALIBRATOR DD5

INTRODUCTION

Fig. 1-8. Schematic Diagram, Calibration Fluid System

Instruction 77-9075

Bacharach, Inc.

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(2) Flowmeter Circuit (Injector Output) (Fig. 1-9) The flowmeter circuit begins at the discharge head which receives injector output. Fluid passes through a screen and orifice, and is routed to a three-way solenoid valve (L8) controlled by a meter switch mounted on the control panel. When the injector is running, and before the switch is actuated, the injector output is returned to the reservoir. When a readout of the injector output is desired, the switch is actuated, the 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 3way solenoid valves. The 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.

1.6. CALIBRATION FLUID TEMPERATURE CONTROL SYSTEM (see Fig. 5-18, 5-19) Calibration fluid is supplied at 100F (as measured in the reservoir). 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. A temperature sensor also mounted in the reservoir, is connected to a solid-state temperature controller which either switches on the heaters or opens the water solenoid valve (Ll) to admit cold water to the cooling coil. A safety switch (S2) protects the system from overheating should the sensor fail. Fluid temperature is kept stable through circulation provided by the continuously running gear pump.

1.7. ELECTRICAL SYSTEM 1.5. PNEUMATIC SYSTEM The electrical system includes the following safety The pneumatic system operates on shop supplied com- interlocks: pressed air. Air pressure is needed for the operation of Main drive motor will not start if flywheel cover the hydraulic pump (intensifier). is not closed. On entering the system shop air pressure is reduced to The HOLD TO OPERATE (green) button is 60 psi (4.1 bar) by a pressure regulator complete with inoperative when the motor is running, water trap, filter, and gage. The correct air pressure disabling the unclamp operation. setting is made at the factory (and must be monitored by the operator). This pressure provides for unlocking the hydraulic cylinder by the intensifier

Fig. 1-9. Flowmeter Circuit

Fig. 1-10. Intensifier Circuit

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Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

INSTALLATION

2.0 INSTALLATION
2.1 INTRODUCTION Select an area where the calibrator will be level and on solid footing, 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. NOTE: The circled numbers shown with the labels on photos refer to step numbers on the following instructions. 2.2 HOLD DOWNS For security in shipment, the cabinet is bolted to the shipping skid, and the flowmeter and console are bolted down using spacer blocks. To remove the bolts and spacers: 1. Open the front doors, and remove the two rear panels. 2. Remove the two shipping bolts that hold the cabinet to the skid. 3. Lift the cabinet from the skid and place it in the selected area. 4. Remove the two shipping spacers between the flow transducer base and console base by removing the two 1/4-20, 3/4 long bolts, nuts and washers. 5. Remove two shipping (wooden) spacers between the console and tabletop, located on each side of the console, by removing the two 1/4-20, 3/4 long bolts and washers. 6. Close the front doors and reinstall the rear panels.
e Remove Console Bolts (Typical Both Sides)

Fig. 2-1. DD5 Cabinet Dimensions

e Wooden Spacers (Each Side)

d Remove Transducer Hold Down Bolts and Shipping Spacers (Typical Both Sides)

Fig. 2-2. Hold Downs

Instruction 77-9075

Bacharach, Inc.

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2.3 UTILITY CONNECTIONS A. Electrical (see Section 1.1C for Specifications) CAUTION Be sure MAIN POWER is OFF when servicing Calibrator. To prevent damage to calibration fluid reservoir heaters, fill reservoir with calibration fluid to proper level before applying electrical power. 1. Customer must supply 3 phase power from an easily accessible wall mounted fusible disconnect switch rated at 30 amps. 2. Check the nameplate (located on the frame, leftside) for the electrical characteristics required. The standard unit requires 230V, 60 Hz. 3 phase see Fig. 5-15 for details. 3. Make sure On-Off Switch/circuit breaker is OFF. Use a #10 wire for 230 and 208 volt units (or a #12 wire for 460 volt units) to wire to magnetic motor starter in the electrical control box. Bring wire through the hole in the rear of the unit using proper hardware. 4. After wiring, turn unit ON and check that the direction of rotation of the small motor (located inside the front panels) is counter-clockwise. 5. If the motor direction is wrong, switch any two wires at the wall disconnect and check again. B. Water 6. Connect a cold water line to the fitting at the rear of the calibrator marked WATER IN (1/4" NPT). 7. Connect a drain line to the fitting marked WATER OUT (1/4" NPT). NOTE: Do not install any valves, shutoffs or other restrictions on the drain line. Water goes in under line pressure and must be free to run out.
f WATER IN g WATER OUT h AIR In 2 Name Plate

d Motor Rotation Direction

3 On-Off Switch/ Circuit Breaker

Fig. 2-3. Electrical Connections

c Electric Power Inlet

Fig. 2-4. Water Connections

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Instruction 77-9075

INJECTOR CALIBRATOR DD5

INSTALLATION

C. Air NOTE: Air pressure regulator was set at the factory. 8. Connect an air line from the shop supply to the fitting at the rear of the calibrator marked AIR (1/4" NPT). 9. Check regulator setting. It must be 60 +5, 0 psi (4.1 bar). The air pressure regulator is behind the lower rear panel. CAUTION Shop air supply must not exceed 125 psi. High shop air pressure can damage air regulator. 10. To adjust air pressure regulator, lift the red ring above the regulator adjustment ring and turn knob. When adjusted, push ring down to lock. 2.4 FILLING RESERVOIRS A. Calibration Fluid 1. Make sure both drain of the calibration fluid reservoir are closed. 2. Through dipstick port, fill reservoir to the F mark on the dipstick with new fluid. Use Bacharach part number 67-5598 (15 US gallon drum). This fluid meets SAE J967 and ISO4113. 3. Place a tag on the reservoir, giving date it was filled. B. Cambox The cambox is filled at the factory. However, if filling is necessary: 4. Make sure the cambox drain plug is in place. Drain plug is accessible after left-hand cabinet door is open.

10

j Lift Red Ring

Adjust Air Pressure to 60 PSI

i Check Regular Setting

h AIR In

Fig. 2-5. Air Pressure Regulator

a Close Both Drains

Fig. 2-6. Fluid Reservoir Drains

4 Cambox Drain Plug

b Fill to "F" Mark On Dipstick

Fig. 2-7. Filling Reservoirs

Instruction 77-9075

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5. 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 inches from the bottom). C. Intensifier 6. The intensifier reservoir is filled at the factory before shipping. If additional fluid is required, add SAE 30W motor oil. A three quarter full bottle is acceptable. D. Flowmeter Transducer 7. The flowmeter transducer cavity is filled at the factory before shipping. If additional fluid is required, see Section 2.5.
5 Fill Cambox to 3 Inches from Top

Fig. 2-8. Cambox 2.5 PRE-OPERATION CHECKS Before trying to operate the calibrator for the first time be sure to complete all the Initial Checks below and Start-Up procedures in Section 2.6. CAUTION CALIBRATOR CAN BE DAMAGED. Do not operate the calibrator until all items on the checklist below have YES responses. INITIAL CHECKS All responses must be YES IS THIS TRUE? 1. On-Off Switch/Circuit breaker is in OFF position. 2. The electrical power supplied corresponds to the data on the nameplate inside the left side door. 3. The air line from the shop air supply is connected to the AIR inlet at the back of the calibrator. YES Fig. 2-9. Initial Checks, Hook-up _____
6 WATER OUT b Electric Power Inlet (Connections inside Electrical Box Cover) a On-Off Switch/ Circuit Breaker c AIR In 5 WATER IN b Electrical Name Plate (inside)

_____*

_____

4. Air pressure regulator gauge (inside _____ lower rear panel) indicates 60 psi (4.1 bar) +5, 0 psi. Reset if necessary.
9 Flowmeter Cavity

*If electrical power does not correspond to data on nameplate (within 10%) consult Bacharach factory.

Fig. 2-10. Initial Checks, Flowmeter

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Instruction 77-9075

INJECTOR CALIBRATOR DD5

INSTALLATION

NOTE: Air pressure regulator was set at the factory. 5. Cold water line is connected to the WATER IN fitting. 6. The drain line is connected to the WATER OUT fitting. NOTE: Do not connect any valve, shut-off, other restriction in the drain line. 7. The calibration fluid reservoir is _____ filled to the F mark on the dipstick. Use Calibration Fluid 67-5598. 8. The cambox is filled with oil to 3-3/4 inch from the top of cam box. See Section 2.4.B. 9. The flowmeter cavity is filled with lube oil (30W) to about 3/8" from the bottom. Replenish if necessary. 10. The intensifier reservoir is filled with oil. A three-quarter full botble is acceptable. _____ _____

4 Air Pressure Regulator Gauge

_____

Reservoir Drain Valves

Fig. 2-11. Initial Checks, Drains

_____

_____

Do not proceed until all responses on the checklist are YES.

7 Dipstick

Fig. 2-12. Initial Checks, Reservoir

2.6 START-UP 1. Switch On-Off Switch/Circuit Breaker to ON. POWER indicator, HEATER indicator and the red dot on the display will be lit, and the calibration fluid system pump will be running. 2. Allow the calibrator to warm up until the CAL FLUID TEMPERATURE gauge indicates 100F +1F (37.8C). This usually takes about 15 to 20 minutes, depending on the ambient temperature. NOTE: The calibration fluid temperature was adjusted at the factory. If readjustment is necessary refer to Section 4-14. 3. The calibrator is now ready for testing injectors. Fig. 2-13. Initial Checks, Cambox
Instruction 77-9075 Bacharach, Inc.

h Cambox Oil

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INSTALLATION

INJECTOR CALIBRATOR DD5

2.7 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. 4. Place 5/8 x 7/8 x 11-1/2 inch wooden blocks under each side edge of the console. 5. Use a 3/4 inch long, 1/4-20 bolt in the center of each edge of the console to hold the console securely to the cabinet. 6. Use two spacers, two 3/4 inch long, 1/4"-20 bolts, nuts and washers to fasten the flowmeter trans-ducer to the console. 7. Do not drain the fluid from the cambox. 8. Bolt the calibrator to a shipping skid. 9. Pack the calibrator in a sturdy crate for shipping.

j Intensifier Reservoir

Fig. 2-14. Initial Checks, Intensifier

2.8

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 enviroment

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Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

OPERATION

3.0 OPERATION
3.1 INTRODUCTION Make sure you have completed the Pre-operation Check-list in Section 2.5 before testing any injectors. Units shipped from the factory have cam 53/71/92 (77-0610) installed. Another Cam must be used for testing the 149 injector, for more information see Section 3.2, 3.3, 3.4, and Table 3-1 below. Procedures for mounting injectors vary according to the type of injector: Type 53, 71, or 92 Marine Type 149 Type 8.2 liter - Section 3.4 - Section 3.5 - Section 3.6 NOTE: Please read the IMPORTANT NOTE on Page 3-12 before checking Kent Moore Master Injectors.

The following is a table of accessories and their application: Table 3-1. Accessory Application
For Injector 53, 71, 92 92 Marine 149 8.2 liter Manifold Block 77-0613 77-0613* 67-7643 ----------Front Support 67-6606 67-6606 67-6605 ----------Adapter Set ------------------------------67-8525** Discharge Head 67-5696 67-5696 67-5700 67-5696 Push Rod Extension ----------77-0912 67-5708 -----------

Cam 77-0610 77-0610 67-6372 77-0610

--------- means the accessory is not needed. * The setup of the Manifold Block for the 92 Marine requires installing Support Assy (77-0913), and the Fuel Connectors (77-0866) **The 8.2 liter injector adapter set consists of a spacer block (67-6851), two angle spacers (67-6850), an injector holder (67-6854), with key (67-6853), and mounting instructions (67-9388).

3.2 INJECTOR MOUNTING (general) Injectors are clamped against standoffs (part of the Manifold Block or Spacer Block) located between the injector and the cambox. Supports are required for the front of the injectors. The 149 injector uses a push rod extension between the push rod and the injector follower. The 8.2 liter injector needs a special holder assembly.

Fig 3-1. Injector Accessories

Instruction 77-9075

Bacharach, Inc.

Page 3-1

OPERATION

INJECTOR CALIBRATOR DD5

3.3 CAM CHANGE NOTE: The DD5 is shipped with Cam 77-0610 (for the 53, 71, 92 & 8.2L injectors) mounted in the cambox. The following procedure is to be used whenever a cam change is required. The cam is held in place on the tapered end of the camshaft by a 3/4 in. hex nut and 3/4 in. plain washer, and is locked to the shaft by a key. To change the cam: 1. Check that the drive motor is off. 2. Open flywheel cover and raise the hinged lid of the cambox. 3. Insert barring tool into a radial hole in flywheel. Rotate flywheel until cam is at maximum lift. 4. Screw the push rod lock (67-5712) onto the push rod. This will keep the tappet spring compressed to allow the cam change. NOTE: 67-5712 is part of Basic Accessories 77-0585 supplied with the DD5. 5. Rotate flywheel another 1/4 turn. 6. Using a 1-1/8 in. box wrench, unscrew and remove the nut, washer and cam. 7. Install the correct cam on the camshaft and secure it with the washer and hex nut. 8. Rotate flywheel so new cam is at max lift. Unscrew and remove the push rod lock. 9. Close cambox lid and flywheel cover. To find the proper cam for the injector type used, see Table 3-1.
g Cam f Nut and Washer

c Barring Tool

f Wrench

Fig. 3-2. Changing Cams

Fig. 3-3. Cam, Nut, and Washer

Page 3-2

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

OPERATION

3.4

MOUNTING INJECTOR TYPES 53, 71, 92, AND 92 MARINE

a Manifold Block

a Drain Fitting

Make sure cam 77-0610 is installed in the cambox. The drain fitting for manifold block assembly (770613) can be positioned in either of two return ports, depending on whether injector to be tested is of the offset or standard design. The barbed elbow drain fitting is shipped in the position for offset injectors. For standard injectors, install the fitting in the other port, marked OUT. The manifold block includes three sets of standoffs: 1. long for low crab injectors, 2. short for high crab injectors, 3. long for 92 Marine injectors. The 92 Marine injectors require installation of the Support Assy and Fuel Connectors to the Manifold Block mentioned in Table 3.1 (See Figure 3-4A). NOTE: The injector must be clamped when tappet roller is against the cam base circle (When the white painted area of the flywheel is showing in the opening on front of the flywheel case). In the rare case that the camshaft stopped with the roller at high cam, raise flywheel cover and turn flywheel in either direction. Tappet roller will slide down to cam base circle. A. Manifold 1. Slide the manifold block assembly 77-0613 over the dowel pins, with the inlet port face up. The return port with the barbed drain fitting should be on the far side in a horizontal position. 2. Install the correct standoffs in the manifold block. B. Discharge Head 3. Insert the discharge head (67-5696) for 53, 71, 92 injectors into the clamp cylinder socket with the quick connect socket facing about 45 toward the console. NOTE: When discharge heads are installed for the first time, wet the O ring with calibration fluid for easier installation. 4. Insert plastic tubing with quick connect plug into the discharge head socket. C. Injector 5. Slip front support (67-6606) over rails.
Instruction 77-9075 Bacharach, Inc.

b Standoffs

Alternate Drain Port

Fig. 3-4. Manifold

Fig. 3-4A. 92 Marine Assembly

e Front Support

c Quick Connect

c Discharge Head

Fig. 3-5. Accessories in Place

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OPERATION

INJECTOR CALIBRATOR DD5

6. Place the injector in position so the lower body rests on top of the semicircular front support 67-6606 and the fuel connectors are aligned with their ports in the manifold block. 7. Make sure the O rings are in position in the manifold block connectors. D. Fuel Inlet/Outlet 8. Install male quick connect into inlet port of the manifold block. 9. Push supply hose quick connect over male quick connect in manifold block. 10. Push one end of the two-foot plastic tubing over 90 drain tube (fill tube) 67-5292 and the other end over the barbed elbow at the OUT port on the manifold. Quick connect, plastic tubing and fill tube are part of the calibrator Basic Accessories. 11. Insert the open end of the fill tube into the drain tray center hole. E. Injector Clamping 12. Push and hold the HOLD TO OPERATE button with left hand. 13. While holding down the HOLD TO OPERATE button, move the CLAMP/UNCLAMP lever to the CLAMP position with right hand. 14. With the injector clamped, wait until the CLAMP MONITOR timing light goes out (after about 1 second). Fig. 3-7. Clamping Injector 15. Release HOLD TO OPERATE button and allow the CLAMP/UNCLAMP lever to return to center position. NOTE: For positive and safe clamping the above procedure must be followed in the sequence described above. The injector is now ready for running tests. See Section 3.7.
14 13

Fig. 3-6. Injector In Place

CLAMP

12

HOLD TO OPERATE

CLAMP MONITOR Light

Fig. 3-8. Front Panel

Page 3-4

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

OPERATION

3.5 MOUNTING MUI INJECTOR TYPE 149 Make sure cam 67-6372 is installed in cambox. NOTE: The injector must be clamped when tappet roller is against the cam base circle. (When the white painted area of the flywheel is showing in the opening on front of the flywheel case). In the rare case that the camshaft stopped with the roller at high cam, raise flywheel cover and turn flywheel in either direction. Tappet roller will slide down to cam base circle. A. Manifold 1. Place push rod extension (67-5708) over the push rod. 2. Slide manifold block (67-7643) over the dowel pins with the inlet port face up. B. Discharge Head 3. Insert the discharge head (67-5700) into the clamp cylinder socket with the quick connect socket facing 45 toward the console. NOTE: When discharge heads are installed for the first time, wet the O ring with calibration fluid for easier installation. 4. Insert the plastic tube with the quick connect plug into the discharge head quick connect socket. C. Injector 5. Slip the front support (67-6605) over the rails. 6. Place the injector in position so the lower body rests on top of the semicircular front support 67-6605 and the fuel connectors are aligned with their ports in the manifold block. 7. Guide the spring and tappet follower of the injector into the manifold block center bore. Fig. 3-9. Manifold

e Front Support

d Quick Connect

c Discharge Head

Fig. 3-10. Accessories in Place

Instruction 77-9075

Bacharach, Inc.

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OPERATION

INJECTOR CALIBRATOR DD5

D. Fuel Inlet/Outlet 8. Install male quick connect into the inlet port of the manifold block. 9. Push supply hose quick connect over male quick connect in manifold block. 10. Push one end of the two-foot plastic tubing over 90 drain tube (fill tube) (67-5292) and the other end over the barbed elbow at the OUT port on the manifold. Quick connect, plastic tubing and fill tube are part of the calibrator Basic Accessories. 11. Insert the open end of the fill tube into the drain tray center hole. Fig. 3-11. Injector In Place E. Injector Clamping 12. Push and hold the HOLD TO OPERATE button with left hand.
13

CLAMP

13. While holding down the HOLD TO OPERATE button, move the CLAMP/UNCLAMP lever to the CLAMP position with right hand. 14. With injector clamped wait until the CLAMP MONITOR timing light goes out (after about 1 second). 15. Release the HOLD TO OPERATE button and allow the CLAMP/UNCLAMP lever to return to the center position. NOTE: For positive and safe clamping the above procedure must be followed in the sequency described above. Fig. 3-12. Clamping Injector The injector is now ready for running tests. See Section 3.7.
12

HOLD TO OPERATE

14

CLAMP MONITOR Light

Fig 3-13. Front Panel

Page 3-6

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

OPERATION

3.6

MOUNTING INJECTOR TYPE 8.2 LITER

a Push Rod Guide a Spacer Block

Make sure cam 77-0610 is installed in cambox. Injector holder set 67-8525, which includes adapter, two angle spacers, a spacer block, and an injector holder, is required. NOTE: The injector must be clamped when tappet roller is against the cam base circle. (When the white painted area of the flywheel is showing in the opening on front of the flywheel case). In the rare case that the camshaft stopped with the roller at high cam, raise flywheel cover and turn flywheel in either direction. Tappet roller will slide down to cam base circle. A. Spacer Block 1. Attach the spacer block to the cambox over the two dowel pins. NOTE: Make sure the spacer block is flush against the push rod guide. B. Discharge Head 2. Install the discharge head (67-5696) into the clamp cylinder socket with the quick connect socket facing 45 toward the console. NOTE: When discharge heads are installed for the first time, wet the O ring with calibration fluid for easier installation. 3. Insert the plastic tube with the quick connect plug into the discharge head quick connect socket. C. Injector 4. Install the injector into the injector holder by hand pushing until the mounting slots on both the injector and the holder are aligned. 5. Then secure with the keys straight edge towards the injector. This will prevent the injector from moving out during testing. 6. Place the injector holder with the injector over the rails.

Dowel Pin

2 Quick Connect

b Discharge Head

Fig. 3-14. Spacer Block and Discharge Head in Place

e Key

d Injector Holder

Fig. 3-15. Injector in Place (Shown Clamped)

Instruction 77-9075

Bacharach, Inc.

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OPERATION

INJECTOR CALIBRATOR DD5

D. Fuel Inlet/Outlet 7. Install male quick connect plug on top of injector holder. Then push supply hose quick connect over male quick connect. 8. Attach the two-foot plastic tubing (part of 77-0585) to the barbed elbow at the bottom of the injector holder. 9. Insert the other end of the tubing into the drain tray center hole. E. Injector Clamping 10. Push and hold the HOLD TO OPERATE button with left hand. 11. While holding down the HOLD TO OPERATE button, move the CLAMP/UNCLAMP lever to the CLAMP position with right hand. 12. With injector clamped, wait until the CLAMP MONITOR timing light goes out (after about 1 second). 13. Release the HOLD TO OPERATE pushbutton and allow the CLAMP/UNCLAMP lever to return to the center position. NOTE: For positive and safe clamping the above procedure must be followed in the sequency described above.
10

11

CLAMP

HOLD TO OPERATE

Fig. 3-16. Clamping Injector

12

CLAMP MONITOR Light

Fig. 3-17. Front Panel The injector is now ready for running tests. See Section 3.7.

3.7 TESTING WARNING Do not open cambox cover while main drive motor is running. Make sure that the Flywheel has stopped turning before opening cambox cover, to prevent being splashed by hot lubricating oil.

Page 3-8

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

OPERATION

CAUTION Do not start Main Drive with Supply Hose connected to the Manifold Block (or 8.2L Injector Holder) and with injector not clamped. This will cause calibration fluid to spray out of the block. NOTE: When starting the main drive for the first time, run it for only a few seconds after pressure develops to make sure that all fuel connections are tight. 1. With the injector clamped as described previously, and calibration fluid temperature between 99-101F, press the START MAIN DRIVE button. As soon as this button is depressed and the camshaft is turning, make certain that rail pressure gauge shows 35 psi. NOTE: If main drive motor wont start, check the flywheel cover. It must be tightly closed for the interlock safety switch to allow the main drive motor to operate. 2. If necessary, set the fuel pressure (regulator located inside the frame, accessible after the front doors are opened) so that RAIL PRESSURE gauge indicates 35 psi. 3. Wait several seconds until trapped air escapes from discharge head as seen in plastic tubing leading to flow meter. 4. Depress START METER button on the console. The button light will come on. The fuel delivery display will show cumulative readings until 100 strokes are completed, then the reading will stay on until the next up-date. The readings will be updated automatically every 100 strokes. When starting the machine cold, let the injector run and deliver fluid to the flowmeter for 30-60 seconds before starting to record readings. 5. After injector and machine are warmed up record the fuel delivery display readings. The reading is in MM3/STROKE, which is equivalent to cc/1000 strokes. To obtain a good reading take at least 3-5 readings. 6. When testing is complete, press the red STOP button on the left hand operators table.

a Flywheel Cover

e Display of Fuel Output b RAIL PRESSURE

f STOP

a START MAIN DRIVE

d START METER

Fig. 3-18. Testing Injectors

Instruction 77-9075

Bacharach, Inc.

Page 3-9

OPERATION

INJECTOR CALIBRATOR DD5

3.8 UNCLAMPING INJECTORS CAUTION Before you start unclamping the injector make sure to wait until the camshaft comes to complete rest. Use the unclamping procedure which applies to the type of injector you are testing; (a) Types 53, 71, 92, or 149 and (b) Type 8.2 liter. A. Unclamping Injector Types 53, 71, 92, & 149 1. Press and hold the HOLD TO OPERATE button. 2. While holding the button down, move the CLAMP/UNCLAMP lever to the UNCLAMP position and let the hydraulic cylinder completely retract. 3. Release the HOLD TO OPERATE pushbutton and allow the CLAMP/UNCLAMP lever to return to its center position. 4. Remove injector.
a HOLD TO OPERATE

b UNCLAMP

Fig. 3-19. Unclamping Injectors

Page 3-10

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

OPERATION

B. Unclamping Injector Type 8.2 Liters 1. Press and hold the HOLD TO OPERATE button. 2. While holding the button down, move the CLAMP/ UNCLAMP lever to the UNCLAMP position and let the hydraulic cylinder completely retract. 3. Release the HOLD TO OPERATE pushbutton and allow the CLAMP/UNCLAMP lever to return to its center position. 4. Remove key from the injector holder slot and disconnect fuel supply hose. Slide injector with holder to the right. 5. Place the two angle spacers from the injector holder set (67-8525) over the rails. 6. Press and hold the HOLD TO OPERATE button. 7. While holding the button down, slowly move the CLAMP/UNCLAMP lever toward the clamp position to gradually extend the clamping cylinder until the injector holder butts against the angle spacers next to the cambox. Continue to hold the CLAMP/UNCLAMP lever until the injector pops out of the injector holder. 8. While still holding the HOLD TO OPERATE button down, move the CLAMP/UNCLAMP lever to UNCLAMP position to retract the cylinder. 9. Release the HOLD TO OPERATE button and allow the CLAMP/UNCLAMP lever to return to the center position.
e Angle Spacers

Fig. 3-20. Unclamping Injector Type 8.2L

3.9 SHUTTING DOWN CALIBRATOR 1. Turn off power at On-Off Switch/Circuit Breaker. 2. Wipe oil spills and splashes from console and operators table. 3. Return all accessories to their locations.

Instruction 77-9075

Bacharach, Inc.

Page 3-11

OPERATION

INJECTOR CALIBRATOR DD5

IMPORTANT NOTE:
The DD5 Calibrator is designed and built to meet all the test requirements imposed by the injector manufacturer. It incorporates a positive displacement flowmeter which generates digital signals with high resolution. This type of system is recognized in the industry to be the most accurate measurement means for this application. Tests conducted at Bacharach, GM - Rochester Product Division and Detroit Diesel Corporation (DDC) indicate that injector output measurements obtained on production-type calibration equipment at GM/ RPD may be different from those obtained on other makes and models of calibrators. In particular, it has been determined that Master Injectors marketed by Kent Moore all read higher on Bacharach DD%$ Calibrators, by the amount shown below. Therefore, when checking Master Injectors, the fuel output as read on the digital readout of the DD5 Calibrator will be higher than the stamped values by the amounts shown: Injector Type 53 71 92 8.2L 149 Difference In Reading (mm3/str) 2.0 2.5 4.6 2.3 3.9

The recheck limits (as given by DDC) of Master Injectors on any calibrator are 2% of stamped value. As an example for type 71 Master Injector: Stamped Value: 72.0 Add Correct Value = 74.5 Tolerance (2%)

+ 2.5

73.0 76.0

Therefore, for a type 71 Master Injector stamped as 72.0, the correct delivery value (fuel output) should be 73.0 - 76.0 mm3/str on a Bacharach DD5 Calibrator. This information is being provided with the full knowledge and agreement of the Detroit Diesel Corporation. Any questions should be referred to the factory: Bacharach, Inc. 621 Hunt Valley Circle New Kensington, PA 15068 Service Manager Tel: 724-334-50000

Page 3-12

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

MAINTENANCE AND ADJUSTMENT

4.0 MAINTENANCE AND ADJUSTMENT

CAUTION Do not attempt to make any adjustments or repairs to the calibrator without first disconnecting the main power line at the wall. 4.1 MAINTENANCE SCHEDULE CHECK THESE DAILY: 1. If calibration fluid is low, add enough calibration fluid to bring the level up to the F on the dipstick. Use Bacharach Calibration Fluid 67-5598 (15 US Gallon). 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. Fig. 4-1. Calibration Fluid Level NOTE: Dont overfill, BEARING DAMAGE may result. CHECK, CHANGE OR CLEAN THESE EVERY THREE MONTHS (or after 120 operating hours, whichever occurs first): 1. Calibration fluid - Replace 2. Suction fuel filter - Replace 3. Final stage filter - Replace 4. Flowmeter transducer strainer - Clean 5. Cambox oil - check and replace if necessary This schedule is only a guideline; maintenance will depend on the working environment and the cleanliness of the injectors. See the following sections for procedures.

Fig. 4-2. Cambox Oil Level

Instruction 77-9075

Bacharach, Inc.

Page 4-1

MAINTENANCE AND ADJUSTMENT

INJECTOR CALIBRATOR DD5

4.2 CHANGING CALIBRATION FLUID AND FILTERS Calibration fluid change periods will depend on the type of service. Inspect fluid periodically for contaminants and viscosity. The fluid must be changed when viscosity is above 3.1 centistokes (cst) at 100 F (38 C). To check viscosity use Viscor Cup (Bacharach P/N 77-0391). At the same time the fluid is changed, change supply and final stage filters. 1. Remove the rear 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. Use Bacharach part number 67-5598. NOTE: It is a good idea to fasten a tag to the reservoir giving the date the fluid was changed. 6. Unscrew the suction filter cartridge from its header, discard, and replace with a new one filled with fluid. 7. Unscrew final stage filter cartridge from its header, discard, and replace with a new one filled with fluid. NOTE: Fasten tags on both filter cartridges giving the date they were changed. 8. Remove and clean flowmeter transducer strainer.
h Flowmeter Strainer

Fig. 4-3. Reservoir Drains

Fig. 4-4. Suction Filter

Fig. 4-5. Flowmeter Strainer

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Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

MAINTENANCE AND ADJUSTMENT

4.3 CHANGING CAMBOX OIL After three months or 120 hours of operation whichever occurs first, Check for proper level and possible contamination. If oil change is necessary drain oil from cambox and refill using the following procedure: 1. Open drain plug on bottom of cambox, accessible after left-hand cabinet door is open, and allow old oil to drain out. 2. Wipe inside of cambox clean. 3. Reinstall drain plug. 4. Fill the cambox with enough 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). See Fig. 4.2. Fig. 4-6. Front View, Doors Open 4.4 CLEANING AND LUBRICATING The DD5 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 where they can mix with the calibration fluid. For the same reason, injectors should be cleaned before testing. The calibrators mechanical parts are largely selflubricating and therefore no special lubricating procedures are required. Both motors are sealed and lubricated for life.

4.5 REFILLING FLOWMETER CAVITY 1. Turn off power, the piston will not move by hand while power is still on. 2. To locate the assembly, remove the top rear panel. 3. Move encoder arm/piston assembly in either direction to extreme end of travel. 4. Examine cavity for between 1/4 and 3/8" level (from the bottom of the cavity) of lube oil. 5. Use SAE 30W lube oil to maintain level. Fig. 4-8. Flowmeter (End View) 6. Move the encoder arm/piston assembly to the approximate center of its travel. Fig. 4-7. Flowmeter Cavity

Instruction 77-9075

Bacharach, Inc.

Page 4-3

MAINTENANCE AND ADJUSTMENT

INJECTOR CALIBRATOR DD5

4.6 TROUBLESHOOTING CHARTS TROUBLESHOOTING CHART FOR MECHANICAL PROBLEMS Fault Clamp action faulty Possible Cause and Remedy May lack unlocking pressure - Press HOLD TO OPERATE button and listen for pump reliefs ("putt" sound). 1. If after three putts, cylinder will still not move, there may be insufficient hydraulic pressure. (a) Check intensifier hydraulic circuit for leaks. (b) Check hydraulic pressure at the cylinder (Section 4.7) 2. If there is noputting, check air pressure gauge for shop air to the calibrator and make sure solenoid valve and air release valve are operating. 1. Cold water supply may be turned off - Turn on supply. 2. Water flow through calibrator may be disrupted - Disconnect return line with HEATER lamp off at console and observe for presence of water flow. 3. Temperature control system may not be operating properly - See Section 1.4 for proper operation.

Calibration fluid temperature too high

TROUBLESHOOTING CHART FOR ELECTRICAL PROBLEMS Fault Motor trips off intermittently Possible Cause and Remedy 1. Motor starter (M1) overload relay trip setting may be too low - Adjust trip load control to the number calculated by multiplying the service factor times the motor full load amps (both found on the motor name plate). 2. Line voltage may be out of specification - Correct line voltage as required. 3. Vibration-induced intermittent interlock may be occurring - Check S4, S3, M1, or M10L (See Figure 5-15B). 4. Main motor may be defective - Replace or repair. 1. Flywheel cover may be open - Close cover 2. Interlock switch (S3) may be out of line or defective - Reposition or replace (Section 4.12) 3. Motor starter reset button may have tripped - Reset M1 button (Section 4.8) 4. Fuse F-1 (2 Amp) may have blown - Replace (Section 4.9) and investigate cause. 5. STOP button may be defective - Repair or replace 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Fuse F-5 (5 Amp) may be blown - Replace (Section 4.9) and investigate Temperature controller may be defective - Replace Potentiometer R1 may be defective - Replace Heaters (HTR1 or HTR2) may be defective - Replace Cooling water solenoid may be defective - Replace Calibration fluid in reservoir may be low - Increase fluid level Temperature Sensor may be defective - Replace Temperature Gage may be defective - Replace Cooling water supply may be absent - Connect and turn on water supply Clamp valve not in neutral - Fix problem

Main motor will not start

Calibration fluid temperature unstable

Page 4-4

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

MAINTENANCE AND ADJUSTMENT

INJECTOR CALIBRATOR DD5 MAINTENANCE & ADJUSTMENT Fault Flowmeter display inoperative Possible Cause and Remedy 1. Sun shines on transducer (rear panel off) makingoptical detectors inoperative - Keep the sun from hitting the transducer. 2. Loose connector - Retighten. 3. Optical detector improperly adjusted or defective - Readjust (Section 4.11) or replace. 4. Bypass solenoid (L8) may be defective - Replace. 5. Relay K1 may be defective - Replace. 6. Tranducer may be defective - Replace. 7. Display P.C. board may be defective - Replace*. 8. Main P.C. board may be defective - Replace*. 1. Encoder wheel bent or slots obstructed - Replace or clean as required (Section 4-11) 2. Loose or broken wiring or shields - Replace or repair 3. Leak in discharge line including discharge head - Repair 4. Electrical noise generated by other shop equipment - Isolate Circuit 1. Air in calibration fluid system - Bleed air from Cal. Fluid Bleed Port. 2. Optical Detector on camshaft may be defective - Replace (Section 4.11) 3. Main P.C. board may be defective - Replace*. 1. Connector to main P.C. board may be loose - Reconnect 2. Flowmeter limit switches may be tripped - Remove power and reposition piston adapter block to center of cavity 3. Flowmeter transducer electrical connectors loose - Reconnect. 4. Bypass solenoid (L8) may be defective - Replace 5. Detector #1 or #2 on flowmeter transducer may be defective - Replace.

Erratic flow readings

Flowmeter display indicates flow beyond injector capability Flowmeter displays all zeros; will not display flow readings

*When replacing a P.C. board, replace both the main P.C. board and the display P.C. board.

4.7 HYDRAULIC SYSTEM/INTENSIFIER A. Checking Hydraulic Pressure To make sure that sufficient hydraulic pressure is applied to the hydraulic cylinder locking sleeve: 1. Install a 0-5000 psi gauge at the gauge/bleed port (Fig. 4-9). 2. When holding the HOLD TO OPERATE button, check the pressure reading. Pressure must be 3700-4000 psi. 3. If pressure is less than 3700 psi, check for air and hydraulic leats between the hydraulic pump and the cylinder. If over 4000 psi, reduce the air pressure. After removing the gauge, make sure to bleed air from the system and refill. See Section B below.

1 Gage/Bleed Port

5 Bleed Port

Fig. 4-9. Front Panel, Table Top

Instruction 77-9075

Bacharach, Inc.

Page 4-5

MAINTENANCE AND ADJUSTMENT

INJECTOR CALIBRATOR DD5

B. Filling Intensifier and Bleeding Air from System 4. Add oil to intensifier reservoir, if necessary (see Section 2.4 & Fig. 2-14). 5. Use 3/16 inch hex to "crack" plug at the bleed port (Fig 4-9). 6. Press and hold HOLD TO OPERATE button and let some oil flow past the loosened plug. 7. Allow air to escape through port until oil flows freely. 8. While the oil flows, tighten the plug, then release the button. 9. Use caution to observe that reservoir does not empty during bleeding. 10. Replenish oil in the reservoir immediately after bleeding.

Fig. 4-10. Main Motor Reset

Limit Switches

4.8 RESETTING SWITCHES A. Resetting the Motor Reset Button In the event of a motor overload condition: 1. Disconnect Main Power to calibrator.
f Optical Detectors

2. Remove the electrical box cover and press the motor reset button (Fig. 4-10). B. Resetting Flowmeter Limit Switches If the flowmeter displays all zeros or will not display flow readings, one of the limit switches may be tripped (i.e. the piston is stuck in its extreme position) see Figure 4-11. 3. Remove power by switching the On-Off Switch/ circuit breaker to OFF. 4. Reposition flowmeter piston so that the adapter block is centered in the cavity. 5. Restart the calibrator (with injector delivering fluid). 6. If the flowmeter again displays all zeros or will not display flow readings, check the optical detectors. They may have to be cleaned or replaced. Page 4-6
Bacharach, Inc.

Fig. 4-11. Limit Switches

Instruction 77-9075

INJECTOR CALIBRATOR DD5

MAINTENANCE AND ADJUSTMENT

7. Restart the calibrator. If the flowmeter still will not work, check the main circuit board. It may have to be replaced.

4.9 CHANGING FUSES (Figure 4-12, 4-13, and 5-15) NOTE: Disconnect Main Power to calibrator before removing panels. F-1 (2 Amps): This fuse is in the main power circuit for all control circuits. If this fuse blows, the operators console will indicate the following: Power Indicator (Red): Heaters Indicator (Amber): LED Display (Red Dot): All Clamping Functions: Main Drive Start: ON ON or OFF OFF OFF OFF
F1 F3 & F4 (Hidden)

Fig. 4-12. Fuses F-1, F-3, and F-4

F-3/F-4 (4 Amps): Both fuses F-3 and F-4 are for special voltage options for 380 and 460 VAC operation. These fuses control input to Transformer T-3. If either fuse blows, the operator console will indicate the following: All power: OFF

F-2 (0.4 Amps): This fuse controls the flowmeter transducer circuit. If fuse blows, the operators console will indicate the following: Power Indicator (Red): Heaters Indicator (Amber): LED Display (Red Dot): Main Drive Start: Flowmeter Transducer piston: ON ON or OFF OFF (blank) ON Inoperative

F5 (5 Amps): This fuse controls the calibration fluid heaters circuit. If this fuse blows, the following will be effected: Heater power: Cooling water supply circuit power: Heater lamp DS1 (Amber) on the operators console: OFF OFF OFF

F2

F5

Fig. 4-13. Fuses F-2 & F-5

Instruction 77-9075

Bacharach, Inc.

Page 4-7

MAINTENANCE AND ADJUSTMENT

INJECTOR CALIBRATOR DD5

4.10

ADJUSTING AIR PRESSURE REGULATOR

Required air pressure is set at the factory to produce the correct pressure for unlocking the hydraulic cylinder. 1. Check regulator setting. It must be 60 +5 0 psi (4.1 bar). The air pressure regulator is behind the lower rear panel. 2. To adjust air pressure regulator, lift the red ring above the regulator adjustment ring. 3. Hold the ring up while adjusting. 4. Push the red ring back down to lock the setting. Fig. 4-14. Air Pressure Regulator

4.11

ADJUSTING OPTICAL DETECTOR ON CAMSHAFT

The optical detector (60-7000) is mounted on a cross bar of the table top on the underside of the encoder wheel (67-6414). The encoder wheel is a thin disk which passes through a slot in the detector. 1. If the encoder wheel rubs the sides of the slot in the detector, loosen the four screws that secure the cross bar to the table top. 2. Adjust the detector forward or back until the encoder wheel rides through the center of the slot.
Optical Detector

Fig. 4-15. Inside Flywheel Cover

4.12

ADJUSTING FLYWHEEL COVER INTERLOCK

1. Loosen the two screws that secure the switch to the rear cover. 2. Adjust Interlock Microswitch position so that the switch is actuated when the flywheel cover is closed.

b Interlock Microswitch

Fig. 4-16. Flywheel Cover Interlock

Page 4-8

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

MAINTENANCE AND ADJUSTMENT

4.13

REPLACING DRIVE BELT

In the rare case that the drive belt must be replaced: NOTE: Turn off Main Power to calibrator. 1. Switch the On-Off Switch/Circuit Breaker to the OFF position. 2. Lift the flywheel cover. 3. Open the hinged side door. 4. Remove the two hex head cap screws that secure the optical detector assembly to its support angle and carefully slide the optical detector assembly away from the encoder wheel. 5. Carefully slip new drive belt over encoder wheel and onto camshaft pulley. 6. Loosen the four hex head cap screws that secure the drive motor to its support plate. 7. Slide drive motor toward left side of calibrator until it is possible to slip drive belt onto the motor pulley. 8. Adjust the belt fit by sliding the drive motor to the right side of the calibrator. The belt should be installed with a snug fit, neither too tight nor too loose. The belts positive grip eliminates the need for initial tension. 9. With the belt fitted as above and the pulleys aligned with each other, tighten the four hex head cap screws securing the drive motor to its support plate. 10. Reinstall the optical detector assembly to its support angle and slowly rotate the encoder wheel making sure that it does not rub the optical detector assembly on either side. 11. Close the flywheel cover and switch the On-Off Switch/Circuit Breaker to ON. 12. Operate the Calibrator and check for correct pulley and belt alignment.

Fig. 4-17. Replacing Drive Belt

Instruction 77-9075

Bacharach, Inc.

Page 4-9

MAINTENANCE AND ADJUSTMENT

INJECTOR CALIBRATOR DD5

4.14

ADJUSTING CALIBRATION FLUID TEMPERATURE

The calibration fluid temperature is factory set at 99 F-101 F. This range is recommended by DDA. If necessary the temperature may be adjusted by the following procedure: 1. Turn ON Calibrator and allow the heaters to warm the calibration fluid as indicated by the HEATER indicator light being on. NOTE: It will take 20-30 minutes for the immersed heaters to bring the calibration fluid up to the preset temperature range. NOTE: Make certain to loosen potentiometer locknut before adjustment and retighten after the desired temperature is indicated on the panel mounted gauge. 2. After HEATER indicator has extinguished, loosen locknut and adjust TEMPERATURE control potentiometer, (Fig. 4-18), to the required temperature. DO NOT turn the potentiometer very far. One complete turn equals approximately a 45 F change, 1/8 turn for a 5.5 F temperature change. Turn CW to increase and CCW to decrease temperature. 3. Allow the automatic temperature control system sufficient time to bring calibraion fluid to the new temperature setting. Note the tempeature gauge reading and make any fine adjustments necessary to achieve the required set point. Wait until heater indicator cycles ON and OFF at least two times before tightening the adjustment locknut.

Fig. 4-19. TEMPERATURE Control Potentiometer

4.15

MOTOR STARTER OVERLOAD RELAY ADJUSTMENT

1. Find the operating volts located on the nameplate of the calibrator. 2. Locate the FLA (Full Load Amps) and SF (Service Factor) for the corresponding voltage, which can be found on the main drive motor nameplate.

Page 4-10

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

MAINTENANCE AND ADJUSTMENT

3. The maximum dial setting on the Motor Starter Overload Relay is calculated by multiplying the FLA value times the SF. Turn the overload adjustment dial to that setting. 4. Set the A (auto), H (hand) switch to H (unlocked position).

4.16

FLOWMETER TRANSDUCER REPLACEMENT

The flowmeter transducer assembly (67-7650) is a precision instrument, and is non-repairable in the field. If troubleshooting indicates a problem with this Unit, replace it by performing the following steps: 1. Disconnect the flexible tubing at both quick disconnects. 2. Disconnect the electrical connectors. 3. Remove the four bolts, washers and nuts that secure the base of the transducer to the console base through vibration mounts. Then carefully remove the transducer. 4. Install a new or rebuilt unit following the preceding steps in reverse order.

Instruction 77-9075

Bacharach, Inc.

Page 4-11

MAINTENANCE AND ADJUSTMENT

INJECTOR CALIBRATOR DD5

NOTES

Page 4-12

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

PARTS LISTS AND DIAGRAMS

5.0 PARTS LIST AND DIAGRAMS

5.1 BASIC ACCESSORIES The following items are part of 77-0585 (Fig. 5-1) Part # 05-4516 03-6063 77-0568 77-0569 67-6469 77-5712 67-5292 Qty Description 1 2ft 1 1 1 1 1 Key, Woodruff (spare) Tubing, Tygon 3/8 x 1/4 ID Paint, Azure Blue Paint, Midnight Blue Barring Tool Push Rod Lock Fill Tube Fig. 5-1. Basic Accessories 5.2 INJECTOR ACCESSORIES The following items are part of 77-7013 (Fig. 5-2) 103-5400 67-2431 67-5696 67-5697 67-5700 67-5708 67-6372 67-6605 67-6606 67-7643 77-0613 67-8525 06-6826 06-6828 05-5109 05-5113 77-0866 77-0912 77-0913 3 1 1 1 1 1 1 1 1 1 1 1 4 4 6 6 2 1 2 Quick Connect Plug 1/8 NPT (Not Shown) Seal, Discharge Head Discharge Head (53, 71, 92) Seal, Discharge Head Discharge Head (149) Push Rod Extension (149) Cam (149) Front Support (149) Front Support (53, 71, 92) Manifold Block Assy (149) Manifold Block Assy (53, 71, 92) G.M. 8.2L Accessories Pegboard Hooks Pegboard Hooks (One Shown) O-Ring, Manifold Block O-Ring, Manifold Block Fuel Connector (92 Marine [NS]) Push Rod (92 Marine [NS]) Support Ass'y (92 Marine [NS])

Fig. 5-2. Injectors Accessories

NOTE: The DD5 is shipped with Cam 77-0610 (for the 53, 71, 92 & 8.2L injectors) mounted in the cambox.

Instruction 77-9075

Bacharach, Inc.

Page 5-1

PARTS LISTS AND DIAGRAMS

INJECTOR CALIBRATOR DD5

5.3 SPARE PARTS LIST This list contains parts that may fail after extended use, and can be purchased through outside vendors. Use thediagrams in Section 5.6 to locate the Figure # and I.D.# (in balloons), and reference that number to this list for the Bacharach part number, or a common vendor and part number. Fig.#/ ID# 5-3/144 5-3/297 5-3/298 5-3/299 5-3/301 5-3/302 5-3/303 5-3/305 5-3/306 5-3/307 5-3/308 5-3/313 5-3/315 5-4/1 5-4/2 5-4/3 5-4/4 5-5/1 5-5/2 5-5/7 5-5/8 5-5/15 5-6/8 5-6/9 5-6/14 5-7/3 5-7/14 5-7/17 5-7/18 5-7/19 5-7/20 5-7/23 5-8A/155 5-8A/158 5-8/190 5-8A/191 5-8A/196 5-8A/198 5-8B/33 5-8B/236 5-8B/237 5-9/9 5-9/28 5-9/16 5-9/19 5-10/15 5-10/17 5-10/18 5-10/18 5-10/50 5-10/51 5-10/61 5-10/71 Page 5-2 Bacharach Description P/N 03-1535 03-2912 03-2913 03-6355 03-5105 03-5106 03-5108 03-5118 03-5120 03-5121 03-5125 03-6013 103-5399 67-2643 67-5426 67-6141 67-6170 67-3443 77-0597 03-4052 03-4173 104-0586 03-4233 03-6063 07-1636 67-6902 03-4180 04-3993 04-3995 05-3400 05-3450 06-6205 03-4173 03-4222 04-4109 05-2121 04-4078 05-2114 67-6430 07-1576 07-1618 60-7000 67-6416 104-0534 104-0540 104-0524 104-0536 104-0537 67-6205 67-6779 76-6910 77-0586 204-4593 Male Conn. 1/4 NPTx1/4 Tube Nilo-Seal, Flexible, 1/4 OD Nilo-Seal, Flexible, 3/8 OD Nilo-Seal, Semi-Rigid, 1/4 OD Hose, Low Press., Rubber #4 Hose, Low Press., Rubber #6 Hose, Low Press., Rubber#10 F. Swivel Fit., 7/16-20 1/4 Hose F. Swivel Fit., 5/8-18 3/8 Hose F. Swivel Fit., 9/16-18 3/8 Hose F. Swivel Fit., 7/8-14 5/8 Hose Hose Low Press. Clear #6 Quick Disconnect Socket Gasket Reservoir Heater (240 Volt) Temperature Sensor Thermostat Pressure Gauge (0-160 psi) Manifold Block Pilot Operated Check Valve Adjustable Relief Valve Pressure Switch 2-Way Tygon Tube (F4040), 1/16wall Filter Element, Final Stage Gear Pump Relief Valve Motor 1/3 HP, 230V, 60Hz Motor 1/3 HP, 220V, 50 Hz Flexible Coupling Coupling Sleeve Pressure Gauge (0-300 psi) Adjustable Relief Valve 2-Way Solenoid Valve Motor 5 HP (60 Hz) Timing Belt 50 Hz Motor 5 HP (50 Hz) Timming Belt 60 Hz Intensifier Assy Air Press. Regulator Filter Element. Suction Optical Detector Assy Directional Control Valve Switch Switch Pushbutton (Red) Switch N. O. Contact Block Dial Thermometer (40-100 F) Pressure Gauge (0-100 psi) Main P.C. Board Assy Display P.C. Board Assy Potentiometer, 6 Ohm, 4 Watt System/ Location Various Various Various Various Various Various Various Various Various Various Various Various Various Cal. Fluid Vendor P/N Vendor U1-4B 44-NF 66-NF 44-SN 2556-4 2556-6 2556-10 4797-4B 4739-6B 4741-6B 4797-10B Type B-44-3 3000-1/4 NPT ------CAV 10-N2P-15 A V12-400-NNL 723-VQ6R-70N 705N3A1A 1/4 ID, 3/8 OD SPE50-3 -RPEC-JEN-FEA 5K602 5KH36LN488(G)X 3J 3JE 146006 V12-400-NNL V52DA2077, E658 480H100 -450H100 -B07-202-A1KAU S-28 --CR104A8115 800T-B6M OB-A-1 T2125(9)506 F-50 --- 58C2

Superior Imperial Eastman Imperial Eastman Aeroquip Food & Beverage Hansen Mfg. Bacharach, Inc. Bacharach, Inc. Bacharach, Inc. Bacharach, Inc. Bacharach, Inc. Bacharach, Inc. Snaptite Norgren Sigma-Netics Inc. Cal. Fluid Skinner-Lancer Various ASCO P/O 07-1635* LHA Inc. Cal. Fluid Bacharach, Inc. Sun Hydraulics Dayton General Electric T. B. Woods T. B. Woods U.S. Gauge Pump & Motor Norgren Cooling Water Skinner Electrical U.S. Motor Standard Parts U.S. Motors Standard Part Cal. Fluid Bacharach, Inc. Norgren P/O 07-1617* Michigan Fluid Pwr. Cal. Fluid Bacharach, Inc. Bacharach, Inc. Electrical General Electric Allen Bradley Arrow Hart Alco Switch Bacharach, Inc. Bacharach, Inc. Bacharach, Inc. Bacharach, Inc. Clarostat

Bacharach, Inc.

Instruction 77-9075

INJECTOR CALIBRATOR DD5

PARTS LISTS AND DIAGRAMS

Fig.#/ ID#

Bacharach Description P/N Lamp, 28V Neon Lamp , Amber Hour Meter, 60 Hz Hour Meter, 50 Hz Transformer Transducer Assy Relay, 120V, 60Hz (3PDT) Relay, 120V, 60Hz (Delay) 3-Way Solenoid Valve Strainer (Complete) Fuse - 0.4 A Fuse - 5 A Temperature Controller See 5-10/267 See 5-10/Same ID # Optical Detector Assy See 5-8A/158 Limit Switch See 5-11/4 See 5-11/156 High Pressure Fuel Line See 5-10/18 See 5-3/Same ID # See 5-3/Same ID # See 5-3/Same ID # Fuse 2A 5A Transformer 330/400/416 Transformer 230/460, 50/60Hz Transformer 240/480, 60Hz Transformer 240/480, 50/60Hz Circuit Breaker Starter 208/230V Starter 460V

System/ Location Electrical

Vendor P/N Standard Part AMP Stemco Inst. Stancor Bacharach, Inc. Potter Brumfield ASCO ASCO Bussman Mfg. Bacharach, Inc. Bacharach, Inc. Micro Switch Bacharach, Inc.

Vendor ASA #757 380628-2 380628-4 380627-4 710-0073 710-0033 P-6377 -KVP14A95-120V CLA-43-70001 8320B130 24/60 8600A1 MDL - 4/10 MDA - 5 - BZ-2R0-A2 --

5-10/187 04-3520 5-10/188 04-3584 5-10/189 04-3585 5-10/192 04-3591 5-10/194 04-3795 5-10/195 04-3796 5-10/267 104-2003 5-11/4 67-7650 5-11/9 04-5187 5-11/10 04-5255 5-11/156 03-4213 5-11/159 03-4254 5-11/181 04-2649 5-11/182 04-2715 5-12A/17 67-6142 5-12A/267 5-12B/All 5-12C/9 60-7000 -5-12C/158 5-12C/260 104-0486 5-12D/4 5-12D/156 5-13A/46 67-6548 5-13A/18 5-13A/All Others 5-13B/All 5-14/All 5-18/3 404-2709 5-18/4 404-2717 5-18/6 104-1946 5-18/7 104-1944 5-18/8 104-1906 5-18/9 104-1913 5-18/16 04-1308 5-18/41 104-0089 5-18/42 104-0090 * P/O = Part of

Little Fuse Inc. Bussman Mfg. General Electric Westinghouse Elect. General Electric A.E.G. A.E.G.

MDA-2 FNQ-5 9T51B171 MTC1F0895 9T51B11 9T51B511 THQC2115WL XLS27-A-0-N XLS175-A-0-LAX-NC

5.4 ASSEMBLY DRAWING LIST Fig.# 5-3 5-4 5-5 5-6 5-7 5-8A 5-8B 5-9 5-10 5-11 5-12A 5-12B Page 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 Description Index Tubing & Hose List Calibration Fluid Reservoir Assy Clamping System Assy Secondary Fuel (Filter Stage) Assy Calibration Fluid Pump & Motor Assy Front & Left Side Views Front & Left Side Views (View C-C) Top View Front View (Top Panel) Rear View (Top Panel) Electrical Wiring Connections Electrical Wiring Connections Fig.# 5-12C 5-12D 5-13A 5-13B 5-14 5-15A 5-15B 5-15C 5-16 5-17 5-18A 5-18B Page 5-32 5-16 5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25 5-26 5-27 Description Electrical Wiring Connections Electrical Wiring Connections Calibration System Interconnections Calibration System Interconnections Pneumatic & Water Interconnections Electrical Diagram Electrical Diagram Electrical Diagram Fluid & Pneumatic Diagram Calibration Fluid System Diagram Electrical Control Box Electrical Control Box

Instruction 77-9075

Bacharach, Inc.

Page 5-3