77 9097

INSTRUCTION 77-9097 SPECIALIST 9000 DIESEL FUEL INJECTION PUMP CALIBRATING STAND
Installation/Operation/Maintenance Rev. 2 - January 2002
Bacharach, Inc. 621 Hunt Valley Circle, New Kensington, PA 15068 Phone: 724-334-5000 FAX: 724-334-5001 Web: www.bacharach-inc.com
Printed in U.S.A. Registared Trademark of Bacharach, Inc.
WARRANTY Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material and manufacture and will conform substantially to Bacharach Inc.s applicable specifications. 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, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND (ii) ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARISING FROM 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, Lamps, Filters, and O Rings are expendable in normal use. Use of any adapters and/or couplings, not approved by Bacharach, for mounting injection pumps to the Specialist Calibrating Stand will void this warranty.
Specialist 9000
Table of Contents
TABLE OF CONTENTS 1.0 INTRODUCTION .............................................................................................................. THE SPECIALIST 9000 ................................................................................................. SPECIFICATIONS ......................................................................................................... 1.2.1 Drive ........................................................................................................................ 1.2.2 Instrumentation ...................................................................................................... 1.2.3 Calibration Fluid System ....................................................................................... 1.2.4 Calibration Fluid Collection and Measuring System ............................................ 1.2.5 Timing and Phasing System................................................................................... 1.2.6 Lube Oil System ...................................................................................................... 1.2.7 Waste System .......................................................................................................... 1.2.8 Services ................................................................................................................... 1.2.9 General Overall Dimensions and Weight .............................................................. INSTALLATION ................................................................................................................ UNPACKING THE STAND ........................................................................................... LOCATION SELECTION .............................................................................................. LEVELING THE STAND .............................................................................................. AIR CONNECTION ....................................................................................................... WATER CONNECTIONS .............................................................................................. FILLING THE RESERVOIRS ....................................................................................... ELECTRICAL CONNECTIONS .................................................................................... NOZZLE CLAMP POST INSTALLATION.................................................................... 1-1 1-1 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-3 1-3 2-1 2-1 2-1 2-1 2-1 2-2 2-2 2-2 2-3 3-1 3-1 3-1 3-2 3-3 3-4 3-5 3-5 3-5 3-6 3-6 3-6 3-6 3-8 3-8 3-8 3-8 3-9 3-9 3-10 3-10 3-10 3-11 3-11 3-13 3-13 3-13 3-14
1.1 1.2
2.0
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.1
3.0
OPERATION ...................................................................................................................... CALIBRATING STAND FEATURES ............................................................................ 3.1.1 Console Panel .......................................................................................................... 3.1.2 Gauge Panel ............................................................................................................ 3.1.3 Upper Front Panel .................................................................................................. 3.1.4 Lower Front Panel .................................................................................................. 3.1.5 Miscellaneous .......................................................................................................... 3.2 PREPARATION .............................................................................................................. 3.2.1 Mounting Injection Pumps, Nozzles and Test Injectors ........................................ 3.2.2 Lower Front Panel Connections ............................................................................. 3.2.3 Graduate Reading ................................................................................................... 3.2.4 Operating Reminders---READ CAREFULLY ....................................................... 3.2.5 Typical Operating Sequence ................................................................................... 3.3 COMPONENT & SYSTEM FUNCTIONS ..................................................................... 3.3.1 Main Drive .............................................................................................................. 3.3.2 Speed Control .......................................................................................................... 3.3.3 Magnetic Pick-up .................................................................................................... 3.3.4 Tachometer/Counter ............................................................................................... 3.3.5 Calibration Fluid System ....................................................................................... 3.3.6 Calibration Fluid Temperature Control ................................................................ 3.3.7 Lube Oil System ...................................................................................................... 3.3.8 Electrical System .................................................................................................... 3.3.9 DC Power Supply .................................................................................................... 3.3.10 Drive Couplings ...................................................................................................... 3.3.11 Fluid Waste System ................................................................................................ 3.3.12 Pneumatic System .................................................................................................. 3.4 TESTING CUMMINS PT PUMPS ................................................................................ 3.5 CORRECT USE OF ALIGNMENT GAUGE .................................................................
Instruction 77-9097
Bacharach, Inc.
Page i
Table of Contents
Specialist 9000
4.0
MAINTENANCE AND TROUBLESHOOTING ............................................................ MAINTENANCE ............................................................................................................ 4.1.1 Periodic Maintenance Guide .................................................................................. 4.1.2 Calibration Fluid / Filter Replacement .................................................................. 4.1.3 Lube Oil ................................................................................................................... 4.1.4 Console and Electrical Panel Access ...................................................................... 4.1.5 Drive Coupling ........................................................................................................ 4.1.6 Air Cylinders ........................................................................................................... 4.2 ADJUSTMENTS / REPLACEMENTS ........................................................................... 4.2.1 Resetting the Calibration Fluid Temperature ....................................................... 4.2.2 Drain Cycle Time Adjustment ................................................................................ 4.2.3 Motor Speed Adjustments ...................................................................................... 4.2.4 Magnetic Pickup Gap Adjustment ......................................................................... 4.2.5 Solenoid Valves ....................................................................................................... 4.2.6 Tachometer/Counter ............................................................................................... 4.2.7 Replacement of Graduates ..................................................................................... 4.3 TROUBLESHOOTING .................................................................................................. 4.3.1 Location of Electrical Components ........................................................................ 4.3.2 Troubleshooting Tips .............................................................................................. 4.3.3 Mechanical Troubleshooting .................................................................................. 4.3.4 Electrical Troubleshooting ..................................................................................... 4.1 PARTS LISTS AND DIAGRAMS .................................................................................... 5.1 CHAPTER 5 - TABLE OF CONTENTS ........................................................................ 5.2 SPARE PARTS LIST ...................................................................................................... 5.3 BASIC ACCESSORIES .................................................................................................. 5.4 415/440/460V TRANSFORMER AND BRAKE HEATER LOCATIONS ...................... 5-5 SALES AND SERVICE CENTERS ............................................................................... 5-6 DRAWINGS AND DIAGRAMS .....................................................................................
4-1 4-1 4-1 4-1 4-2 4-2 4-3 4-3 4-3 4-4 4-4 4-4 4-5 4-5 4-5 4-6 4-6 4-7 4-7 4-8 4-9 5-1 5-1 5-2 5-5 5-6 5-6 5-7
5.0
APPENDIX A - LISTING OF PUMP MOUNTING DIAGRAMS .......................................... A-1 FOR BACHARACH CALIBRATING STANDS APPENDIX B - INTERNAL TIMING/PHASING USING ...................................................... B-1 HIGH PRESSURE FLOW METHOD APPENDIX C - ACCUMULATOR ACCESSORIES ................................................................ C-1 FOR TEST INJECTOR INSTALLATION
Page ii
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Warnings and Cautions
WARNINGS, CAUTIONS, AND NOTES WARNINGS

1. 2. 3. 4. DO NOT run drive system with flexible coupling mounted and no pump attached. Use flexible coupling guard at all times. Always connect flexible coupling to a pump when operating Stand. DO NOT depress run button without being aware of speed control selection and settings. DO NOT work on injection pumps unless red PUMP ROTATION lamp is ON and green RUN lamp is OFF. DO NOT attempt to make any adjustments or repairs to electrical components of the Stand without first disconnecting main power line at the wall. Many connections within the Stand carry lethal voltages. Any work done on electrical system should be performed by qualified personnel. Use of any adapters and/or couplings, not approved by Bacharach, to mount injection pumps to Stand may be dangerous and could void warranty. Bacharach approved couplings and mounting adapters are designed specifically to work with the 9000 Calibrating Stand. On 380, 415, 440, and 460 Volt units, high voltage is present on the resistor bank (located on the upper rear of the unit) when the drive is on.
5.
6.
CAUTIONS
1. When stopping drive with the directional switch, make sure you turn the switch to STOP (vertical) position and NOT to the opposite direction of rotation position. NOTE: Accidently changing the direction of rotation of some pumps could damage the pump. DO NOT operate drive system until the calibration fluid reservoir is FULL. A drive system component (heater element located in the calibration fluid reservoir) may be damaged (208, 220, and 230 volt Stands only). DO NOT apply electrical power or attempt to operate the Stand until all steps in Section 2 are completed. All hoses and connectors must be in good repair. To maintain a free flow of cooling water, do not install a valve or any restriction in the water drain hose. DO NOT leave the Stand unattended while the drive system is rotating.
2.
3. 4. 5.
NOTES
This calibrating stand satisfactorily passed tests operating from an industrial electrical power line with normal AC conditions and without a 3 phase isolation transformer. Due to other equipment on the same 3 phase power line severe conditions may exist that require a power line isolation transformer. An isolation transformer may be required by local electrical codes. It provides the following advantages: 1. Operator Safety - Isolation transformers cause a drive to "float", which reduces danger of electrical shock in the event someone accidentally contacts any electrical conducting parts, e.g., terminals of a speed control potentiometer in the operator station, or the neutral buss of regulating system. Electrical Codes - Isolation transformers may be required by local electrical codes. Drive Protection - Isolation transformers protect drive equipment where the motor or DC loop wiring is exposed to a damp or hazardous atmosphere, or where motor or DC loop is subject to accidental grounding since most plant power distribution systems have either a neutral or one phase connected to ground. Reliability - Isolation transformers give added protection to SCR's by reducing line transients and limiting short circuit currents. High overvoltage effects frequently encountered on ungrounded systems are minimized.
Bacharach, Inc.
2. 3.
4.
Instruction 77-9097
Page iii
Warnings and Cautions
Specialist 9000
THE SPECIALIST 9000 CALIBRATING STAND Page iv

Bacharach, Inc. Instruction 77-9097
Specialist 9000
Introduction
1.0
1.1
INTRODUCTION
THE SPECIALIST 9000
D.C. volts as well as calibration fluid temperature (F or C) in the reservoir or at the bulkhead. The lower front panel contains all the fluid controls and connections. The bypass adjustable relief valve is located on the lower front panel. In addition to pressurized fluid supply, there are two separate supply lines drawing fluid directly from the reservoir, one for injection pumps, the other for Cummins PT pumps. Quick connects for all hoses (except for Direct Supply connections) have been provided for quick pump hookup. The cursor vernier is readable in 1/4 degree increments and has no parallax. The calibration fluid collection system consists of a single 8-bore accumulator block (standard) with expansion capacity to 12-bore accumulators using the Accessory Kit - 12 Cylinder Option (77-0772) for pumps with 12 cylinders (outlets). The accumulator block can swing to either side of the Stand, to facilitate pump hook-up without accumulator disassembly. The calibration fluid and lube oil reservoirs have access ports for filling and feature a fluid level indicator visible without removal of external panels. The calibration fluid reservoir slides out for easy filter replacement and cleaning. Some additional features of the Specialist 9000 are: Increased moment of inertia (reduced weight, but increased diameter of the flywheel) compared to other BACHARACH calibrating stands. The bedplate is shock mounted to reduce shock, vibration and noise. Tandem (two stage) gear pump for low and high pressure, driven by an separate motor. Accumulator with individual injector clamping, accommodating all required test injectors. Built in lube oil system. Plastic, removable waste reservoir that features fluid level indication without removing panels. Compressed air supply at front panel quick connect. Return flowmeter for measurement of return flow rate of rotary pumps.
The Bacharach Specialist 9000 Diesel Fuel Injection Pump Calibrating Stand is designed for testing and calibrating diesel injection pumps used on engines employed in construction, automotive, industrial, farm, and similar equipment. The drive system consists of an anti-backlash pump coupling directly mounted to a flywheel driven by a 15 hp AC motor. The motor speed is controlled by a variable frequency AC motor controller. A dual mode tachometer/stroke counter is used to monitor RPM when in the TACH mode. In the COUNT mode it counts drive coupling revolutions. Controls for pump rotation selection, speed settings, run, stop and emergency stop are located on the console panel. The speed setting consist of three controls (potentiometers). Each control can vary the drive speed between 50 and 3500 RPM (nominal). This allows the operator to preset two test speeds while the third control can be used to vary the RPM. A three position switch is used to select the desired control. The graduate system contains 12 graduates (located on the upper panel) of 160cc capacity. The system START and INTERRUPT switches are located on the face of the tachometer/counter and preform the same functions as the FILL and INTERRUPT on the console. The console also contains a graduate DRAIN switch and a counter BYPASS switch for checking flow at governor cutoff. Calibration fluid heater and pump controls, lube pump switch, and D.C. voltage controls are also located on the console. An on, off switch for powering the Stand is located on the front of the console, below the console panel. The console is hinged to swing forward for easy access to most electrical components. Above the graduates are five large gauges: Calibration Fluid Supply Vacuum/Pressure, Gallery Pressure Final Stage, Lube (Oil) Pressure and two Auxiliary Pressure gauges for measuring transfer pump, housing/cambox pressures of rotary pumps or other pressures. The gauges have English and metric scales. Both shaft speed and stroke counts are displayed on a digital, dual mode display on the upper front panel. A second digital display shows
Instruction 77-9097
Bacharach, Inc.
Page 1-1
Introduction
Specialist 9000
Read this manual carefully and become familiar with the Model 9000 Calibrating Stand before attempting to operate it. Should you have any additional questions concerning the Stand, contact one of the Bacharach, Inc. Sales and Service Departments listed in Section 5.5. 1.2 SPECIFICATIONS
5. 6. 7. 8. 9.
Gallery Pressure gauge C: 0-100 psi (0-7 bar) downstream of final stage filter. Lube (Oil) Pressure gauge D: 0-100 psi (0-7 bar) in lube oil supply line. Auxiliary Pressure gauge E: 0-30 psi (0-2 bar). Return flowmeter: 60-600 cc/min. Degree wheel: 10" Diameter, recessed for safety, cursor with vernier, readable to 1/4 degree (15 min) with no parallax.
1.2.1 Drive: 1. 2. 3. 4. 5. 6. AC, adjustable frequency Electric Motor. Direct Drive. Speed Range: 50-3500 rpm. Speed Control: Rotary dial speed control, plus two presettable controls. Flexible Coupling: Backlash free laminated disc design, permits angular misalignment. Flywheel: Moment of inertia: WR2=2820 lb. in.2 (0.825 kgm 2); ISO ratings 520 mm3/str @550 RPM. Acceleration/Deceleration: Factory set at 200 RPM/sec.
10. Hour Meter: On when the Calibration Fluid system is on. Useful for periodic servicing and maintenance (filter, fluid changes, etc.). 11. Variable DC Power Supply: Designed to actuate solenoids found on some fuel pumps. Located at left side of console Input voltage: 115 VAC, 50/60 Hz Output voltage: 0-24 VDC Current: 5 amps maximum at 24 VDC Circuit breaker: located on console panel Meter display 7/16" LED display - location: upper front panel, left side - range: 0-99.9 VDC - resolution: 0.1 VDC Leads: two, 36 inches long; one black and one red (supplied) Output terminals: located on right side of lower front panel Unregulated 1.2.3 Calibration Fluid System: 1. 2. 3. Reservoir Capacity: 13 U.S. gallons (50 liters), Drain Valves (2); fluid level indicator. Fluid cooling medium: Cold tap water. Calibration Fluid Heating: Submerged electrical heating elements. Automatic (adjustable) temperature control to 1 C (1.8 F). Factory set at 40 1 C (104 1.8 F).
7.
1.2.2 Instrumentation: 1. Dual Mode Digital Tachometer/Counter: LED Display 0-9999, Preselectable Counter 0-9999; accuracy to 1 digit; relay output for count mode. Digital LED display: For D.C. voltage or calibration fluid temperature measured in the reservoir or at the bulkhead in F or C; resolution of display 0.1. Auxiliary Pressure Gauge A: 0-160 psi (0-10.5 bar). Calibration Fluid Supply Vacuum/Pressure gauge B: 0-30 in. Hg. (0-760 mmHg) vacuum and 0-60 psi (0-4 bar) pressure. Gauge is located in calibration fluid supply line to measure inlet suction or supply pressure.
2.
3. 4.
Page 1-2
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Introduction
4.
Transfer Pump: Dual Gear (Tandem): Low Pressure = 228 GPH (14.4 lit/min) at 0 psi, integral relief valve set at 56 psi; High Pressure = 30 Gal/hr (1.9 lit/min) at 0 psi, integral relief valve set at 700 psi. Driven by an electric 1/2 HP motor, 230 VAC, single phase, 60 Hz.
2.
Lube Oil Pump: gear type, 150 GPH (9.5 lit/ min) at 0 psi; integral relief valve set at 75 psi (5.2 bar), driven by separate electric motor: 1/4 HP, 230 VAC, single phase, 60 Hz. Pressure Regulator (adjustable relief valve): 0-55 psi. Lube oil drain routed to reservoir by gravity with no restrictions. Lube Oil Filter: 10 micron rating (nominal), spin-on type.
3. 4. 5.
5. 6. 7.
Pressure Regulator: Adjustable relief valve, 0-60 psi, (4.1 bar). Final Stage Filter: Spin-on type, 2 micron rating (nominal). Primary Filter: Immersed in reservoir, 10 micron rating (nominal).
1.2.7 Waste System: 1. Plastic removable reservoir: 5 U.S. gallons (19 liters).
1.2.4 Calibration Fluid Collection and Measuring System: 1. Single 8 bore accumulator block (standard), 12 bore accumulator block (optional). Accumulator block can be rotated to either side of the Stand for pump connection. Measuring Graduates: 12 top filling and bottom draining graduates 160cc clear acrylic pyramidal design with 1cc divisions (0.5cc divisions between 0-35cc). Electro-pneumatically operated drain valves for fill and drain. Drain time adjustable from1 to 60 seconds (factory preset at 30 sec.).
1.2.8 Services: 1. 2. 3. Electric Power Supply: Standard : Optional : (See TABLE 2-1. Wiring) 230 VAC, 3 Phase, 60 Hz. 208 VAC, 3 Phase, 60 Hz. 220 VAC, 3 Phase, 50 Hz. 415 VAC, 3 Phase, 50 Hz. 460 VAC, 3 Phase, 60 Hz. 380 VAC, 3 Phase, 50 Hz. 440 VAC, 3 Phase, 50 Hz. 80-120 psi (maximum). Cold Tap, approx. 2.2 GPM (7.6 lit./min.) @60F max. (as required by system).
2.
4. 5.
Air Pressure: Water:
1.2.5 Timing and Phasing System: 1. 2. Spill flow method, adjustable pressure, with shut off type quick connect coupling. Eight bleed-off valves provided for hook-up between high pressure fuel injection tubing and calibrating nozzle holders.
1.2.9 General Overall Dimensions and Weight 1. 2. 3. 4. Height: Width: Depth: Weight (dry): 73 in. 30 in. 67 in. (1.85 m) (.76 m) (1.70 m)
1.2.6 Lube Oil System: 1. Reservoir capacity 4 U.S. gallons (15 liters), drain valve (1), fluid level gauge.
Approximately 2000 lbs. (907 Kg)
Instruction 77-9097
Bacharach, Inc.
Page 1-3
Introduction
Specialist 9000
NOTES:
Page 1-4
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Installation
2.0
INSTALLATION
CAUTION DO NOT apply electrical power or attempt to operate the Calibrating Stand until all steps in Section 2 are completed. NOTE: Various parts in the Model 9000 Calibrating Stand may have been protected with a thick, waxy-film, heavy-duty rust inhibitor. Prior to first use, this film must be removed using mineral spirits or a standard degreasing solvent. After the rust inhibitor is removed, the part should be immediately recoated with a very light preservative oil (P-9) or equivalent.
All hoses, fittings and other accessories are packed in a box containing code 77-0789 Basic Accessory kit (See Section 5.3). Carefully check the contents against the bill of material to be certain that small parts are not discarded. 2.2 LOCATION SELECTION
The calibration and testing of fuel injection equipment is best performed in an area separate from the general shop. Clean filtered air should be supplied to the work area at a slight positive pressure. The installation site should also be accessible to compressed air, cold water, electrical outlets, and a drain (for cooling water). The Stand should be located on a reasonably smooth and solid surface such as concrete. There should be sufficient space around the Stand to permit removal of panels for periodic inspection and maintenance, see Figure 5-1. 2.3 LEVELING THE STAND
2.1
UNPACKING THE STAND
The Stand is shipped in a heavy corrugated board container and bolted to a pallet. Use metal shears to cut the straps to remove container. After removing the wooden brace holding the bed-plate down in front, remove nuts from bolts fastening Stand to the pallet. Use a lift truck to remove the Stand from the pallet. CAUTION Take care that the lift truck forks do not damage the four levelers protruding from beneath the Stand. Arrows on the side panels of the Stand show fork locations. Inspect the Stand for any damage that may have occurred during shipment. Claims for damage must be filed with the carrier within a reasonable period of time after delivery (usually 15 days). The bedplate was secured to the frame for shipment. After the Stand is properly positioned in its permanent location, remove rear and side panels. Remove the angle secured to the bedplate and frame in the rear. NOTE: Inspect interior for damage or connections which may have loosened or parted.
The Stand must be leveled to permit accurate reading of the graduates. To level the Stand, use the following procedure. 1. Turn down the four heavy duty levelers, located in the base of the Stand, until they just touch the floor. 2. Place a carpenters level across, and then in parallel with the frame (not the bedplate) on the Stand. Adjust the heavy duty levelers until the required level condition is achieved. NOTE: Levelers must carry the full load and base support angles must not touch the floor. When properly leveled there should be a minimum clearance of 1/8" between the floor and base support angles. 2.4 AIR CONNECTION
The air pressure inlet connection (AIR IN) is on the utility bulkhead (Figure 2-1) at the lower rear of the Stand. Remove the cap plug and install a suitable 1/4 NPT fitting to match the shop air supply line (120 psi maximum).
Instruction 77-9097
Bacharach, Inc.
Page 2-1
Installation
Specialist 9000
After connecting the air supply, set the air pressure gauge on the regulator assembly to 60 5 psi. Lift the red ring to unlock the regulator knob, adjust, and press the ring down to lock the regulator setting. The air supply pressure gauge and regulator knob are located on the lower left side of the Stand (Fig. 3-6).
After the water inlet and drain have been connected to the Stand (and the water turned on), inspect all connections for leaks. A leak could spray water on electrical components. For operating details of the cooling water system see Section 3. 2.6 FILLING THE RESERVOIRS
1. Calibration Fluid Reservoir---Fill this reservoir with approximately 13 U.S. gallons (50 liters) of calibration fluid through the fill spout. Use ONLY SAE J967 (ISO4113) calibration fluid (67-5598). Observe level a the level gauge visible through lower left panel. 2. Lube Oil Reservoir---Fill this reservoir with 4 U.S. gallons (15 liters) of a good quality SAE 30W motor oil through the fill spout. Observe level at the level gauge visible through the lower left panel.
Figure 2-1. ELECTRICAL, AIR, AND WATER CONNECTIONS 2.5 WATER CONNECTIONS
The cold water inlet (WATER IN) is located on the utility bulkhead at the rear of the Stand (Figure 2-1). Remove the cap plug, and install a suitable 1/4 NPT fitting to fit the cold water supply hose. The drain connection (WATER OUT) requires a 1/4 NPT fitting for connection to the drain hose or pipe. The drain hose or pipe must have a minimum ID of 3/8 in. This is necessary to provide an unrestricted water flow from the Stand. Drain should be by gravity only. CAUTION All hoses and connectors must be in good condition. To maintain free flow of the cooling water, do not install a valve or any restriction in the water drain hose.
Figure 2-2. FILLING THE RESERVOIRS 2.7 ELECTRICAL CONNECTIONS NOTE: Before wiring the 9000 Stand, refer to proper wiring drawings in Section 5 and Table 2-1.
Page 2-2
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Installation
Connect the main power supply lines to the terminal blocks as shown Figures 2-1 and 5-14 or 5-22. Connect the supply ground wire to the ground lug on contactor panel. The voltage supplied must agree with nameplate data visible at the Stand's upper left side. Make certain the 9000 is properly fused at the wall mounted disconnect in accordance with the NEC (National Electrical Code) and local codes. Table 2-1 will assist in selecting the proper fuse (BUSS Limitron KTN or equivalent) and wire sizes (AWG) for various options. 2.8 NOZZLE CLAMP POST INSTALLATION
Eight Nozzle Clamp Post Assemblies (77-0748), plus eight Set Screws (102-0753) which are to be installed into the accumulator block, can be found in the Basic Accessories kit (77-0789) provided with the 9000 Stand. 1. Slide each nozzle clamp post assembly into the holes provided for them on top of the accumulator. 2. Align the flat spot on the base of the assembly with threaded hole on back of the accumulator. 3. Place each set screw into a threaded hole and tighten until it holds the assembly in place. Eight Nozzle Clamps (77-0756) and eight Clamp Screw Assemblies (77-0775) also come in the basic accessories kit. They must be assembled before mounting a nozzle holder in the accumulator. Figure 2-3. NOZZLE WITH CLAMP ASSEMBLY AND POST INSTALLED
TABLE 2-1. WIRING PART No. VOLTS 77-7083 77-7085 77-7081 77-7086 77-7084 77-7097 77-7082 208V 220V 230V 380V 415V 440V 460V Hz 60 50 60 50 50 50 60 AMPS 65 65 65 45 45 45 45 WIRE SIZE (THHN) 6AWG 6AWG 6AWG 8AWG 8AWG 8AWG 8AWG
Instruction 77-9097
Bacharach, Inc.
Page 2-3
Installation
Specialist 9000
NOTES:
Page 2-4
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Operation
3.0 OPERATION
3.1 CALIBRATING STAND FEATURES
3. DC Supply adjustment: Sets DC voltage. 4. DC Supply indicator: Lit when DC Supply is ON. 5. RESET switch: To reset DC power after a fault has been cleared. Lube Oil 6. LUBE OIL switch: Activates the lube oil supply pump. Provides pressurized lube oil required by certain injection pumps. 7. Lube Oil indicator: Lit when Lube oil pump is ON. Calibration Fluid 8. Calibration Fluid switch: Activates the tandem pump and calibration fluid automatic temperature control system simultaneously. This switch should always be turned on before attempting to test injection pumps. 9. Calibration Fluid indicator: Lit when Calibration Fluid switch is ON. 10. HEAT ON indicator: Lit when the calibration fluid reservoir heaters are on. When extinguished, heaters are off and cooling water is circulating through the calibration fluid cooling system (provided water is connected). 11. TEMP. ADJUST control: To set calibration fluid temperature in the calibration fluid reservoir.
3.1.1 Console Panel (Figures 3-1 & 3-2) The following is a description of control and light functions on the console panel: NOTE: The numbers in the text refer to the numbers on the corresponding figures. Stand Power 1. On-Off switch: Located on the front of the console (Figure 3-1). The lighted switch provides control circuit voltage.
Figure 3-1. CONTROL CIRCUIT POWER DC Supply 2. DC Supply switch: Turns DC power supply ON and OFF.
Figure 3-2. CONSOLE PANEL CONTROLS Instruction 77-9097 Bacharach, Inc. Page 3-1
Operation
Specialist 9000
Drive System 12. PUMP ROTATION switch: controls direction of rotation and stops the Stand drive shaft. NOTE: CW and CCW refer to rotation of the injection pump (viewing its drive shaft). 13. STOP indicator (red): Lit when power is not supplied to the drive motor controller. 14. ON indicator (green): Indicates power is connected to the main drive motor and shaft should be rotating. 15. EMERGENCY STOP switch: Shuts down main drive motor and disconnects power to controller. 16. RPM switch: Selects speed control (MAIN, PRESET 1, or PRESET 2). 17. RPM MAIN control: Controls increase and decrease of main drive RPM. 18. RPM PRESET 1 control: Same as RPM MAIN control, can be preset and locked to selected speed. 19. RPM PRESET 2 control: Same as RPM PRESET I control. 20. RUN switch: Starts rotation of motor shaft (Pump Rotation switch must be in CW or CCW and EMERGENCY STOP must be unlocked and pulled out). Shaft will run at speed selected by RPM control (MAIN, PRESET 1, or PRESET 2). Measuring System 21. FILL switch: Begins graduate filling (Draw) sequence after the desired number of strokes has been set on the tachometer/counter (TACH/ COUNTER) thumb-wheel switch. 22. INTERRUPT switch: Depressing the interrupt switch cancels the draw sequence. NOTE: The FILL and INTERRUPT switches are duplicated on the TACH/ COUNTER and operate in parallel with switches located on console panel.
23. DRAIN switch: Opens drain valves at the bottom of the graduate. Turning the switch ON starts the timed drain cycle. After the drain cycle is completed, the drain valves close and the DRAIN switch should be turned OFF to reset this function. Turning the switch OFF during draining will interrupt the drain cycle. The automatic drain cycle is factory set to drain the graduates in 30-35 seconds. However, the cycle is fully adjustable from 1 to 60 seconds. 24. Drain indicator: Lit during the drain cycle. 25. BYPASS switch: Allows operator to fill graduates while tach/counter is in TACH MODE (i.e. indicating RPM). 26. Bypass indicator: Lit in bypass mode. 3.1.2 Gauge Panel (Figure 3-3) The following is a description of gauge functions on the gauge panel: 1. AUXILIARY PRESSURE (A): Used for checking transfer pump pressure on distributor type pumps. 2. CALIBRATION FLUID SUPPLY VACUUM/ PRESSURE (B): A compound gauge which indicates either positive or negative pressure (vacuum) of calibration fluid in the fuel supply line (taken just behind the front panel). 3. GALLERY PRESSURE FINAL STAGE (C): Used only when the final stage filter is employed. This gauge indicates the pressure of the calibration fluid in the supply line downstream from the final stage filter. 4. LUBE PRESSURE (D): Indicates lubricating oil pressure in the lube oil line (taken just behind the front panel). 5. AUXILIARY PRESSURE (E): Used for checking transfer pump pressure on distributor type pumps (also used for aneroid tests).
Page 3-2
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Operation
Figure 3-3. GAUGE PANEL 3.1.3 Upper Front Panel (Figure 3-4) The following is a description of instrument and control functions on the upper front panel: 1. TACH/COUNTER: This is a dual purpose unit consisting of a digital tachometer and a preselectable stroke counter. As a convenience, stroke cycle controls and mode indicator lights are also mounted on its front panel. a) Display: Indicates main shaft speed (RPM) when in the TACH MODE, or the total number of strokes counted when in the COUNT MODE. The display automatically reverts to the TACH MODE after the preset number of strokes has been reached. b) TACH MODE, COUNT MODE indicators: Mode indicator lights. c) START COUNT switch: Provides the same function as the FILL switch on the console panel. d) SELECT STROKE switches: 4-digit thumbwheel switch. e) INTERRUPT switch: Provides the same function as the INTERRUPT switch on the console panel. 2. D.C. SUPPLY VOLTS switch: Selects temperature readings (C or F, Bulkhead or Reservoir) or D.C. volts readings (of D.C. power supply).
Figure 3-4. UPPER FRONT PANEL
Instruction 77-9097
Bacharach, Inc.
Page 3-3
Operation
Specialist 9000
Figure 3-5. LOWER FRONT PANEL 3. CALIBRATION FLUID TEMPERATURE indicator: Displays the temperature of the calibration fluid in *C or F (measured in the reservoir or the supply line immediately behind the front panel) or displays D.C. voltage from the D.C. power supply. 4. Flowmeter type flowmeter: Indicates the flow rate of return calibration fluid of rotary distributor type pumps. 5. Graduates: Measure the fuel delivery of the individual pump cylinder/outlet routed from the accumulator block. 3.1.4 Lower Front Panel (Figure 3-5) The following is a description of controls, fittings and connections on the lower front panel: 1. D.C. Supply jacks: Output from DC supply. 2. LUBE PRESSURE regulator: Sets/adjusts lube oil pressure. 3. LUBE SUPPLY quick connect (with shutoff): Provides lube oil for the pump. 4. AUX 0-30 PSI quick connect (with shutoff): For connecting to AUXILIARY PRESSURE (E) gauge. 5. CALIBRATION FLUID RETURN connectors (4): Routes calibration fluid back to the calibration fluid reservoir. 6. DIRECT SUPPLY quick connect: For fuel pumps that have their own suction pumps. 7. DIRECT SUPPLY fitting (3/4" NPT): Specifically for testing Cummins PT pumps. 8. FINAL STAGE FILTER quick connects (TO & FROM): Routes calibration fluid to/from final stage filter. 9. CALIBRATION FLUID PRESSURE regulator: Adjusts the calibration fluid low pressure range. 10. AIR PRESSURE fitting (with shutoff): Supplies compressed air. Page 3-4 Bacharach, Inc. Instruction 77-9097
Specialist 9000
Operation
11. AUX 0- 160 PSI quick connect (with shutoff): For connecting to AUXILIARY PRESSURE (A) gauge. 12. SHUTOFF VALVE: Admits calibration fluid to CALIBRATION FLUID SUPPLY quick connect and is used to check vacuum on rotary type pumps. 13. CALIBRATION FLUID SUPPLY: Provides pressurized calibration fluid to the pump. 14. RETURN TO FLOWMETER fitting: Routes fluid to flowmeter. 15. HIGH PRESSURE CALIBRATION FLUID quick connect (with shutoff): Provides high pressure calibration fluid to the pump for timing and phasing. 16. HIGH PRESSURE CALIBRATION FLUID valve: Adjusts the calibration fluid high pressure range. 3.1.5 Miscellaneous (Figure 3-6) The following is a description of indicator and control functions on the left side of the Stand:
1. HOURS meter: On only when the Calibration Fluid system is on. 2. Air Pressure regulator: Adjusts air pressure required to operate graduate fill and drain functions, (as well as other uses) as required. 3. Calibration Fluid Level indicator and fill port: Used for checking and filling the Calibration fluid reservoir. 4. Lube Oil Fluid Level gauge and fill port: For checking and filling Lube oil fluid reservoir.
3.2
PREPARATION
3.2.1 Mounting Injection Pumps and Test Injectors Appendix A contains a list of Pump Connection Diagrams available from Bacharach. These diagrams will assist the operator in mounting fuel pumps on the Stand. For exact pump test procedure and specifications, refer to pump manufacturers service literature. Refer to Appendix C to find out what adapters, spacers, bleed-off tubing and clamps are needed to mount and hold down the test injectors. Some injectors require no adapters, while others may require one or more in order to mount them into the accumulator. To install a test injector (Figures 5-2 thru 5-5 show typical injector installations): 1. Use appropriate nozzle holder adapters and O-rings, as called for in Appendix C, on the test injector, 2. Slide the injector into an accumulator bore. 3. Slide the nozzle clamp under a set of posts on the nozzle clamp post assembly so that the ends rest on top of the injector. The notches on top of the nozzle clamp should rest under the pins on the posts. 4. Screw down the clamp screw assembly so that it holds the injector tight.
Figure 3-6. MISCELLANEOUS
Instruction 77-9097
Bacharach, Inc.
Page 3-5
Operation
Specialist 9000
3.2.2 Lower Front Panel Connections All panel connections have straight-thru quick connects for full flow, minimum restrictions and quick hose hookup. One way shutoff quick connects are used to provide high pressure calibration fluid, lube oil and compressed air. All connecting points are identified for easy use. NOTE: Use PVC tubing for suction and return connections. For all others, use rubber covered low pressure hoses. All hoses are supplied in basic accessories kit. 3.2.3 Graduate Reading To properly read the graduate, follow the procedure given below and refer to Figure 3-7: With eyes at the level of the calibration fluid, move side to side until the black stripe (on the back wall of the graduate) is aligned with the meniscus as shown. This will be the point where distance A is at its minimum. The reading line is at the peak of the meniscus. Follow this line to the graduations on the scale for the reading (in ccs).
3.2.4 Operating Reminders (READ CAREFULLY) CAUTION DO NOT operate drive system unless calibration fluid reservoir level shows above ADD. A drive system component (heater element located in calibration fluid reservoir) may be damaged (208, 220, and 230 volt Stands only). DO NOT run drive system with the flexible coupling mounted and no pump attached. When RUN button is depressed, drive shaft will run at approximately 50 RPM, or at previously selected speed. DO NOT depress RUN button without being aware of speed control setting and direction of rotation. DO NOT change drive shaft Pump Rotation without stopping drive shaft first. DO NOT work on injection pump unless red PUMP ROTATION lamp is ON and the green RUN lamp is OFF. Before starting up the Stand, make sure that the following conditions exist: 1. CALIBRATION FLUID PRESSURE regulator is turned fully counterclockwise (CCW). 2. HIGH PRESSURE CALIBRATION FLUID valve is fully CCW. 3. LUBE PRESSURE regulator is fully CCW. 4. RPM MAIN, PRESET 1 and PRESET 2 are fully CCW (make sure PRESET 1 & 2 are unlocked). 5. SHUTOFF VALVE is closed.
Figure 3-7. GRADUATE READING
Page 3-6
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Operation
3.2.5 Typical Operating Sequence The following sequence requires a pump mounted on the 9000 according to pump mounting diagrams or pump manufacturers instructions, all necessary connections are made, and the pump is ready for testing. 1. Turn on the water and air supplies. Make sure water connections and hoses are not leaking. 2. Turn on main disconnect switch to provide power to the Stand. 3. All switches and controls on the Stand should be in the OFF or fully CCW position. 4. Turn ON the on-off switch located on the lower front of the console (lighted rocker switch). 5. Turn the SHUTOFF VALVE to ON. NOTE: It is a good practice to start or stop pump motors only when the red STOP lamp is lit, and the green RUN lamp is off. 6. Turn ON the Calibration Fluid (and the Lube Oil if required) and set pressure(s) as required before running a pump. The calibration fluid tandem pump and heaters will turn on. Allow enough time for calibration fluid to reach operating temperature. NOTE: When calibration fluid reaches preset temperature, HEATERS ON lamp turns off NOTE: Operate pump at speed and direction of rotation specified by manufacturer. NOTE: Negative pressure (vacuum) generated by an injection pumps supply pump (feed or transfer) can be read on compound gauge after closing the SHUTOFF VALVE. CAUTION Use the flexible coupling guard at all times. Always connect the flexible coupling to a pump when operating the Stand.
WARNING When stopping drive with the directional switch, make sure you turn the switch to STOP (vertical) position and NOT to the opposite direction of rotation position. NOTE: Accidently changing rotation direction of some pumps could damage them. 7. Adjust the CALIBRATION FLUID PRESSURE regulator for the correct pressure. 8. Set the RPM switch to the MAIN position. Set the PUMP ROTATION switch to the desired position. 9. Depress and hold the RUN button until the shaft begins to rotate (approximately 50 RPM). The pump can run at various speeds by using the RPM MAIN control and observing the tachometer. NOTE: If the PUMP ROTATION switch is turned to STOP or the EMERGENCY STOP button is depressed the drive will stop. When restarting, the shaft speed (RPM) will return to its previous setting unless the speed control is returned fully co un ter-clock wise. For the operators convenience both PRESET controls provide the same speed range as the RPM MAIN control plus they can be locked at a set speed. PRESET 1 may be set and locked at one speed, and PRESET 2 at another. By operating the RPM switch to PRESET 1 or 2 the speeds can be quickly selected. EXAMPLE: With all three speed controls fully CCW and after depressing RUN button, turn MAIN control to increase speed to 500 RPM. Turn RPM switch to PRESET 1 and set and lock at 700 RPM. Turn RPM switch to PRESET 2 and set and lock at 900 RPM. Now switch back to MAIN control and change to any other speed. When the RPM switch is turned to PRESET 2 the motor will run at 900 RPM.
Instruction 77-9097
Bacharach, Inc.
Page 3-7
Operation
Specialist 9000
NOTE: Before moving a PRESET control, make sure that it is in the unlocked position. When a PRESET control is first unlocked it requires extra effort to free the knob from the lock position. 10. Stroke/count cycle begins when the Measuring System FILL switch or TACH/ COUNTER START COUNT is pressed. If desired, stroke/count cycle may be stopped at any time by depressing INTERRUPT switch on either console panel or TACH/COUNTER. 11. After reading graduates, switch DRAIN to ON. The graduates will drain for a preset time (the drain light will be on during the drain cycle) and shut off automatically (the light will turn off). Reset the DRAIN switch to the OFF position.
The magnetic pick-up assembly consists of a small inductive coil mounted below a 120 toothed gear. As each tooth of the wheel passes the pickup, it generates a pulse by electromagnetic induction. These pulses are then transmitted to the TACH/ COUNTER, which while in the TACH MODE indicates main drive motor speed continuously and is updated every second. Therefore, at a Stand speed of 60 rpm, the tachometer will update once for one full revolution. The input signal (120 pulses/revolution) is stored in memory, then divided by a precise time period provided by a crystal oscillator. The result is then presented on the LED digital display which will indicate speed in revolutions per minute (RPM). The same signal is used to count motor shaft revolutions in the COUNT MODE.
3.3
COMPONENT & SYSTEM FUNCTIONS
3.3.1 Main Drive The main components are a 15 HP AC motor, transistor inverter, breaking unit and resistor load. The motor carries a flywheel, and a flexible coupling drives the pump directly. The adjustable frequency drive is efficient, provides quiet operation, and ample power to drive most injection pumps. The breaking unit is only required for high inertia loads. The inverter is field programmable and is factory pre-programmed for driving injection pumps. It also contains diagnostic capabilities for troubleshooting purposes. Consult the factory for more information. 3.3.2 Speed Control The Stand speed is controlled by one of three rotary potentiometers (controls). The RPM MAIN control is adjustable over the full range of speeds as are both of the RPM PRESET controls. The RPM PRESET controls can be set and locked at any speed allowing the operator to run at that speed (at any time) just by turning the RPM switch to that RPM PRESET position. The motor will run at approximately 50 RPM when the Drive System is ON and the speed control (selected by the RPM switch) is fully counterclockwise.
Figure 3-8. SPEED CONTROL 3.3.3 Magnetic Pick-up NOTE: The gap (see Section 4.2.4) between the magnetic pickup and gear teeth is critical to the accurate operation of the TACH/COUNTER,
Page 3-8
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Operation
Normally the TACH/COUNTER will be in its TACH MODE. It can be switched to COUNT MODE by depres-sing either the FILL switch on the console panel or START COUNT switch on the TACH/ COUNTER. The desired number of strokes are set on the thumbwheel switch on the units front panel. The TACH/COUNTER automatically switches back to its TACH MODE after the preset number of strokes has been reached. Before switching, it will hold the last count for one second. However, it may also be manually switched to TACH MODE by depressing the INTERRUPT switch on the TACH/COUNTER or console panel, in which case it will revert immediately. A BYPASS switch is provided to keep the TACH/ COUNTER in the TACH MODE while filling the graduates. This allows for monitoring exact RPM when the fuel delivery shuts off. Figure 3-9. MAGNETIC PICK-UP 3.3.4 Tachometer/Counter The TACH/COUNTER (located on the left side of the upper front panel) consists of a digital display and a preselect counter. It displays either Stand RPM, or the number of revolutions counted. The display has four LED digits. Two single LED indicators on the tachometer panel indicate whether the unit is in its TACH MODE or COUNT MODE. 3.3.5 Calibration Fluid System (Figure 5-11) Calibration fluid can be supplied to the pump under test in three different ways: 1. When connected to the DIRECT SUPPLY quick connect on the lower front panel, the fluid can be drawn from the reservoir by a supply pump mounted on the injection pump. 2. When connected to the CALIBRATION FLUID SUPPLY on the lower front panel, the fluid is supplied under pressure to the injection pump gallery or to the supply pump. 3. Cummins PT pump utilizes the 3/4" bulkhead fitting on the right hand side of the lower front panel marked DIRECT SUPPLY. NOTE: If an injection pump is being tested without its supply pump, route fluid from the CALIBRA TION FL UID SUPPLY to the FINAL STAGE FILTER (TO) using Hose Assembly 74-1390 and out the FINAL STAGE FILTER (FROM) to the pump. When the CALIBRATION FLUID switch is turned ON, the two stage (tandem) pump and the automatic temperature control system are activated simultaneously. The pump begins to circulate fluid and the heaters in the reservoir are turned on as long as the fluid temperature is below the preset value. Page 3-9
Figure 3-10. TACHOMETER/COUNTER
Instruction 77-9097
Bacharach, Inc.
Operation
Specialist 9000
The tandem pump draws fluid from the reservoir and supplies it to the low and high pressure circuit. The low pressure fluid is routed to the pressure regulator and the SHUTOFF valve. The pressure regulator regulates upstream pressure bypassing fluid to the reservoir. With the regulator fully counterclockwise (bypass fully open) fluid pressure is at its minimum. When the regulator is turned clockwise pressure is gradually increasing. With the SHUTOFF valve OFF (closed) or ON (open) and the CALIBRATION FLUID SUPPLY line deadheaded, the maximum pressure attainable is approximately 60 psi as regulated by the low pressure pumps integral relief valve. If the SHUTOFF valve is open, fluid is routed to the CALIBRATION FLUID SUPPLY quick connect on the lower front panel. Note that calibration fluid supply pressure can be read on the gauge (B) only if the SHUTOFF valve is ON. Just before exiting the bulkhead, fluid temperature is measured with a transducer and indicated on the digital display (with switch on BULKHEAD). The high pressure fluid outlet from the gear pump is routed to the front panel mounted needle valve and quick connect. The needle valve controls the pressure, bypassing fluid to the reservoir. If high pressure is not required, the valve should be turned fully counterclockwise. When pressure is required the valve is turned gradually clockwise. When turned fully clockwise (valve closed), pressure is approximately 700 psi as regulated by the high pressure pumps integral relief valve. The panel mounted quick connect has a shutoff valve so fluid will not exit until the hose is connected to it. Except for the high pressure, all quick connects in this system are straight thru and have no shutoff valves to permit unrestricted flow. There are four panel mounted drain/return connections to route fluid to the reservoir. Three have quick connects. One is a barb fitting (for 1/4" ID hoses) usually used for return flow of rotary pumps. Another panel mounted barb fitting is used to route return fluid from rotary pumps to the flowmeter.
3.3.6 Calibration Fluid Temperature Control This system is intended to maintain fluid temperature within the preset limits to meet test requirements of all pump manufacturers. The system consists of: Four (4) electric immersion heaters Cooling coil (Figure 5-12) Temperature controller (Figure 5-16) Solenoid valve (Figure 5-16) Overheat switch Sensor With the CALIBRATION FLUID switch ON, the system is activated and indicator is lit. The reservoir fluid is heated by electric immersion heaters as indicated by the HEAT ON lamp. When fluid reaches a preset temperature the reservoir immersed sensor causes the heaters to shut off, cooling coil solenoid valve to energize, and HEAT ON lamp to extinguish. This admits cold water to the reservoir immersed cooling coil, cooling the fluid. When the fluid temperature reaches its lower preset limit the sensor deenergizes the cooling water solenoid valve, turns on the heaters and HEAT ON lamp. Cycling between heating and cooling assures uniform fluid temperature. To maintain close fluid temperature control under most operating conditions the reservoir is divided into three (3) compartments: cooling, heating and main. All bypass fluid from the injection pump and fluid delivered through the test injectors via the graduate rack is dumped into the cooling compartment. From there fluid passes through an opening in a baffle into the heat compartment. From this compartment fluid enters the main compartment through another opening and past the sensor. The suction filter located in the main compartment routes fluid through a hex manifold to a tandem pump, and when required to one of two direct draw front panel connections. An overheat switch is surface mounted on the reservoir and at some higher, preset temperature will turn off the circuit if the temperature control circuit has not shut off the heaters. NOTE: In the 208, 220, and 230 VAC units an additional electric heater is installed in the main compartment. This heater dissipates energy only during deceleration of the main drive motor. Its influence on fluid temperature is negligible.
Page 3-10
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Operation
3.3.7 Lube Oil System (Figure 5-12) When required, this system provides lube oil (under pressure) for testing certain types of fuel injection pumps. It consists of a reservoir, supply pump, spin-on type filter, pressure regulator, required interconnection plumbing and a pressure gauge. When in operation, lube oil is drawn out of the reservoir, by the pump, through a filter, and out to the injection pump under test. The pressure regulator regulates upstream pressure to the injection pump and bypasses excess fluid to the reservoir. The filter is placed into the system primarily to protect the injection pump under test. Lube oil pressure regulator knob is located on the front panel and marked LUBE PRESSURE. Pressure indication may be read on the LUBE PRESSURE (D) mounted on the gauge panel. Lube oil is returned by gravity through a PVC hose and standoff pipe (located at the rear right corner of the drain pan) to the reservoir. The label LUBE RETURN identifies the pipe, and a plastic cap on a chain is provided to protect the reservoir against contaminates. 3.3.8 Electrical System (See Figure 5-14) 208/230 VAC (1-phase) operates: pump motors (B2, B3) solenoid valve (water) SOL1 tachometer/counter calibration fluid heaters (TCl) hour meter transformer (T1), provides 115 VAC to: fluorescent light & control circuit transformer (T2), provides 24 VDC to: variable DC Power Supply transformer (T3), provides 24 VDC to: control Circuit All control circuits are 110VAC or 24 VAC. 1-Phase.
3.3.9 DC Power Supply To connect DC Power Supply to Pump Solenoid: 1. Ensure that D.C. Supply switch on the console panel is OFF. Set the D.C. Supply control on the console panel fully CCW. 2. Insert black lead plug into negative power supply outlet, marked (-) on the right side of the lower front panel. Insert red lead plug into positive outlet, marked (+). 3. Attach alligator clip of black lead to pumps negative post or any metal part of the pump, and attach red lead to the positive post. 4. Turn CALIBRATION FLUID TEMPERA TURE switch located on the left side of upper front panel to D.C. SUPPLY VOLTS. To Activate and Test Pump Solenoid: 1. Turn ON the D.C. Supply switch located on the console panel. 2. Turn the D.C. Supply control to increase output voltage as required. 3. To test the solenoid, when required, watch voltmeter display located on the left side of the upper front panel while increasing voltage from zero and listen for solenoid to engage. Record cut-in voltage. 4. Follow pump manufactures instructions for correct cut-in and cut-out voltage. 5. Return the CALIBRATION FLUID TEMPERATURE switch to one of the measuring sources and desired scales. 3.3.10 Drive Couplings The 9000 Stand is shipped with two couplings, one is the standard Bacharach flexible coupling, the second is for driving Cummins pumps. The standard flexible coupling is installed on the drive shaft when it leaves the factory. The other is packed separately in the basic accessories.
Instruction 77-9097
Bacharach, Inc.
Page 3-11
Operation
Specialist 9000
The flexible coupling front ends with a flange with a pilot bore and three slots to mate with the drive hubs available from Bacharach for driving most injection pumps in current use. The coupling is secured to the driving flange by four shoulder bolts. It eliminates backlash and provides a pilot that ensures concentricity. Most fuel injection pumps should be tested with this flexible coupling. Check the manufacturers service instructions. If desired the above coupling can be removed and replaced by a jaw type coupling or the Cummins drive flange. These couplings are secured to the driving flange with two metric hex head cap screws (also supplied). Six tapped holes in the driving flange to secure the coupling (four 1/4"-28 and two M10 x 1.5) feature self locking thread. Removing Bacharach Flexible Coupling (74-1051) 1. Insert the barring tool into one of the holes on the rear flange. Holding the tool will keep the drive shaft from turning when removing bolts. 2. Remove the four shoulder bolts that secure the coupling to the rear flange. 3. Slide the coupling away from the front panel. NOTE: Be sure not to lose the four spacers.
Installing Bacharach Flexible Coupling 1. Remove the coupling presently installed. 2. Align bolt holes in the rear flange with bolts at the rear of the coupling. Make sure all four spacers are installed on the bolts in the rear. 3. Insert barring tool into a hole on drive flange and tighten shoulder bolts with a torque wrench to 9 ft-lb (See Figure 4-8). Installing Cummins Drive Flange (77-0806) If a Cummins PT pump is to be driven on the Stand: 1. Remove the coupling presently installed. 2. Slide the Cummins drive flange pilot into the bore of the driving flange. 3. Align the holes of the Cummins drive flange with the large tapped holes in the driving flange and thread two M10 x 1.5 hex head cap screws into the driving flange. 4. Insert barring tool into a hole on the driving flange and tighten screws with a torque wrench to 23 ft-lb.
Figure 3-11. STANDARD FLEXIBLE COUPLING Page 3-12
Figure 3-12. CUMMINS DRIVE FLANGE
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Operation
Removing Cummins Drive Flange 1. Insert barring tool into a hole on the rear flange. 2. Remove the two M10 x 1.5 hex head cap screws. 3.3.11 Fluid Waste System The fluid waste system consists of two drain trays, a removable 5 gallon plastic container, and associated hoses. The fluid level of the container can be viewed on the lower right side of the Stand, without removal of panels. The container should be checked periodically. When the container is full the fluid is to be disposed of properly. 3.3.12 Pneumatic System (Figure 5-10 & 5-12) Shop compressed air enters at the utility bracket in the rear of the Stand (AIR), and is routed to the pressure regulator on the lower left side of the Stand. Regulated pressure is routed to the front panel and the graduate assembly. Air pressure is available at a front panel quick disconnect for use by the operator for purposes such as cleaning, testing aneroids, boost control devices, etc. NOTE: Remember that air pressure available at the panel is the same as set on the regulator. For the correct operation of the fill and drain functions the air pressure must be 60 5 psi. The compressed air routed to the graduate assembly is admitted through the solenoid valves to single acting pneumatic cylinders. One cylinder is used to push the graduate housing forward thereby filling the graduates. The other cylinder pushes a lever that in turn opens the drain valves, in the bottom of the graduates, draining the fluid.
3.4
TESTING CUMMINS PT PUMPS
To drive the Cummins PT pumps on the Stand first remove the flexible coupling. In place of the flexible coupling install the Cummins Drive Flange (77-0806) according to directions in Section 3.3.10. To connect the pump inlet to the DIRECT DRAW bulkhead fitting, a 3/4" Ball Valve (03-4248) and Connector (03-2668) (part of basic accessories kit) must be installed on the right side of the lower front panel.
Figure 3-13. 3/4" BALL VALVE AND CONNECTOR INSTALLED As calibration fluid for a PT pump is directly drawn from the reservoir, fluid temperature must be measured at the reservoir. Turn the upper front panel Calibration Fluid switch to Reservoir F (or C). All other connections and procedures are in the operation and maintenance manual for the Flowconsole.
Instruction 77-9097
Bacharach, Inc.
Page 3-13
Operation
Specialist 9000
3.5
CORRECT USE OF ALIGNMENT GAUGE
For correct engagement of the drive hub (mounted on an injection pump) to the flexible coupling, use the Alignment Gauge (67-4787) supplied with the coupling (Figure 3-14). Insert pins of gauge on the outside of the lamination sets. When correct engagement occurs the gauge will drag slightly exhibiting a slide fit between the pins on one side and the lamination and flanges on the other. Excessive pull or push on the laminations cause permanent distortion requiring replacement. CAUTION To avoid laminated disc distortion and damage, the flexible coupling must always be connected to an injection pump coupling before the Stand is operated. To check the Stand speed without an injection pump connected, remove the coupling. WARNING To reduce risk of injury, especially at high RPM, front flange lock nuts and rear hex head capscrews must be checked for tightness periodically.
Figure 3-14. USE OF ALIGNMENT GAUGE
Page 3-14
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Maintenance & Troubleshooting
4.0
4.1
MAINTENANCE AND TROUBLESHOOTING

MAINTENANCE taminants (clean if necessary). To inspect and clean the reservoir, it will have to be moved out on the side of the filter spout. Before moving the reservoir (see Figure 4-1 & 4-2): a. Remove the two hex head cap screws and nuts securing reservoir to frame (installed for shipment). Disconnect the temperature transducer cable from the harness. Disconnect heater cable from rear of bulkhead panel.
4.1.1 Periodic Maintenance Guide CAUTION Before initiating any maintenance, disconnect power supply at the wall distribution panel. Calibration Fluid Type: SAE J967 (ISO 4113) (67-5598). Periodic change: Approximately every 200 hours or 3 months (or when viscosity increases beyond 3.0 cst @40C). Primary filter: Purolator #6691583 (07-1614). Filter change: Every fluid change. Final stage filter element: Fram #P1121 (07-1606). Filter change: At operators discretion.* Lube Oil Type: 30W non-detergent motor oil (high grade). Periodic change: Every 4 months.* Filter: Fram #PH8A (07-1602). Filter change: Every oil change.
b. c.
d. Remove the four knurled nuts that secure the reservoir return assembly to the reservoir lid. e. Lift and hang the assembly by its hook from the U channel above it (part of the frame).
When sliding the reservoir out make sure the hoses and plastic tubing connected to the reservoir at the opposite end are free. When the reservoir is pulled out to its maximum it will have to be supported from the floor. With the reservoir out, the primary filter can be replaced and inside cleaned (see Figure 4-3). After replacing the filter, the reservoir and reservoir return assembly can be reinstalled to their original positions, and the temperature transducer and heater cable can be reconnected. The two hex head cap screws and nuts removed earlier were installed for shipment only and do not have to be reinstalled. With reservoir returned to its original position it must be refilled with new calibration fluid through fill spout. Observe level indicator while filling, make sure all compartments are full. Reservoir holds approximately 13 U.S. gallons (50 liters). Use only clean SAE J967 Fluid. The final stage filter (Figure 4-4) is located in the lower right side. After removing the lower right side panel, this filter may be removed with an automotive oil filter wrench. For filter types, see Section 4.1.1. _____________ * Depending on no. of pumps tested with this filter.
Main Drive Motor Front and rear drive motor bearings are equipped with plugs for grease fittings. Use an allen wrench to remove both plugs and install fittings. Use a pressure gun on the fitting until all old lubricant is flushed out. Relubricate with G.E. D6A2C5 grease or equivalent (unless special grease is specified on nameplate) every two (2) to five (5) years (based on Stand use). 4.1.2 Calibration Fluid / Filter Replacement To replace calibration fluid, first pump out the used fluid. Remaining fluid must be drained. Refer to Figure 4-1 and locate drain petcocks (2) on the right side of the reservoir. Make sure you drain from both petcocks. It is recommended that after draining fluid the reservoir be inspected for con-
Instruction 77-9097
Bacharach, Inc.
Page 4-1
Specialist 9000
Figure 4-1.LOCATING RESERVOIR(S) DRAIN PETCOCKS
Figure 4-4. FINAL STAGE FILTER
Figure 4-5. LUBE OIL FILTER Figure 4-2. CALIBRATION FLUID RESERVOIR 4.1.3 Lube Oil Refer to Figure 4-1 to locate the lube oil reservoir drain. After draining used lube oil the reservoir must be filled with clean good grade SAE 30W motor oil through the spout. Observe the level indicator while filling. The filter is located beside the final stage calibration fluid filter (Figure 4-5). The filter may be removed by using an automotive oil filter wrench. 4.1.4 Console and Electrical Panel Access CAUTION Support the console before removing screws, it is heavy and will want to drop down abruptly. Figure 4-3. PRIMARY FILTER
Page 4-2
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Access to console panel switches, lights, and most electrical components can be gained by tilting console (which is hinged at the bottom of the frame) forward. Remove the two screws securing the top of the console to the frame and gently lower until the two hangers support it (Figure 4-6 & 4-7). The insides are now accessible for inspection, troubleshooting, or repair. To close console, reverse the opening procedure. For console panel switches and controls see Section 3.1.1. For electrical panel components see Figure 5-20. The coupling is attached to the drive flange by four hex head shoulder bolts. The front or driving flange of the coupling is designed for direct attachment to the pump drive hub. The shoulder bolts should be checked for tightness every six months. The torque must be 9 ft-lb (see Section 3.3.10). The "Bacharach" flexible coupling has set of laminations on each side. If required, all laminations in a set must be replaced at the same time (900-8191 contains one set of laminations). The total thickness must be approximately .141 inches regardless of the number of laminations. Figure 4-7. THE CONSOLE OPENED FOR ACCESS TO ELECTRICAL COMPONENTS 4.1.5 Drive Coupling 4.1.6 Air Cylinders Air cylinders may become sticky or sluggish. This is generally due to moisture in the compressed air supply. To prevent moisture from getting into the air supply within the Stand, make certain that the filter trap is not clogged with water. If clogged, drain it. If an air cylinder should stick or become sluggish, disconnect the hose and lubricate the cylinder with a few drops of 20W oil. Place a drop of oil on the rod and operate several times, then replace hose, this usually solve the problem. If not, replace cylinder. 4.2 ADJUSTMENTS / REPLACEMENTS CAUTION Figure 4-8. SHOULDER BOLT TORQUE Do not attempt to make any adjustments or repairs to the electrical components of the Stand without first disconnecting the main power line at the wall. Any work done on the electrical system should be performed by qualified personnel.
Figure 4-6. REMOVING CONSOLE SCREWS
Instruction 77-9097
Bacharach, Inc.
Page 4-3
Specialist 9000
4.2.1 Resetting the Calibration Fluid Temperature The temperature is factory set to 39 to 41C measured at the bulkhead. The temperature may be readjusted to a different temperature setting by the following simple procedure (starting from ambient temperature). a) Connect Calibration Fluid Supply to Calibration Fluid Return with Hose Assembly 74-1390. b) Turn SHUTOFF VALVE to ON. c) Close the Calibration Fluid Pressure regulator by turning it fully clockwise. Figure 4-9. CALIBRATION FLUID TEMPERATURE 4.2.2 Drain Cycle Time Adjustment Drain cycle time delay is located on the electrical panel inside the console. Refer to Figure 4-10 to locate the time delay relay control knob. To increase the drain time, turn the knob clockwise. To decrease, turn counterclockwise. The drain time is factory set at 30-35 seconds to provide maximum delivery measurement accuracy. It is adjustable from 1 to 60 seconds. 4.2.3 Motor Speed Adjustments The motor (main drive) speed is factory set and should not need adjustment.
d) Turn Calibration Fluid Temperature switch to BULKHEAD. e) Switch Calibration Fluid Supply to ON (calibration fluid pump will start circulation and heaters will start heating indicated by the lit amber light). NOTE: It will take 20-30 minutes (depending on ambient temperature) for the immersed heaters to bring the calibration fluid up to the preset temperature range (39 to 41C). NOTE: Make certain to loosen control lock-nut before adjustment and retighten after the desired temperature is on the digital display. f) After HEATER indicator light has extinguished (indicates cooling has started) observe temperature indication, and adjust TEMP. ADJUST (Figure 4-9) to the required temperature. Turn the control in very small increments, CW to increase and CCW to decrease. One complete turn equals about a 25 C change (1/8 turn about a 3 C change).
Figure 4-10.
LOCATION OF TIME AND SPEED ADJUSTMENTS
g) Allow the automatic temperature control system sufficient time to bring the calibration fluid to the new temperature. Wait until heater indicator comes ON and OFF (cycle) at least two times before tightening the adjustment locknut.
In case the motor speed needs adjustment, there are two controls found on the electrical panel inside the console (Figure 4-10). The minimum speed control is used to set the minimum motor speed at 50 RPM when the Stand is running under no load and the speed controls are fully CCW. The span control is used to set the maximum motor speed at 3500-3540 RPM when the stand is running under no load and the RPM MAIN control is fully CW.
Page 4-4
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
CAUTION Do not run Stand with flex coupling mounted and no pump attached. Do not adjust minimum speed control for less than 50 RPM. 4.2.4 Magnetic Pickup Gap Adjustment WARNING To avoid personal injury and damage to the equipment, before attempting to set the gap spacing, make certain that power to Stand has been shut off at the wall and that the Stand main circuit breaker is off. NEVER attempt to set the gap with the Stand running. That would be extremely hazardous and may destroy the pick-up. For correct speed indication, the gap between the magnetic pickup and gear must be .001 to .006 in. If the gap is out of adjustment an erratic tachometer display appears. When this occurs, readjust the gap. The following steps detail the adjustment procedure:
d) Turn power on, then check the Stand for correct RPM indication. e) Reinstall the panel.
4.2.5 Solenoid Valves Solenoid valves may occasionally stick, leak, or foreign matter may lodge in the valve seat or the orifice. If necessary, dismantle the valve by removing the coil and stem. Dismantling the valves may require a special spanner wrench available from the local valve distributor (Skinner or ALCO). When reinstalling, fill or drain solenoid valves, make certain that the varistor (or arc suppressor) is still firmly secured to the wires and that the bare wires do not touch bare metal parts. 4.2.6 Tachometer/Counter The tachometer/counter assembly is not field repairable, and must be replaced or returned to Bacharach should it be defective. Check Section 4.3 to determine if the unit requires replacement. To replace TACH/COUNTER: a) Identify wires and respective terminals to help with reconnection. Disconnect the wires from the rear terminal strips of the TACH/ COUNTER assembly (see Figure 4-12). b) Remove the screws fastening the unit to the gauge panel being careful not to loose any parts (the front panel will come apart in several pieces) and remove the defective unit. c) Install replacement unit and reconnect wires. To verify wire connections use Figure 5-13.
Figure 4-11. PICKUP GAP ADJUSTMENT a) Remove the upper left panel of the Stand to provide access to the magnetic pickup. b) Loosen socket head cap screw on the magnetic pickup bracket. Turn pickup in direction desired and adjust until the gap between the top of the teeth and the pickup is set. Measure the gap using a feeler gauge (preferably nonmagnetic). Retighten screw. c) Manually rotate the flywheel and check the gap every 90 from the original set point. While rotating the flywheel, make certain that all of the teeth clear the pickup.
Figure 4-12. WIRING CONNECTIONS FOR THE TACHOMETER/COUNTER
Instruction 77-9097
Bacharach, Inc.
Page 4-5
Specialist 9000
4.2.7 Replacement of Graduates It is a good practice to periodically remove graduates and thoroughly clean them. Also, occasionally a graduate may become defective and require replacement. In either event, the graduates must be removed. The following steps detail the procedure for graduate replacement: a) Disconnect the hoses attached to the flowmeter at the rear of the bezel. b) Remove the four screws retaining the front panel bezel in place and remove bezel with the attached flowmeter (see Figure 4-13). c) Loosen (do not remove) the top, bottom and side retaining strips. Note that the fastening screws require a 9/64 inch Allen key. Make certain that the lower retaining strip is loose enough that it can be pushed down until all four screws are at the bottom of the slots.
e)
To install a graduate, insert the bottom lip of the graduate behind the bottom retaining strip. Push down on the bottom slot in the graduate to compress the drain valve spring until the top lip of the graduate can be inserted behind the top retaining strip. Align all graduates vertically and push bottom retaining strip to its highest position and tighten.
f)
g) Tighten the top and side retaining strips and reinstall the bezel and flowmeter hoses.
d) Refer to Figure 4-14 and push down on the bottom slot in the graduate to be removed while at the same time pushing back on the top of the graduate. It may be necessary to exert enough downward force on the graduate to compress the drain valve spring so that the upper lip of the graduate clears the flange of the retaining strip. When this occurs, relax the force on the graduate slot and lift the graduate out.
Figure 4-14. REMOVING A GRADUATE 4.3 TROUBLESHOOTING
The following troubleshooting tables provide procedures for field repair of some possible mechanical and electrical problems. CAUTION Always remember that many connections within the Stand carry lethal voltages. Once a problem is located, switch off the main circuit breaker and wall mounted power disconnect. CAUTION Do not attempt to change or repair any components with power applied to the Stand.
Figure 4-13. LOOSENING THE RETAINING STRIPS WITH A 9/64 ALLEN KEY
Page 4-6
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
4.3.1 Location of Electrical Components All relays relating to the drive are located on the electrical panel. The panel can be found in the rear (lower left hand side) of the Stand (Figure 4-15).
4.3.2 Troubleshooting Tips Solenoids--To check if a solenoid is energized, where practical, place a steel scale on the top of the solenoid. The electromagnetic field from the core will attract the scale. Relays--Relay operation can be visually checked by watching the contacts drop and spring back when power is removed and then reapplied. Before attempting to troubleshoot the Stand, determine whether the problem is mechanical, electrical, or a combination of both. 1. Mechanical Problems. (a) Leakage of fluid(s) due to worn seals or loose connections. 2. Electrical Problems (a) Blown fuses or heater elements, removing power from one or more circuits.
Figure 4-15. ELECTRICAL PANEL WITH AC CONTROLLER (208/230 V)
(b) Relay contacts dirty, sticking or vibration problems. (c) Extreme line voltage drops (or transients).
Figure 4-16. ELECTRICAL PANEL, WITH AC CONTROLLER (380*, 415, 440, 460 V) LOCATED ON RIGHT SIDE _______________ * 380 V version only has two fuses.
Instruction 77-9097 Bacharach, Inc.
Page 4-7
Specialist 9000
4.3.3 Mechanical Troubleshooting
CAUTION Be sure wall mounted disconnect power switch is turned off before troubleshooting.
Symptom Air in Calibration Fluid Supply Line
Possible Cause Low fluid level or Loose connection(s) in system or Shut-off valve leaky or defective or Tandem supply pump shaft seal leaking Low or no air supply or Solenoid valve stuck or inoperative or Loose electrical connection or Air cylinder stuck Make sure Stand is level and on rubber pads under leveling screws No water supply or Water solenoid valve stuck closed or Controls set wrong or Calibration fluid pump inoperative Air pressure in excess of 60 psi
Remedy Check and add fluid if needed Tighten as required Repair or replace shut-off valve Repair or replace supply pump seal Troubleshoot Repair or replace solenoid valve Repair connection Repair or replace air cylinder Make corrections
Graduate rack inoperative
Excessive vibration when main drive motor is running Calibration temperature in reservoir not stable
Troubleshoot Repair or replace solenoid valve Reset Troubleshoot Reduce pressure as required
Excessive noise when fill button pushed and graduates loose or cracked
Page 4-8
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
4.3.4 Electrical Troubleshooting Symptom No power (all systems inoperative) Possible Cause Fuse/s blown in wall disconnect or Fuse/s F1, F2, F12, or F13 blown CR-1, TDR-1, or OLR-1 relay defective, malfunctioning or icorrectly set or Motor starter M1 defective, malfunctioning or incorrectly set or Motor controller defective, malfunctioning or incorrectly set Plug P1 disconnected or Fuse F3 or F4 blown or TC-1 or CR-2 failed Fuse F5 blown or Fuse F6 blown Fuse F7 blown Fuse F8 blown Fuse F9 blown Fuse F10 blown or CB1 tripped Fuse F11 blown Remedy Replace Fuse/s Replace F1, F2, F12, or F13 Reset or replace component (Investigate)
All systems function except main drive motor
Reset or replace M1
Reset or replace Motor controller
No calibration fluid temperature control
Reconnect P1 Replace Fuse F3 or F4 Replace TC-1 or CR-2 Replace F5 Replace F6 Replace F7 Replace F8 Replace F9 Replace F10 Reset CB1 Replace F11
Lower front console on/off switch lights, All other functions inoperative. Tach/counter inoperative Only Tach/counter working. Cal. fluid fill & drain inoperative No 0-24V pump solenoid supply No 24V control circuit voltage (Run-stop lights)
Instruction 77-9097
Bacharach, Inc.
Page 4-9
Specialist 9000
4.3.4 Electrical Troubleshooting (Cont.) Symptom Motor and drive function at low and high speeds but trips out upon deceleration with light loads No bulkhead temperature reading Possible Cause Braking resistor BR1 open or Braking resistor wire loose or disconnected Sensor open (check for resistance) or Transducer defective Sensor open (check for resistance) or Transducer defective Magnetic pickup defective or Misadjusted Heater/s defective or Water solenoid valve stuck open CR-4 relay bad CR-3 relay bad DS-9 lamp bad Remedy Replace BR1 Tighten or Replace wire Replace Sensor Replace Transducer Replace Sensor Replace Transducer Repair or replace Magnetic pickup Readjust Magnetic pickup Replace Heater/s Repair or replace solenoid valve Replace CR-4 Replace CR-3 Replace complete fixture
No reservoir tempperature reading
Tach does not read RPM or Count
Calibration fluid heating time slow
Lube pump inoperative Calibration fluid pump inoperative Fluorescent lamp will not light
Before replacing fuses make a visual check of components in the associated circuit for loose wires or damaged parts. The AC (motor) controller (shown on the right hand side in Figure 4-15) is not field repairable. The controller should give years of trouble free service. Problems with the controller and its components should be handled by a qualified person with knowledge of A.C. variable frequency drive systems. If a problem is traced to the controller, it is suggested that the unit be returned to Bacharach for repairs or replacement. If a qualified person is available, and you would want to service the unit, contact the Bacharach Service Department for instructions.
Page 4-10
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Parts Lists and Diagrams
5.0
5.1
PARTS LISTS AND DIAGRAMS

CHAPTER 5 - TABLE OF CONTENTS
Refer to the following list for use in finding assembly and informational drawings on the Specialist 9000 Fuel Pump Injection Calibrating Stand and Accessories. Section 5.1 5.2 5.3 5.4 5.5 5.6 Page 5-1 5-2 5-5 5-6 5-6 5-7 Description CHAPTER 5 - TABLE OF CONTENTS SPARE PARTS LIST BASIC ACCESSORIES 415/440/460V TRANSFORMER AND BRAKE HEATER LOCATIONS SALES AND SERVICE CENTERS DRAWINGS AND DIAGRAMS
How to find the part number of a component: 1. By using Section 5.6 Contents (below), determine the figure(s) where the part may be found. 2. Look up the approprate page(s) and/or figure(s). 3. Determine the item number (circled number) of the part (parts are identified only on selected pages). 4. Look up the figure then item number using the list in Section 5-2 to find the part number. SECTION 5.6 CONTENTS Page
5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25 5-26 5-27 5-28 5-29
Figure #
Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11 Figure 5-12 Figure 5-13 Figure 5-14 Figure 5-15 Figure 5-16 Figure 5-17 Figure 5-18 Figure 5-19 Figure 5-20 Figure 5-21 Figure 5-22 Figure 5-23
Description
FOUNDATION AND INSTALLATION DRAWING CALIBRATING NOZZLE & HOLDER INSTALLATION ('S' SIZE) TEST INJECTOR INSTALLATION (AMBAC / MACK W/ VERTICAL OUTLETS) TEST INJECTOR INSTALLATION (AMBAC / MACK BAR STOCK TYPE) TEST INJECTOR INSTALLATION (BOSCH LOW DEAD VOLUME) BOTTOM SECTIONAL VIEW FRONT VIEW LEFT SIDE VIEW CALIBRATION FLUID RESERVOIR ASSEMBLY PNEUMATIC, LUBE OIL, AND COOLING WATER INTERCONNECTING DIAGRAMS CALIBRATION FLUID AND FLUID WASTE INTERCONNECTING DIAGRAMS PNEUMATIC, WATER COOLING, LUBE AND CALIBRATION FLUID SYSTEMS SCHEMATIC DIAGRAMS ELECTRICAL INTERCONNECTING DIAGRAM ELECTRICAL DIAGRAM (SCHEMATIC) 208, 220, 230 VAC ELECTRICAL DIAGRAM (SCHEMATIC) 380, 415, 440, 460 VAC ELECTRICAL DIAGRAM (SCHEMATIC) ELECTRICAL DIAGRAM (SCHEMATIC) ELECTRICAL DIAGRAM (SCHEMATIC) CONTROLLER ASSEMBLY ELECTRICAL CONTROL PANEL ELECTRICAL CONTROL PANEL ELECTRICAL INTERCONNECTING DIAGRAM PROGRAM SETTINGS
Instruction 77-9097
Bacharach, Inc.
Page 5-1
Specialist 9000
5.2
SPARE PARTS LIST
Parts that need to be replaced on a periodic basis, or once they are expended are listed below. Fig. # 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-7 Item # 2 3 4 5 6 7 14 34 49 59 60 84 160 1A 2 3 1B 30 31 32 33 45 53 79 232 2 10 20 64 68 166 167 168 169 187 2 5 6 7 8 11 12 29 31 36 37 81 Part # 04-3983 04-3984 04-3998 04-3997 67-6907 77-0696 07-1606 77-0703 77-0767 77-0813 77-0814 77-0816 03-4222 67-5512 67-0628 67-0346 05-5107 77-0697 77-0698 77-0699 77-0700 67-6204 77-0781 67-6845 104-0657 77-0642 67-4787 07-1576 74-1051 67-4301 04-3795 04-3796 04-4110 04-4111 77-1037 77-0784 04-2834 67-5426 67-2643 67-6141 67-5433 07-1614 03-4015 02-5176 05-5159 03-0972 77-0928 Description Where Used (System/Assy)
5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 Page 5-2
1/4 HP, 50 HZ Motor Lube Oil System 1/4 HP, 60 HZ Motor Lube Oil System 1/2 HP, 50 HZ Motor Cal. Fluid 1/2 HP, 60 HZ Motor Cal. Fluid Low Pressure Gear Pump Lube Oil System Tandem Pump Cal. Fluid Filter Cartridge Lube Oil System Waste Reservoir Fluid Waste Tool Tray Controller Assy., 208, 220, 230V Electrical Controller Assy., 415, 440, 460V Electrical Controller Assy. 380V Electrical Solenoid Valve Cold Water Graduate & Valve Assy. Graduate Assy. Graduate Part of 67-5512 Drain Valve Assembly Part of 67-5512 O-Ring Part of 67-0346 Gauge, Compd. 30Hg, 0-60 psi Cal Fluid Gauge, Pressure 0-100 psi Lube Oil Gauge, Pressure 0-30 psi Gauge, Pressure 0-160 psi Tach/Counter Electrical PCB Assy. Precision Therm. Flowmeter Cal. Fluid Rocker Switch (On-Off) Electrical Power Supply Electrical Alignment Gauge Part of 74-1051 Air Regulator Filter/w Gauge Pneumatic Flexible Coupling Assembly Flexible Coupling Guard & Clamp Bar Assy. Hour Meter, 60 Hz. Electrical Hour Meter, 50 Hz. Electrical Motor, 208V, 15 H.P. Electrical Motor, 220, 230, 440, 460V, 15 HP Electrical Motor, 380V, 15 HP Electrical Temp. Transducer Assy. Cal. Fluid Heater (208/220/230V) Cal. Fluid Heater Cal. Fluid Gasket Cal. Fluid Temperature Sensor Cal. Fluid Cooling Coil Cal. Fluid Filter Element Cal. Fluid Drain Valve Cal. Fluid Lock Washer 9/16 Cal. Fluid O-ring Cal. Fluid Pipe Plug 1" Cal. Fluid Heater, Finned (440/460V)
Bacharach, Inc. Instruction 77-9097
Specialist 9000
5.2 Fig. # 5-10 5-10 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-13 5-13 5-19 5-19 5-19 5-19 5-19 5-19 5-19 5-19 5-19 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-20 5-21 5-21 5-21 5-21 5-21 5-21 5-21 5-21
SPARE PARTS LIST (Cont.) Item # 23 32 2 20 21 22 36 24 25 33 34 35 76 63 8 9 13 15 17 22 26 28 29 8 45 48 49 50 51 52 56 57 60 61 62 63 66 67 88 89 90 46 53 54 55 58 59 68 70 Part # 05-5146 77-0815 07-1602 03-4107 03-4173 03-4276 77-0684 03-5385 03-5394 103-5382 103-5384 103-5397 67-5725 77-0817 04-9990 04-9991 04-5159 04-6176 04-5257 104-3688 204-5175 604-2712 604-2716 67-6142 04-0891 04-2351 04-2617 04-2655 04-2663 04-2720 04-4833 04-4995 04-5111 04-5234 04-5198 04-5256 04-9989 204-2637 104-1984 104-2007 104-2011 04-1327 04-3592 04-3593 04-3594 04-4876 04-4877 204-4593 77-0694 Description O-Ring (Dump Rod) Solenoid Valve Filter Cartridge Needle Valve, 1/8 NPT Relief Valve , 1/2 NPT 2-Way Valve, 3/8 NPT Temperature Transducer Quick Connect, 1/8 NPT Quick Connect, 1/4 NPT Quick Connect, 1/8 NPT Quick Connect, 1/8 NPT Quick Connect, 3/8 NPT Fluorescent Lamp (60 Hz) Lamp, Fixed Assy (50 Hz) Arc Suppressor, .5uF, 220 ohm Arc Suppressor, .25uF, 22 ohm Relay Contactor Resistor, 1K, 1/4W, 5% Time-Delay Relay Overload Relay, 230V Control Relay Fuse, 20A, 250V Fuse, 15A, 500V (415/440V) Temperature Controller Capacitor, 1500uF, 50V Diode, 1N4002 Fuse, .5A, 250V Fast-Blow Fuse, 1A, 250V Slow-Blow Fuse, 3A, 125V Slow-Blow Fuse, 10A, 250V Slow-Blow Potentiometer, 100, 2W Potentiometer, 2.5K, 2W Fullwave Rectifier Non-latching Relay Non-latching Relay Time Delay Relay Arc Suppressor .1uF, 100 Ohm Fuse, 1.5A, 250V Slow-Blow Transformer, 115/230V - 12/24V Transformer, 115/24V Transformer, 230V/115V Circuit Breaker Yellow Indicator Light Red Indicator Light Green Indicator Light Potentiometer, 2K, 2W Potentiometer, 2K, 2W Potentiometer, 6 Ohm, 4W Ratio Drive, 10:1
Bacharach, Inc.
Where Used (System/Assy) Graduate Assy. Graduate Assy. Cal. Fluid Lower Front Panel Lower Front Panel Lower Front Panel Lower Front Panel Pneumatic Lube Oil Cal. Fluid Cal. Fluid Cal. Fluid Electrical Electrical Controller Controller Controller Controller Controller Controller Controller Controller Controller Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Control Console Page 5-3
Instruction 77-9097
Specialist 9000
5.2 Fig. # 5-21 5-21 5-21 5-21 5-21 5-21 5-21
SPARE PARTS LIST (Cont.) Item # 80 81 82 83 84 85 87 251 243 81 247 422 428 Part # 104-0553 104-0554 104-0555 104-0557 104-0558 104-0559 104-1964 104-1956 104-1955 77-0928 204-0600 104-3689 604-2716 Description Contact Block N.O. - N.C. Contact Block N.C. Contact Block N.O. Push Button, Blk, Flush Push Button, Red, Emerg. Stop Contact Block N.O. - N.O. Variac, 120V, 1.75A Transformer (415-440/220-230, 50Hz) Transformer (460/230, 60Hz) Brake Heaters (4) Ceramic Bushing (8) Overload Relay Fuse, 15 A, 460 V (F12 & F13) Where Used (System/Assy) Control Console Control Console Control Console Control Console Control Console Control Console Control Console Electrical Electrical Electrical Electrical Electrical Electrical
Listed below are common hoses, tubing, and fittings used in the 9000 Calibrating Stand (See to Fig. 510 &11). Hoses/tubing to be ordered by the foot except item 318, 319. Item # 14 28 229 300 302 303 304 305 System 306 307 309 310 311 312 313 314 315 318 319 Part # 03-6019 03-6117 103-2982 03-2930 03-2913 03-2914 03-5107 03-5108 03-5109 03-6063 03-5123 03-5127 03-5310 03-5535 103-5156 103-5337 103-5340 67-2800 67-6629 Description PVC Tubing 1/2 I.D. Tygon Tubing 5/16 I.D. F. Connector 1/4 NPT x 1/4 Poly-Flo Tubing, 1/4 O.D. Nylo Seal Tubing, 3/8 O.D. Nylo Seal Tubing, 1/2 O.D. Low Pressure Hose #8 Low Pressure Hose #10 Low Pressure Hose #12 Tygon Tubing, 1/4 I.D. Female Swivel Ftg. 3/4 x 16 #8 Female Swivel Ftg. 1-1/16 x 12 Hose Clamp #12 Tee, 1/2 x 1/2 x 1/2 Plastic Hose, 3/4 I.D. Hose Clamp #8 Hose Clamp #10 High Pressure Hose Assy, #4 High Pressure Hose Assy, #5 Where Used (System Assy) Accumulator Assembly Cal. Fluid System Graduate Assy. Cooling Water System Lube Oil Lube Oil Fluid Waste Cal. Fluid System Cal. Fluid System Cal. Fluid System Cal. Fluid System Cal. Fluid System Cal. Fluid System Cal. Fluid System Cal. Fluid System Cal. Fluid System Cal. Fluid System Cal. Fluid System
NOTE: Order hoses and tubing by length (ft).
Page 5-4
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
5.3 Item 1. 2. 3. 4. 5. 6. 7. 7a. 7b. 7c. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 43. 45.
BASIC ACCESSORIES (77-0789) Part # 67-0449 67-2817 67-2824 67-2840 67-2896 67-3133 67-3134 03-1534 03-1535 03-1583 67-6693 74-1030 74-1334 74-1336 74-1390 77-0568 77-0569 77-0748 77-0756 77-0775 77-0432 77-9097 06-9388 77-0806 03-0543 03-1004 03-1005 03-1546 03-1547 03-1548 03-1588 03-1589 03-1596 03-2668 03-4248 03-5382 05-5162 05-5202 06-8825 77-0625 03-1543 67-3456 67-3457 102-0753 67-5387 Description Nozzle Spacer, Mack engine nozzles High Pressure Hose Bleed-Off Valve Barring Tool Leak-Off Manifold Kit Lube Oil Drain Hose Lube Oil Supply Hose (Includes: Male Connector 1/4 x 1/8 Male Connector 1/4 x 1/4 Male Elbow 1/4 x 1/8 Nozzle Holder Adapter Aux. Pressure Hose Assy. Hose Assembly, Rubber 1/2 ID x 36" Hose Assembly, PVC 1/2 ID x 36" Hose Assembly, Rubber 1/2 ID x 36" Paint, Touch-up, Azure Blue Paint, Touch-up, Midnight Blue Nozzle Clamp Post Assy. Nozzle Clamp Clamp Screw Assy. Power Supply Leads Instruction Manual Allen Wrench (8mm) Drive Flange Assy. (Cummins) Street Elbow 1/4 FPT x 1/8 NPT Plug 1/8 NPT Plug 1/4 NPT Male Connector 1/2 Tube x 1/8 NPT Male Connector 1/2 Tube x 1/4 NPT Male Connector 1/2 Tube x 3/8 NPT 90 Male Elbow 3/4 Tube x 1/4 NPT 90 Male Elbow 3/8 Tube x 1/8 NPT 90 Male Elbow 1/2 Tube x 1/4 NPT Male Connector 3/4 NPT x 3/4 Tube Ball Valve, 2-way, 3/4 NPT Quick Connect Coupling, 3/8 NPT O-Ring 1-7/16" ID x 1-5/8" OD O-Ring 15/16" ID x 1-3/16" OD Warranty Registration Card Nozzle Holder Adapter Male Connector, 3/8 NPT Quick Connect, 1/8 NPT Quick Connect, 1/4 NPT Cup Point Set Screw, 5/16-18 x 1/2 Flange Mounting Bracket
Derived from 77-0789CS1R4
Instruction 77-9097
Bacharach, Inc.
Page 5-5
Specialist 9000
5.4
415/440/460V TRANSFORMER AND BRAKE HEATER LOCATIONS
415/440V TRANSFORMER (104-1956) 460V TRANSFORMER (104-1955) 5.5 SALES AND SERVICE CENTERS
BRAKE HEATERS (77-0928) AND CERAMIC BUSHINGS (204-0600)
California 7281 Garden Grove Blvd., Suite H Garden Grove, CA 92841 Phone: 714-895-0050 Fax: 714-895-7950 E-mail: calservice@bacharach-inc.com Indiana 8618 Louisiana Place Merrillville, IN 46410 Phone: 219-736-6178 Fax: 219-736-6269 E-mail: indservice@bacharach-inc.com New Jersey 7300 Industrial Park Rte. 130, Bldg. 22 Pennsauken, NJ 08110 Phone: 856-665-6176 Fax: 856-665-6661 E-mail: njservice@bacharach-inc.com
Pennsylvania 621 Hunt Valley Circle New Kensington, PA 15068 Phone: 724-334-5051 Fax: 724-334-5723 E-mail: help@bacharach-inc.com Texas 5151 Mitchelldale, B-4 Houston, TX 77092 Phone: 713-683-8141 Fax: 713-683-9437 E-mail: txservice@bacharach-inc.com
Page 5-6
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
5.6
DRAWINGS AND DIAGRAMS
Derived from 77-9044S1R0
Figure 5-1. FOUNDATION AND INSTALLATION DRAWING Page 5-7/5-8(blank)
Instruction 77-9097
Specialist 9000
Figure 5-2. CALIBRATING NOZZLE & HOLDER INSTALLATION ('S' SIZE) Page 5-9/5-10(blank)
Instruction 77-9097
Specialist 9000
Figure 5-3. TEST INJECTOR INSTALLATION (AMBAC/MACK W/VERTICAL OUTLETS) Page 5-11/5-12(blank)
Instruction 77-9097
Specialist 9000
Figure 5-4. TEST INJECTOR INSTALLATION (AMBAC / MACK BARSTOCK TYPE) Page 5-13/5-14(blank)
Instruction 77-9097
Specialist 9000
Figure 5-5. TEST INJECTOR INSTALLATION BOSCH LOW DEAD VOLUME Page 5-15/5-16(blank)
Instruction 77-9097
Specialist 9000
Figure 5-6. BOTTOM SECTIONAL VIEW Page 5-17/5-18(blank)
Instruction 77-9097
Specialist 9000
Derived from 77-7081S17R0, 67-5512S1R2 & 67-0346S1R1
Figure 5-7. FRONT VIEW Page 5-19/5-20(blank)
Instruction 77-9097
Specialist 9000
Figure 5-8. LEFT SIDE VIEW Page 5-21/5-22(blank)
Instruction 77-9097
Specialist 9000
Derived from 77-7081S5&6R0
Figure 5-9. CALIBRATION FLUID RESERVOIR ASSEMBLY Page 5-23/5-24(blank)
Instruction 77-9097
Specialist 9000
Figure 5-10. PNEUMATIC, LUBE OIL, AND COOLING WATER INTERCONNECTING DIAGRAMS Page 5-25/5-26(blank)
Instruction 77-9097
Specialist 9000
Figure 5-11. CALIBRATION FLUID & FLUID WASTE INTERCONNECTING DIAGRAMS Page 5-27/5-28(blank)
Instruction 77-9097
Specialist 9000
Figure 5-12. PNEUMATIC, WATER COOLING, LUBE AND FLUID / PNEUMATIC SCHEMATICS Page 5-29/5-30(blank)
Instruction 77-9097
Specialist 9000
Figure 5-13. ELECTRICAL INTERCONNECTING DIAGRAM Page 5-31/5-32(blank)
Instruction 77-9097
Specialist 9000
Figure 5-14. ELECTRICAL DIAGRAM (SCHEMATIC) 208/230 VOLTS

Instruction 77-9097
Page 5-33/5-34(blank)
Specialist 9000
Figure 5-15. ELECTRICAL DIAGRAM (SCHEMATIC) 360/480 VAC Page 5-35/5-36(blank)
Instruction 77-9097
Specialist 9000
Figure 5-16. ELECTRICAL DIAGRAM (SCHEMATIC) Page 5-37/5-38(blank)
Instruction 77-9097
Specialist 9000
Instruction 77-9097
Specialist 9000
Instruction 77-9097
Specialist 9000
Figure 5-19. CONTROLLER ASSEMBLY Page 5-43/5-44(blank)
Instruction 77-9097
Specialist 9000
Figure 5-20. ELECTRICAL CONTROL PANEL Page 5-45/5-46(blank)
Instruction 77-9097
Specialist 9000
Derived from 77-0675S3&4R0
Figure 5-21. ELECTRICAL CONTROL PANEL Page 5-47/5-48(blank)
Instruction 77-9097
Specialist 9000
Figure 5-22. ELECTRICAL INTERCONNECTING DIAGRAM Page 5-49/5-50(blank)
Instruction 77-9097
Specialist 9000
Figure 5-23. PROGRAM SETTINGS Page 5-51/5-52(blank)
Instruction 77-9097
Specialist 9000
Appendix A
APPENDIX A - LISTING OF PUMP MOUNTING DIAGRAMS FOR BACHARACH CALIBRATING STANDS

Drawing No. Pump Make/Model/Application 67-9186C 67-9196C 67-9185C 67-9078B 67-9135D 67-9156D 77-9041D 67-9080B 67-9285C 67-9410D 77-9070D 67-9076B 67-9077C 67-9079B 67-9151C 67-9129C 67-9311D 67-9439D 67-9424D 77-9083D 67-9451D 74-9117D 67-9081B 67-9153C 67-9276C 67-9305D 67-9341D 67-9428D 67-9134C 67-9139C 67-9140C 67-9141C 67-9229D 67-9228D 67-9238D 67-9252D 67-9444D 67-9440D AMBAC APE6BB - Mack AMBAC APE6BB, APE6Z AMBAC APE8VBB, including Short Housing and APE8VG AMBAC APF1A, APF1B AMBAC PSJ/PSM AMBAC 100 - IH AMBAC PSB12BT - Mil. AMBAC APE.A AMBAC PSB6A - Mil. AMBAC 100 - Allis Chalmers AMBAC PSU, 2/4 (M50) Bosch PES6P - IH DT817B,C Bosch PES8A75C - IH/Trucks Bosch EP/VA - IH/Farm Bosch PES6P - John Deere Bosch PES6A - John Deere Bosch EP/VE - VW Rabbit Bosch PES4M - Mercedes 190 Bosch PES6MW - IH DT (I) 466 Bosch P7100 - Mack Bosch EPVE - CDC Bosch PES6MW - Cummins 6CTA/8.3L CAV NN - Mack/Scania CAV Roto Diesel - John Deere CAV DP15 CAV Roto Diesel - Peugeot CAV-DPA (General) CAV-DPA - Case/Cummins Caterpillar 1100 Caterpillar 1673 Caterpillar 1674 Caterpillar 1693 Caterpillar Sleeve Metering 3208 (V8) Caterpillar Sleeve Metering 3304, 3306 Caterpillar 3406 Caterpillar 3408, 3412 Caterpillar 3306 B (New Scroll Type) Caterpillar 3406 B (New Scroll Type) Drawing No. Pump Make/Model/Application 77-9082D 77-9085D 67-9253C 77-9086D 67-9125C 67-9177C 67-9176C 67-9287C 67-9342D 67-9399C 67-9400C 67-9401C 67-9402C 67-9395C 67-9445D 67-9457C 77-9053C Cummins PT - Flowconsole Cummins PT - Flowmaster Diesel Kiki PES6A - IH/Nissan Simms P5184/1 Stanadyne DM - John Deere Stanadyne DM - Allis Chalmers Stanadyne DM - Allis Chalmers (Oiler & Bracket Installation) Stanadyne DB-2 - GM 5.7L/V8, 4.3L/V6 Stanadyne DB, DC Stanadyne DB2 - IH, 6.9L/V8 Stanadyne DB2 - Allis Chalmers 433 Stanadyne DB2 - Onan 2.3L, 3.4L Stanadyne DB2 - Waukesha VRD220,VRD330 Stanadyne DB2 - GM 6.2L/V8 Stanadyne DB2 - John Deere Stanadyne DB4 - Cummins 'B' Stanadyne DB2 - Teledyne Continental 2.7L
NOTE: All low pressure hoses and tubing that connect various pumps to the front panel, shown in the Pump Mounting Diagram, should be disregarded. They do not mate with the quick connect couplings and fittings, and should be replaced with the ones supplied with the stand. Fittings necessary to connect the Flowconsole (77-7009) to the quick connects of the test stand are supplied in the Basic Accessory Kit (77-0789). The 9000 stand incorporates all of the necessary pressure indicators. Pressure gages attached to rubber hoses, if supplied with the accessory sets, will not be needed. All other accessories and fittings shown in the Customer Instructions are to be used as indicated.
Bacharach, Inc.
Instruction 77-9097
Page A-1
Appendix A
Specialist 9000
NOTES:
Page A-2
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Appendix B
APPENDIX B - INTERNAL TIMING/ PHASING USING HIGH PRESSURE FLOW METHOD

The High Pressure Timing System employed is designed for checking and setting internal timing and phasing of inline multi-plunger fuel injection pumps, incorporating delivery valves with high opening pressures, using the spill flow method. With the high pressure developed by the gear pump, the delivery valve and spring do not require removal from the fuel pump for the timing operation. With the Bleed-off Valve (67-2824) installed between the nozzle holder and fuel line, the point of fuel shut-off (or beginning of fuel flow), as seen at the bleed-off valve overflow pipe, can be detected instantly. The following procedure is offered as a general guide to high pressure timing the pump. 1. Mount the fuel injection pump to be tested on the Stand using appropriate adapters and brackets. NOTE: Do not install fuel delivery lines or supply and return hoses. 2. Cap off or plug one side of the fuel gallery. If the pump is equipped with an overflow valve, plug the return connection. Connect the high pressure hose (67-2817) between the bulkhead quick disconnect marked HP Fuel Supply and the fuel pump gallery using appropriate fittings supplied. CAUTION First connect the high pressure hose to the injector pump gallery and then to the bulkhead quick connect. 3. Install the necessary number of bleed-off valves to the nozzle holders to be used in calibrating the pump. These nozzle holders should be either calibrating nozzle holders or engine holder assemblies. To install bleed-off valves at the nozzle holder (Figure B-1): (a) First attach the N-4 nut to the valve. FIGURE. B-1 BLEED-OFF VALVE INSTALLED BETWEEN NOZZLE HOLDER AND HIGH PRESSURE FUEL LINES Open the bleed-off valve for No. 1 pump cylinder (Fig. B-1). Turn on calibration fluid switch. Increase pressure slowly by closing high pressure needle valve far enough to open the delivery valve. With the pump connected, manually turn (with barring tool) the Stand coupling in the correct direction of rotation until No. 1 plunger begins to rise. Continue to maintain direction of travel by tapping on barring tool and observe fuel flow at the drain pipe of the bleed-off valve. (b) Turn nut counterclockwise onto the left hand threads of the valve for approximately one full turn. (c) Engage valve with nut to the male thread of the nozzle holder and tighten by hand. (d) Position the overflow pipe vertically downward to accumulator drain trough and wrench tighten the valve to the nozzle holder assembly. 4. Install appropriate size delivery lines from pump to bleed-off valve. Make certain all bleed-off valves are closed. HAND TIGHTEN ONLY. CAUTION Do not use a wrench on the thumb screw of the valve. This will damage the valve seat.
Instruction 77-9097
Bacharach, Inc.
Page B-1
Appendix B
Specialist 9000
NOTE: The pump must be turned slowly (in increments) so that the point of fuel shut-off as observed at the drain pipe can be detected instantly. 5. On some pumps the testing pressure is critical and must be adjusted with a needle valve to achieve the desired result. See pump manufacturers' instructions. 6. When the steady stream of fuel is reduced to a drip, stop turning the pump. This is called port closure. NOTE: The point of port closure is the instant where the fuel flow changes from a steady flow to a dribble (droplets). To insure accuracy in finding this point, it is recommended that the procedure to achieve this point be repeated at least three times, making sure that the approach is made always in the correct direction of pump rotation. This point is also called beginning of injection (start of delivery). When this point has been achieved, the pump plunger must be at a certain distance from its bottom (or top) dead center. Pump manufacturers give either the distance from bottom dead center to this point or from top dead center to this point (plunger lift). Consult pump manufacturers' instructions for this dimension and adjustment procedure. After adjustment, the foregoing procedure must be repeated to verify. Close No.1 bleed-off valve. 7. When position of the exact beginning of injec tion has been obtained, the pump is considered to be internally timed. With pump camshaft in the exact position when fuel is being cut off at the No. 1 pump cylinder, move cursor to indicate a round number (0 degree, 60 degrees, 90 degrees, etc.) on the degree wheel. Some pumps are externally marked for the beginning of injection. These marks are on the pump body (or bearing end plate) and coupling. If these marks do not coincide after the foregoing adjustment has been accomplished, one of the marks must be erased and relocated so that they do coincide.
Pumps which are flow-timed on the engine usually do not have any external marks for the beginning of injection. After the beginning of injection of the No. 1 plunger has been adjusted, the pump must be phased. 8. The beginning of injection for the remaining cylinders must be found in the sequence of engine firing order as stated by the pump manufacturer. The angular difference between consecutive points for beginning of injection for the following pumps are: 4 cylinder pumps; 90 degrees 6 cylinder pumps; 60 degrees 8 cylinder pumps; 45 degrees For tolerances refer to pump manufacturers' instructions. 9. Turn pump manually in the correct direction of rotation with the barring tool to approximate the following: 85 degrees for 4 cylinder pump 55 degrees for 6 cylinder pump 40 degrees for 8 cylinder pump Then open the bleed-off valve of the respective cylinder which is in line for firing order. With the needle valve at the same setting as before, flow must again be observed at the drain pipe. Tap lightly on the barring tool until the point of the fuel cut-off is obtained. At this point, observe the relative position of the cursor to the degree wheel and record the reading in degrees. As mentioned before, this reading must be at certain predetermined degrees from the No. 1 cylinder cut-off point. If it is not within manufacturers' limits, an adjustment must be made. After adjustment, repeat the procedure and close bleed-off valve. Continue with the same procedure for the remaining cylinders in the sequence of engine firing order. 10. Turn off the calibration fluid switch. Open high pressure needle valve (fully CCW). Disconnect high pressure hose from the pump, remove plug(s) from the fuel gallery (or overflow valve) and connect regular fuel supply and return hoses to the pumps. The above mentioned procedure is valid for fuel injection pumps which are timed for port closure.
Page B-2
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Appendix B
This means that the pump is timed for the beginning of injection (start of delivery). Pumps timed for port opening are timed in exactly the same manner except that instead of observing the fuel cut-off point on the overflow pipe, the pump is turned past this point until fuel starts to flow. Delivery is ended at this point and the timing is performed for the end of injection (end of delivery) rather than the beginning of injection. This method of timing will depend upon the system design. The method of timing is either given by the pump manufacturer in his test data or stamped on the name plate of the pump. After all cylinders are checked for the start of delivery and they fall within manufacturers' specifications, the pump is considered to be internally timed and phased. All bleed-off valves except the one belonging to the cylinder under test must be closed. Failure to do so may result in the inability of the fuel pump to develop sufficient pressure to open the delivery valve under test. The design of the bleed-off valve permits the use of the following nuts (on one end of the valve) provided that a 60 degree seat is required: Part No. 65-0278 65-0279 65-0280 65-0285 65-0281 65-0282 65-0312 65-0307 Thread 12x15mm 14x1.5mm 18x1.5mm 1/2"-20 9/16"-18 5/8"-18 16x1.5mm 9/16"-24 Identification N-3 N-4 N-5 N-6 N-7 N-8 N-23 N-26
Instruction 77-9097
Bacharach, Inc.
Page B-3
Appendix B
Specialist 9000
NOTES:
Page B-4
Bacharach, Inc.
Instruction 77-9097
Specialist 9000
Appendix C
APPENDIX C -
ACCUMULATOR ACCESSORIES FOR TEST INJECTIOR INSTALLATION
The following is a list of test injectors by manufacturer and the accessories needed to install them into the accumulator. See Figures 5-2 to 5-5 in Section 5 of the instruction manual. ACCUMULATOR ACCESSORIES APPLICATION TABLE Test Injector Mfg. AMBAC & Bosch Type/Size DN12SD12, ADN8S2 Orifice Type SAE/ISO (all 'S' size) AKF130... AKN212... Horizontal Inlet Vertical Inlet Bar Stock AKN.. (4 Valve Head) Low Dead Volume (1 688 901 101) Low Dead Volume (1 688 901 027) T' Size IP 1715 1U5500 (was 6V 9470) T Size (105780-8130) 'Low Dead Vol.', 'S' size Nozzle Holder Adapter 67-6693* Nozzle Holder Adapter ------------Nozzle Clamp Notes
77-0756*
AMBAC
------67-6693* ------------------------67-6693*
77-0830 77-0770 67-0449* 67-6245 77-0625* ------------67-6684 77-0771 77-0512 ------
" 77-0829 77-0756*
Military "
AMBAC (MACK) Bosch Caterpillar Diesel KIKI
Mack (for P1700 pumps) EPVE-CDC
Early Style (Injector Obsoleted)
*These parts can be found in the Basic Accessory Kit.
Instruction 77-9097
Bacharach, Inc.
Page C-1
Appendix C
NOTES:
Page C-2
Bacharach, Inc.
Instruction 77-9097

77 9097

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77 9097

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INSTRUCTION 77-9097 SPECIALIST 9000 DIESEL FUEL INJECTION PUMP CALIBRATING STAND

Installation/Operation/Maintenance Rev. 2 - January 2002

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.1

Warnings and Cautions

WARNINGS, CAUTIONS, AND NOTES WARNINGS

Warnings and Cautions

THE SPECIALIST 9000 CALIBRATING STAND Page iv

Air Pressure: Water:

Approximately 2000 lbs. (907 Kg)

UNPACKING THE STAND

Figure 3-4. UPPER FRONT PANEL

Figure 3-6. MISCELLANEOUS

Figure 3-7. GRADUATE READING

COMPONENT & SYSTEM FUNCTIONS

Figure 3-10. TACHOMETER/COUNTER

Figure 3-11. STANDARD FLEXIBLE COUPLING Page 3-12

Figure 3-12. CUMMINS DRIVE FLANGE

TESTING CUMMINS PT PUMPS

CORRECT USE OF ALIGNMENT GAUGE

Figure 3-14. USE OF ALIGNMENT GAUGE

Maintenance & Troubleshooting

MAINTENANCE AND TROUBLESHOOTING

Maintenance & Troubleshooting

Figure 4-1.LOCATING RESERVOIR(S) DRAIN PETCOCKS

Figure 4-4. FINAL STAGE FILTER

Maintenance & Troubleshooting

Figure 4-6. REMOVING CONSOLE SCREWS

Maintenance & Troubleshooting

LOCATION OF TIME AND SPEED ADJUSTMENTS

Maintenance & Troubleshooting

Figure 4-12. WIRING CONNECTIONS FOR THE TACHOMETER/COUNTER

Maintenance & Troubleshooting

Figure 4-14. REMOVING A GRADUATE 4.3 TROUBLESHOOTING

Maintenance & Troubleshooting

Figure 4-15. ELECTRICAL PANEL WITH AC CONTROLLER (208/230 V)

Maintenance & Troubleshooting

4.3.3 Mechanical Troubleshooting

Symptom Air in Calibration Fluid Supply Line

Graduate rack inoperative

Maintenance & Troubleshooting

All systems function except main drive motor

Reset or replace Motor controller

No calibration fluid temperature control

Maintenance & Troubleshooting

No reservoir tempperature reading

Tach does not read RPM or Count

Calibration fluid heating time slow

Parts Lists and Diagrams

PARTS LISTS AND DIAGRAMS

Parts Lists and Diagrams

SPARE PARTS LIST

Parts Lists and Diagrams

Parts Lists and Diagrams

5.2 Fig. # 5-21 5-21 5-21 5-21 5-21 5-21 5-21

NOTE: Order hoses and tubing by length (ft).

Parts Lists and Diagrams

Derived from 77-0789CS1R4

Parts Lists and Diagrams

415/440/460V TRANSFORMER AND BRAKE HEATER LOCATIONS

BRAKE HEATERS (77-0928) AND CERAMIC BUSHINGS (204-0600)

Parts Lists and Diagrams

DRAWINGS AND DIAGRAMS