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INSTRUCTION 77-9075INJECTOR CALIBRATOR DD5

Part Number s 77-7072 thru 77-7076

Installation/Operation/MaintenanceRev. 1 - June 1993

Bacharach, Inc.

621 Hunt Valley Circle, New Kensington, PA 15068Ph: 724-334-5000 Fax: 724-334-5001 Website: www.bacharach-inc.com

Printed in U.S.A.

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WARRANTY

Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free fromdefects in material and manufacture and will conform substantially to Bacharach, Inc.s applicablespecifications. Bacharachs liability and Buyers remedy under this warranty are limited to therepair 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 beendefective; 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. Bacharachsliability and Buyers remedy under this warranty of title are limited to the removal of any titledefects or, at the election of Bacharach, to the replacement of this Product or parts thereof that aredefective in title. The warranty set forth in paragraph 1 does not apply to parts the OperatingInstructions designate as having a limited shelf-life or as being expended in normal use.

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED INLIEU OF (I) ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDINGWITHOUT LIMITATION. THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FIT-NESS FOR A PARTICULAR PURPOSE: AND (II) ANY OBLIGATION, LIABILITY, RIGHT,

CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARISING FROMBACHARACHS NEGLIGENCE, ACTUAL OR IMPLIED. The remedies of the Buyer shall belimited to those provided herein to the exclusion of any and all other remedies including, withoutlimitation incidental or consequential damages. No agreement varying or extending the foregoingwarranties, remedies or this limitation will be binding upon Bacharach, Inc. unless in writing,

signed by a duly authorized officer of Bacharach.

NOTE: Fuses and gaskets are expendable items and are excluded fromthe terms of this warranty.

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CONTENTS DESCRIPTION

This manual is designed and written to be contained into five separate chapters. Each chapter containsspecific information that is designed to be read and used in a logical sequence. Information contained ineach chapter is defined below.

Chapter 1. Introduction - Descriptions of the unit and its controls, along with construction notes.

Chapter 2. Installation - Includes unpacking, installation, and set-up, as well as repacking for shipping and storage.

Chapter 3. Operation - Cam change, injector mounting, testing, and unmounting described in detail.Chapter 4. Maintenance and Adjustment - Covers maintenance, troubleshooting, and adjustments.Chapter 5. Parts List and Diagrams - Contains parts lists and diagrams of the DD5 unit.

WARNINGS AND CAUTIONS

WARNING

Do not open cambox cover while main drive motor is running. Mke sure that the Flywheel has

stopped turning before opening cambox cover, to prevent being splashed by hot lubricating oil.

CAUTION

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

CAUTION

CALIBRATOR CAN BE DAMAGED. Do not operate the calibrator until all items on the

checklist in Section 2.5 have YES responses.

CAUTION

Do not start Main Drive with Supply Hose connected to Manifold Block (or Injector Holder 8.2L)

and with injector not clamped. This will cause calibration fluid to spray out of the block.

CAUTION

Do not attempt to make any adjustments or repairs to the calibrator without first disconnecting

the main power line at the wall.

DD5-EUI CONTENTS DESCRIPTION

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TABLE OF CONTENTS

TECHNICAL DATA AND FEATURES ........................................................................... iii

1.0 INTRODUCTION ............................................................................................................. 1-11.1 INSTRUMENTS, CONTROLS, AND FEATURES ................................................. 1-21.2 ACCESSORIES ......................................................................................................... 1-41.3 CONSTRUCTION ..................................................................................................... 1-5

1.4 CALIBRATION FLUID SYSTEM ............................................................................ 1-61.5 PNEUMATIC SYSTEM ............................................................................................ 1-81.6 CALIBRATION FLUID TEMPERATURE CONTROL SYSTEM............................1.81.7 ELECTRICAL SYSTEM ........................................................................................... 1-8

2.0 INSTALLATION............................................................................................................... 2-12.1 INTRODUCTION ..................................................................................................... 2-12.2 HOLD DOWNS ......................................................................................................... 2-12.3 UTILITY CONNECTIONS....................................................................................... 2-22.4 FILLING RESERVOIRS .......................................................................................... 2-32.5 PRE-OPERATION CHECKS ................................................................................... 2-42.6 START-UP................................................................................................................. 2-52.7 REPACKING FOR SHIPPING ................................................................................ 2-6

2.8 SHIPPING AND STORAGE .................................................................................... 2-6

3.0 OPERATION..................................................................................................................... 3-13.1 INTRODUCTION ..................................................................................................... 3-13.2 INJECTOR MOUNTING (general) .......................................................................... 3-13.3 CAM CHANGE ......................................................................................................... 3-23.4 MOUNTING INJECTOR TYPES 53, 71, AND 92 .................................................. 3-33.5 MOUNTING INJECTOR TYPE 149 ........................................................................ 3-53.6 MOUNTING INJECTOR TYPE 8.2 LITER ............................................................ 3-73.7 TESTING .................................................................................................................. 3-83.8 UNCLAMPING INJECTORS ................................................................................ 3-103.9 SHUTTING DOWN CALIBRATOR ....................................................................... 3-11

4.0 MAINTENANCE AND ADJUSTMENT ........................................................................ 4-14.1 MAINTENANCE SCHEDULE ................................................................................ 4-14.2 CHANGING CALIBRATION FLUID AND FILTERS ............................................ 4-24.3 CHANGING CAMBOX OIL ..................................................................................... 4-34.4 CLEANING AND LUBRICATING .......................................................................... 4-34.5 REFILLING FLOWMETER CAVITY...................................................................... 4-34.6 TROUBLESHOOTING CHARTS ............................................................................ 4-44.7 HYDAULIC SYSTEM/INTENSIFIER ..................................................................... 4-54.8 RESETTING SWITCHES ........................................................................................ 4-64.9 CHANGING FUSES ................................................................................................. 4-74.10 ADJUSTING AIR PRESSURE REGULATOR ........................................................ 4-84.11 ADJUSTING OPTICAL DETECTOR ON CAMSHAFT ......................................... 4-84.12 ADJUSTING FLYWHEEL COVER INTERLOCK.................................................. 4-84.13 REPLACING DRIVE BELT ..................................................................................... 4-94.14 ADJUSTING CALIBRATION FLUID TEMPERATURE ..................................... 4-104.15 MOTOR STARTER OVERLOAD RELAY ADJUSTMENT................................... 4-104.16 FLOWMETER TRANSDUCER REPLACEMENT ................................................ 4-11

5.0 PARTS LIST AND DIAGRAMS ..................................................................................... 5-15.1 BASIC ACCESSORIES (77-0585) ............................................................................ 5-15.2 INJECTOR ACCESSORIES (77-7013) .................................................................... 5-15.3 SPARE PARTS LIST ................................................................................................ 5-25.4 ASSEMBLY DRAWING LIST.................................................................................. 5-35.5 DIAGRAMS............................................................................................................... 5-4

TABLE OF CONTENTS DD5

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TECHNICAL DATA AND FEATURES

5HP Electric drive motor

Digital fuel measurement

Floor standing unit; full welded frame construction

Operating speed: 2000 RPM

Cast iron cambox with tapered roller bearings and quick change cam capability

Injector clamping: hydraulic

Calibration fluid reservoir capacity: 8 U.S. Gallons (30 liters)

Filtration:

- Primary filter (spin-on type): 10 micron- Final stage filter (spin-on type): 3 micron- Flowmeter transducer: screen

Calibration fluid temperature control:

- Solid state control- 100F + 1F (factory setting)- Cooling by cold tap water- Heating by two 500 watt immersed electric heaters

Instrumentation & Controls:

- Injector Supply (Rail) Pressure Gauge, 4" Dial, Scale: 0-100 psi.

- Calibration Fluid Temperature Gauge, 4" Dial, Dual Scale: 40-140F (5-60C).- Supply pressure regulator- Clamping pressure regulator- Main drive start, stop switches- Measurement system start switch

Measurement System:

- Positive displacement Flowmeter (U.S. Patent No. 4141243)- Measurement Units - mm3/str.- Digital display resolution - 0.1 mm3/str.- Measurement sampling - 100 strokes- Stroke counter - electronic/optical

- Accuracy: + . 75% of reading or 1 mm3/str. whichever is greater

DD5 CHARACTERISTICS

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Indicator Lights:

- Power (red) - Heat/Cool (amber) - Clamping (amber)

Accessibility: Two front and one upper left hand side hinged doors. All other panels have quickturn fasteners for easy removal.

Dimensions: 50"W (1.27m) x 30"D (.76m) x 56"H (1.42m)

Weight (Dry): 1150 lbs. (521 kg)

Utilities Required:

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

- Air Pressure: 80-120 psi (2 CFM)

- Water: Cold tap, approximately 1.2 GPM (4.5 liter/min)

Accessories:

- All the required accessories are included for mounting and testing Detroit Diesel 53, 71, 92,149 and 8.2L injectors.

- Provision for hanging all accessories on pegboard inside lower doors.

CHARACTERISTICS DD5-EUI

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INJECTOR CALIBRATOR DD5 INTRODUCTION

Instruction 77-9075 Bacharach, Inc. Page 1-1

1.0 INTRODUCTION

The Bacharach Model DD5 Injector Calibrator provides fast, accurate and safe calibration of unit injec-tors manufactured by Detroit Diesel Allison (GM). The calibrator will test the 53, 71, 92, 149, and 8.2LMUI unit injectors.

The DD5 was tested at the Bacharach factory with high precision instruments to insure:

Accurate calibration fluid temperature

Flowmeter accuracy

Correct clamping force

Overall correlation with DDA Master Injectors

Fig. 1-1. Model DD5 Injector Calibrator

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INTRODUCTION INJECTOR CALIBRATOR DD5

Page 1-2 Bacharach, Inc. Instruction 77-9075

1.1 INSTRUMENTS, CONTROLS, AND FEATURES

Feature Operation

A. Console and Table Top (Fig. 1-2)

Injector RAIL 0 to 100 psi, 4 in. dial.

PRESSURE Gauge

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

METER START Button Switches on flowmeter. Lights while meter is running.

MM3/STROKE Fuel Four-digit LED display with resolution of 0.1 mm3/stroke (Red flashingDelivery Display dot indicates update in LED display).

POWER Indicator Indicates On-Off Switch/Circuit Breaker is closed, and calibration fluidLight system pump is operating.

Hour Meter (Left Side) 0 to 9999 hours. Operates when On-Off Switch/Circuit Breaker is ON.

CLAMP MONITOR Lights for about 1 second during clamping operation.Light

START MAIN DRIVE Applies power to 5 HP main drive motor, starts camshaft rotation.Button

HEATER Indicator When lit, indicates power is being applied to calibration fluid reservoirLight heaters. When off, water circulates through the cooling coil in the

calibration fluid reservoir.

TEMPERATURE Pot Permits setting of calibration fluid temperature (Potentiometer).

B. Left Side & Operators Table (Fig. 1-3)

On-Off Switch/ When switched on, starts the calibration fluid system pump motor, turnsCircuit Breaker on the calibration fluid automatic temperature control, hour meter and

control circuit power.

HOLD TO OPERATE Functions only when main drive motor is OFF. There is no physical move-Button ment of the clamping mechanism when this button is pressed but it must be

held down to operate the clamp selector valve. This is part of the two handsafety operation system.

STOP Button Shuts down main drive motor and resets flow meter.

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Fig. 1-2. Console and Table Top

Fig. 1-3. Left Side & Operation Table

HOLD TO OPERATESwitch

STOP Switch

Hole Provided ToKeep Barring Tool

On-Off Switch /Circuit Breaker

POWER on

Injector RAILPRESSURE Gauge

Delivery DisplayMM3/ STROKE

CALIBRATION FLUIDTEMPERATURE

HEATER on

TEMPERATUREPotentiometer

CLAMP MONITORSTART MAIN DRIVE

METER START

Hour Meter

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Feature Operation

C. Right operators Table

CLAMP/UNCLAMP Clamps/Unclamps injector to support bracket. Will operate only whenLever (4-way valve) the HOLD TO OPERATE button is held down.

D. Inside Frame

Rail Pressure Gauge Diaphragm type back pressure regulator regulates rail (supply) pressureto injector inlet.

Clamp Pressure Gauge 2" dial, indicates clamp pressure, mounted on clamp pressure regulator.

Air Pressure Filter/ Admits, regulates, filters, and measures air pressureRegulator/Gauge

Fig. 1-4. Right Operators Table

1.2 ACCESSORIES

The DD5 is supplied with two Accessory Sets:

1. 77-0585 Basic Accessories

2. 77-7013 Accessory Set for testing 53, 71, 92, 149, 8.2L MUI injectors (Accessories contained inthis set should be hung on the inside front LH door with the supplied hooks. See Section 5 for a list ofparts in the sets, and Fig. 3-1 [Injector Accessories]).

Fig. 1-5. Front View With Doors Open

Main Drive Motor

Injector Accessorieson Peg Board

Reservoir

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1.3 CONSTRUCTION

Cabinet: The frame is welded steel 1-1/4" squaretubing and angle iron. Upper left side and both frontdoors are hinged for ease in performing routine main-tenance. Accessories are stored on the backside of thefront door for accessibility. All other external panels

are secured with 1/4 turn fasteners for easy removal.Rotating parts are protected with a hinged cover, andinterlocked with the main drive motor for safety.

Console and Operators Table: The instrumentconsole is mounted to the operators table with vibra-tion absorbing mounts for the controls and gauges.

Vibration absorbing leveling pads at the bottom of theframe are provided for easy leveling of the unit.

Hydraulic Clamp:An air driven hydraulic pump("intensifier") provides the high pressure required tounlock the clamp cylinder..

Main Drive Motor: The calibrator is powered by a5 HP induction motor operated by a magnetic starterwith overload protection. It drives a camshaft whichactivates the plunger in the injector being tested.

Flywheel:A flywheel is mounted on the driven endof the camshaft to provide for uniform rotation. Anencoder wheel, also camshaft mounted, in conjunc-tion with an optical pick-up, counts strokes.

Cambox:The cambox is constructed of cast iron and

contains a 1-" diameter camshaft supported byheavy duty tapered roller bearings. The cam is on oneend of the shaft on a non-locking taper with key, se-cured by a nut and washer, and allows for quick &easy cam changes. Rotating cam dips and splashes tolubricate cam, bearings, tappet roller, and pusher rod.

Calibration Fluid Pump:A 1 HP electric motordrives a gear pump supplying fluid to the injector anddouble-acting hydraulic cylinder which clamps andunclamps the injector. The motor and pump runcontinuously keeping the calibration fluid circulat-ing to stabilize fluid temperature.

Calibration Fluid Reservoir:Calibration fluid isstored in a 8 U.S. gallon (30 liter) reservoir whichcontains two 500-watt electric heaters, cooling coil,dipstick, two drain valves, and is thermostaticallycontrolled.

Flowmeter Transducer: For measuring fuel out-put (delivery) from the injector, the calibrator uses apositive displacement flow measuring device with adigital readout (U.S. Patent No. 4141243).

Fig. 1-7. Flowmeter Transducer

Fig. 1-6. Cambox

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1.4 CALIBRATION FLUID SYSTEM (Fig. 1-8)

The calibration fluid system consists of two circuits:

(1) Injector Supply and Clamp Circuit

Calibration fluid is drawn from the reservoir throughan externally mounted suction filter (3) into the motor

driven gear pump (5). At the same time, fluid tempe-rature is being measured by the temperature gage (2).Fluid is routed through a free passage inside the reliefvalve (6) into the clamp selector valve (7), port "P".When in neutral position fluid passes thru the clampselector valve port R and is routed to the rail pressureregulator (8) and final stage filter (9).

When the gear pump operates but main drive is off, allfluid is returned to the reservoir through the railpressure regulator at about 35 psi, set by the regulator.

When the main drive START button is depressed thesolenoid valve L4 (10) on the downstream side of thefinal stage filter opens and the fluid is routed throughthe injector supply hose, and quick disconnect (12), andeventually to the injector under test. At the same timefluid pressure is measured by the rail pressure gage(11).

NOTE: The supply hose ends with a quick dis-connect (12) that is sealed when disconnected.

When clamping is required it is necessary to unlock thehydraulic cylinder (14).

The hydraulic cylinder is mechanically locked undernormal operating conditions by an interference fit be-tween a sleeve and cylinder rod. To allow the cylinderto move for clamping or unclamping an injector, an airdriven hydraulic pump (intensifier) assembly (seeFig. 1-10) applies high hydraulic pressure to the sleeve.

The intensifier assembly consists of an air-driven hy-draulic pump, reservoir, 3-way air solenoid valve L3,and a 2-way hydraulic air release valve. With power on,under normal operating conditions, the 2-way hydrau-lic air release valve is open so that pump output port is

vented back to the reservoir.

When a clamp or unclamp operation is desired (initi-ated by pressing the HOLD TO OPERATE button), the3-way air solenoid valve is energized and the 2-wayhydraulic air release valve closes. Air is admitted to theair-driven hydraulic pump, generating high pressure tounlock the hydraulic cylinder. As long as the button isheld down, the cylinder is free to move.

When the Clamp selector valve is moved to CLAMP,fluid from port P is diverted through port 2, through

the manifold (13), to the piston (clamp) side ofhydraulic cylinder (14), port 2. This line is alsoconnected through the manifold to the clamp pres-sure regulator (17), pilot operated check valve(POCV) #1 port C and POCV #2, port P. Maximumpressure in this line, as set by the regulator, is about100 psi. When fluid is directed to the piston side ofthe cylinder, fluid trapped in the rod side of thecylinder is routed thru POCV #2 to the reservoirand also through the R port in the selector valveas well as the rail pressure regulator. When fluidpressure in the piston side of the cylinder reaches apreset pressure the pressure switch (S11, not seenin Fig. 1-8) starts a timer, and turns on the ClampMonitor light. After about one second the power isremoved from the air solenoid valve (L3) and thecylinder is automatically locked regardless of theposition of the HOLD TO OPERATE button andclamp selector valve.

When clamp selector valve is moved to UNCLAMPthe fluid from port P is diverted to port 1 to the rod(unclamp) side of the hydraulic cylinder, port 1. Onits way this line is connected to POVC #2 port C andPOVC #1 port P. The maximum pressure in this

line, as set by relief valve (6) is about 200 psi. Whenfluid is routed to the rod side of the cylinder, fluidtrapped in the piston side is returned thru themanifold and the POCV #1 to the reservoir, alsothrough the R port in the selector valve and the railpressure regulator.

The POCV operates as follows: when fluid pressureis applied to port P and no pressure is applied to portC all ports are isolated from each other. Whenpressure is applied to port C (in addition to port P)the valve opens and lets fluid from port P flow toport V. Port C is always isolated from ports P and V.

Port V is connected to the reservoir.

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

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(2) Flowmeter Circuit (Injector Output)(Fig. 1-9)

The flowmeter circuit begins at the discharge headwhich receives injector output. Fluid passes through ascreen and orifice, and is routed to a three-way solenoidvalve (L8) controlled by a meter switch mounted on the

control panel. When the injector is running, and beforethe switch is actuated, the injector output is returned tothe reservoir. When a readout of the injector output isdesired, the switch is actuated, the injector output isrouted through the flowmeter before it is returned tothe reservoir. The metering system uses a patentedpositive displacement type flowmeter. Fluid drives apiston in a reciprocating motion controlled by two 3-way solenoid valves. The motion of the piston, mechani-cally connected to a linear measurement device, pro-duces signals which represent displaced volume. Thesesignals and signals generated by camshaft rotation areelectronically computed. Delivery is then digitally dis-played in terms of mm3/stroke.

1.5. PNEUMATIC SYSTEM

The pneumatic system operates on shop supplied com-pressed air. Air pressure is needed for the operation ofthe hydraulic pump (intensifier).

On entering the system shop air pressure is reduced to60 psi (4.1 bar) by a pressure regulator complete withwater trap, filter, and gage. The correct air pressure

setting is made at the factory (and must be monitoredby the operator). This pressure provides for unlockingthe hydraulic cylinder by the intensifier

Fig. 1-9. Flowmeter Circuit

1.6. CALIBRATION FLUID TEMPERATURECONTROL SYSTEM (see Fig. 5-18, 5-19)

Calibration fluid is supplied at 100F (as measuredin the reservoir). Two 500 watt electric immersionheaters mounted in the reservoir heat the fluid.Cold water flowing through a coil of copper tubing,

mounted in the reservoir, cools the fluid.

A temperature sensor also mounted in the reser-voir, is connected to a solid-state temperature con-troller which either switches on the heaters oropens the water solenoid valve (Ll) to admit coldwater to the cooling coil. A safety switch (S2) pro-tects the system from overheating should the sen-sor fail.

Fluid temperature is kept stable through circula-tion provided by the continuously running gearpump.

1.7. ELECTRICAL SYSTEM

The electrical system includes the following safetyinterlocks:

Main drive motor will not start if flywheel coveris not closed.

The HOLD TO OPERATE (green) button isinoperative when the motor is running,

disabling the unclamp operation.

Fig. 1-10. Intensifier Circuit

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INJECTOR CALIBRATOR DD5 INSTALLATION


2.1 INTRODUCTION

Select an area where the calibrator will be leveland on solid footing, convenient to shop air, cold

water line, drain and electrical supply. Allow spacearound the unit for operation and maintenance.

Allow for clearance of the cabinet doors and foreasy removal of panels. If possible, locate the unitaway from heavy vibrations and dusty or dirtyatmosphere.

NOTE: The circled numbers shown with thelabels on photos refer to step numbers on

the following instructions.

2.2 HOLD DOWNS

For security in shipment, the cabinet is bolted tothe shipping skid, and the flowmeter and consoleare bolted down using spacer blocks. To remove thebolts and spacers:

1. Open the front doors, and remove the two rearpanels.

2. Remove the two shipping bolts that hold thecabinet to the skid.

3. Lift the cabinet from the skid and place it in

the selected area.

4. Remove the two shipping spacers between theflow transducer base and console base byremoving the two 1/4-20, 3/4 long bolts, nutsand washers.

5. Remove two shipping (wooden) spacers be-tween the console and tabletop, located on eachside of the console, by removing the two 1/4-20,3/4 long bolts and washers.

6. Close the front doors and reinstall the rear

panels.

2.0 INSTALLATION

Fig. 2-1. DD5 Cabinet Dimensions

Fig. 2-2. Hold Downs

eRemove Console Bolts(Typical Both Sides)

eWooden Spacers(Each Side)

dRemove Transducer Hold Down Boltsand Shipping Spacers (Typical Both Sides)

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INSTALLATION INJECTOR CALIBRATOR DD5


2.3 UTILITY CONNECTIONS

A. Electrical (see Section 1.1C for Specifications)

CAUTION

Be sure MAIN POWER is OFF when servic-

ing Calibrator. To prevent damage to cali-bration fluid reservoir heaters, fill reservoir

with calibration fluid to proper level beforeapplying electrical power.

1. Customer must supply 3 phase power from aneasily accessible wall mounted fusible discon-nect switch rated at 30 amps.

2. Check the nameplate (located on the frame,leftside) for the electrical characteristicsrequired.

The standard unit requires 230V, 60 Hz. 3phase see Fig. 5-15 for details.

3. Make sure On-Off Switch/circuit breaker isOFF. Use a #10 wire for 230 and 208 volt units(or a #12 wire for 460 volt units) to wire tomagnetic motor starter in the electrical controlbox. Bring wire through the hole in the rear ofthe unit using proper hardware.

4. After wiring, turn unit ON and check that thedirection of rotation of the small motor (located

inside the front panels) is counter-clockwise.

5. If the motor direction is wrong, switch any twowires at the wall disconnect and check again.

B. Water

6. Connect a cold water line to the fitting at therear of the calibrator marked WATER IN (1/4"NPT).

7. Connect a drain line to the fitting markedWATER OUT (1/4" NPT).

NOTE:Do not install any valves, shutoffs orother restrictions on the drain line. Water

goes in under line pressure and must be freeto run out.

Fig. 2-3. Electrical Connections

Fig. 2-4. Water Connections

c Electric Power Inletf WATER IN

g WATER OUT

hAIR In

dMotor Rotation Direction

2Name Plate 3On-Off Switch/ Circuit Breaker

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Adjust Air Pressureto 60 PSI

C. Air

NOTE:Air pressure regulator was setat the factory.

8. Connect an air line from the shop supply to thefitting at the rear of the calibrator marked AIR

(1/4" NPT).

9. Check regulator setting. It must be 60 +5, 0psi (4.1 bar). The air pressure regulator isbehind the lower rear panel.

CAUTION

Shop air supply must not exceed 125 psi.

High shop air pressure can damage airregulator.

10. To adjust air pressure regulator, lift the redring above the regulator adjustment ring andturn knob. When adjusted, push ring down tolock.

2.4 FILLING RESERVOIRS

A. Calibration Fluid

1. Make sure both drain of the calibration fluidreservoir are closed.

2. Through dipstick port, fill reservoir to the F

mark on the dipstick with new fluid. UseBacharach part number 67-5598 (15 US gallondrum). This fluid meets SAE J967 and ISO-4113.

3. Place a tag on the reservoir, giving date it wasfilled.

B. Cambox

The cambox is filled at the factory. However, iffilling is necessary:

4. Make sure the cambox drain plug is in place.Drain plug is accessible after left-hand cabinetdoor is open.

Fig. 2-5. Air Pressure Regulator

Fig. 2-6. Fluid Reservoir Drains

Fig. 2-7. Filling Reservoirs

10

j Lift Red Ring

i Check Regular Setting hAIR In

aClose Both Drains

bFill to "F" Mark OnDipstick

4Cambox Drain Plug

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Fig. 2-8. Cambox

Fig. 2-9. Initial Checks, Hook-up

Fig. 2-10. Initial Checks, Flowmeter

5. Fill the cambox with SAE 30W motor oil tobring the level up to within 3-3/4 inch from thetop (or about 1-1/2 inches from the bottom).

C. Intensifier

6. The intensifier reservoir is filled at the factory

before shipping. If additional fluid is required,add SAE 30W motor oil. A three quarter fullbottle is acceptable.

D. Flowmeter Transducer

7. The flowmeter transducer cavity is filled at thefactory before shipping. If additional fluid isrequired, see Section 2.5.

2.5 PRE-OPERATION CHECKS

Before trying to operate the calibrator for the firsttime be sure to complete all the Initial Checksbelow and Start-Up procedures in Section 2.6.

CAUTION

CALIBRATOR CAN BE DAMAGED. Do not

operate the calibrator until all items on thechecklist below have YES responses.

INITIAL CHECKSAll responses must be YES

IS THIS TRUE? YES

1. On-Off Switch/Circuit breaker is in _____OFF position.

2. The electrical power supplied corres- _____*ponds to the data on the nameplateinside the left side door.

3. The air line from the shop air supply _____is connected to the AIR inlet at theback of the calibrator.

4. Air pressure regulator gauge (inside _____lower rear panel) indicates 60 psi(4.1 bar) +5, 0 psi. Reset if necessary.

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

9Flowmeter Cavity

5Fill Cambox to 3 Inches from Top

bElectric Power Inlet(Connections insideElectrical Box Cover)

bElectrical Name Plate (inside)5WATER INcAIR In

aOn-Off Switch/Circuit Breaker

6WATEROUT

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NOTE:Air pressure regulator was setat the factory.

5. Cold water line is connected to the _____WATER IN fitting.

6. The drain line is connected to the _____

WATER OUT fitting.

NOTE:Do not connect any valve,shut-off, other restriction in the

drain line.

7. The calibration fluid reservoir is _____filled to the F mark on the dipstick.Use Calibration Fluid 67-5598.

8. The cambox is filled with oil to 3-3/4 _____inch from the top of cam box. SeeSection 2.4.B.

9. The flowmeter cavity is filled with _____lube oil (30W) to about 3/8" fromthe bottom. Replenish if necessary.

10. The intensifier reservoir is filled _____with oil. A three-quarter full bot-ble is acceptable.

Do not proceed until all responses on thechecklist are YES.

2.6 START-UP

1. Switch On-Off Switch/Circuit Breaker to ON.POWER indicator, HEATER indicator and thered dot on the display will be lit, and the cali-bration fluid system pump will be running.

2. Allow the calibrator to warm up until the CAL

FLUID TEMPERATURE gauge indicates100F +1F (37.8C). This usually takes about15 to 20 minutes, depending on the ambienttemperature.

NOTE: The calibration fluid temperaturewas adjusted at the factory. If readjust-ment is necessary refer to Section 4-14.

3. The calibrator is now ready for testing injectors.

Fig. 2-11. Initial Checks, Drains

Fig. 2-12. Initial Checks, Reservoir

Fig. 2-13. Initial Checks, Cambox

7Dipstick

hCambox Oil

Reservoir Drain Valves

4Air Pressure Regulator Gauge

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2.7 REPACKING FOR SHIPPING

1. Drain the calibration fluid reservoir from bothdrain valves.

2. Pack all the accessories listed in Section 5.2.Do not ship the calibrator with its accesso-

ries hanging on the door.

3. Disconnect all power and utilities.

4. Place 5/8 x 7/8 x 11-1/2 inch wooden blocksunder each side edge of the console.

5. Use a 3/4 inch long, 1/4-20 bolt in the center ofeach edge of the console to hold the consolesecurely to the cabinet.

6. Use two spacers, two 3/4 inch long, 1/4"-20bolts, nuts and washers to fasten the flow-meter trans-ducer to the console.

7. Do not drain the fluid from the cambox.

8. Bolt the calibrator to a shipping skid.

9. Pack the calibrator in a sturdy crate forshipping.

2.8 SHIPPING AND STORAGE

1. Make sure the calibrator is kept uprightduring shipping and storage.

2. Do not drop or stack calibrators.

3. Store in a temperature and humidity con-trolled enviroment

Fig. 2-14. Initial Checks, Intensifier

jIntensifier Reservoir

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INJECTOR CALIBRATOR DD5 OPERATION


3.1 INTRODUCTION

Make sure you have completed the Pre-operationCheck-list in Section 2.5 before testing any injectors.

Units shipped from the factory have cam 53/71/92(77-0610) installed. Another Cam must be used fortesting the 149 injector, for more information seeSection 3.2, 3.3, 3.4, and Table 3-1 below. Proceduresfor mounting injectors vary according to the type ofinjector:

Type 53, 71, or 92 Marine - Section 3.4 Type 149 - Section 3.5 Type 8.2 liter - Section 3.6

The following is a table of accessories and theirapplication:

--------- means the accessory is not needed.

* The setup of the Manifold Block for the 92Marine requires installing Support Assy(77-0913), and the Fuel Connectors (77-0866)

**The 8.2 liter injector adapter set consists of aspacer block (67-6851), two angle spacers(67-6850), an injector holder (67-6854), withkey (67-6853), and mounting instructions(67-9388).

3.2 INJECTOR MOUNTING (general)

Injectors are clamped against standoffs (part of theManifold Block or Spacer Block) located between theinjector and the cambox. Supports are required forthe front of the injectors. The 149 injector uses a pushrod extension between the push rod and the injectorfollower. The 8.2 liter injector needs a special holderassembly.

NOTE:Please read theIMPORTANTNOTEon Page 3-12 before checking Kent

Moore Master Injectors.

Fig 3-1. Injector Accessories

3.0 OPERATION

Table 3-1. Accessory Application

For Manifold Front Adapter Discharge Push RodInjector Block Support Set Head Cam Extension

53, 71, 92 77-0613 67-6606 ----------- 67-5696 77-0610 -----------92 Marine 77-0613* 67-6606 ----------- 67-5696 77-0610 77-0912149 67-7643 67-6605 ----------- 67-5700 67-6372 67-57088.2 liter ----------- ----------- 67-8525** 67-5696 77-0610 -----------

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OPERATION INJECTOR CALIBRATOR DD5


3.3 CAM CHANGE

NOTE: The DD5 is shipped with Cam77-0610 (for the 53, 71, 92 & 8.2L

injectors) mounted in the cambox.

The following procedure is to be used whenever a cam

change is required.

The cam is held in place on the tapered end of thecamshaft by a 3/4 in. hex nut and 3/4 in. plain washer,and is locked to the shaft by a key. To change the cam:

1. Check that the drive motor is off.

2. Open flywheel cover and raise the hinged lid ofthe cambox.

3. Insert barring tool into a radial hole in flywheel.Rotate flywheel until cam is at maximum lift.

4. Screw the push rod lock (67-5712) onto the pushrod. This will keep the tappet spring compressedto allow the cam change.

NOTE: 67-5712 is part of Basic Accessories77-0585 supplied with the DD5.

5. Rotate flywheel another 1/4 turn.

6. Using a 1-1/8 in. box wrench, unscrew and re-move the nut, washer and cam.

7. Install the correct cam on the camshaft andsecure it with the washer and hex nut.

8. Rotate flywheel so new cam is at max lift. Un-screw and remove the push rod lock.

9. Close cambox lid and flywheel cover.

To find the proper cam for the injector type used,see Table 3-1.

Fig. 3-2. Changing Cams

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

fWrenchcBarring Tool

gCam fNut and Washer

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Fig. 3-4. Manifold

Fig. 3-4A. 92 Marine Assembly

Fig. 3-5. Accessories in Place

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

Make sure cam 77-0610 is installed in the cambox.The drain fitting for manifold block assembly (77-0613) can be positioned in either of two return ports,depending on whether injector to be tested is of the

offset or standard design. The barbed elbow drainfitting is shipped in the position for offset injectors.For standard injectors, install the fitting in the otherport, marked OUT.

The manifold block includes three sets of standoffs: 1.long for low crab injectors, 2. short for high crabinjectors, 3. long for 92 Marine injectors.

The 92 Marine injectors require installation of theSupport Assy and Fuel Connectors to the ManifoldBlock mentioned in Table 3.1 (See Figure 3-4A).

NOTE: The injector must be clampedwhen tappet roller is against the cam basecircle (When the white painted area of the

flywheel is showing in the opening on frontof the flywheel case). In the rare case that

the camshaft stopped with the roller athigh cam, raise flywheel cover and turn

flywheel in either direction. Tappet rollerwill slide down to cam base circle.

A. Manifold

1. Slide the manifold block assembly 77-0613 overthe dowel pins, with the inlet port face up. Thereturn port with the barbed drain fitting shouldbe on the far side in a horizontal position.

2. Install the correct standoffs in the manifold block.

B. Discharge Head

3. Insert the discharge head (67-5696) for 53, 71, 92injectors into the clamp cylinder socket with thequick connect socket facing about 45 toward theconsole.

NOTE: When discharge heads are install-ed for the first time, wet the O ring with

calibration fluid for easier installation.

4. Insert plastic tubing with quick connect pluginto the discharge head socket.

C. Injector

5. Slip front support (67-6606) over rails.

eFront Support cQuick Connect cDischarge Head

aManifold Block aDrain Fitting

bStandoffs Alternate Drain Port

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6. Place the injector in position so the lower bodyrests on top of the semicircular front support67-6606 and the fuel connectors are aligned withtheir ports in the manifold block.

7. Make sure the O rings are in position in themanifold block connectors.

D. Fuel Inlet/Outlet

8. Install male quick connect into inlet port of themanifold block.

9. Push supply hose quick connect over male quickconnect in manifold block.

10. Push one end of the two-foot plastic tubing over90 drain tube (fill tube) 67-5292 and the otherend over the barbed elbow at the OUT port on themanifold.

Quick connect, plastic tubing and fill tube arepart of the calibrator Basic Accessories.

11. Insert the open end of the fill tube into thedrain tray center hole.

E. Injector Clamping

12. Push and hold the HOLD TO OPERATE but-ton with left hand.

13. While holding down the HOLD TO OPERATEbutton, move the CLAMP/UNCLAMP lever tothe CLAMP position with right hand.

14. With the injector clamped, wait until the CLAMPMONITOR timing light goes out (after about 1second).

15. Release HOLD TO OPERATE button and allowthe CLAMP/UNCLAMP lever to return to centerposition.

NOTE:For positive and safe clamping the

above procedure must be followed in thesequence described above.

The injector is now ready for running tests. SeeSection 3.7.

Fig. 3-6. Injector In Place

Fig. 3-7. Clamping Injector

Fig. 3-8. Front Panel

13 CLAMP

12 HOLD TOOPERATE

14 CLAMP MONITOR Light

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3.5 MOUNTING MUI INJECTOR TYPE 149

Make sure cam 67-6372 is installed in cambox.

NOTE: The injector must be clampedwhen tappet roller is against the cam base

circle. (When the white painted area of the

flywheel is showing in the opening on frontof the flywheel case). In the rare case that

the camshaft stopped with the roller athigh cam, raise flywheel cover and turn

flywheel in either direction. Tappet rollerwill slide down to cam base circle.

A. Manifold

1. Place push rod extension (67-5708) over the pushrod.

2. Slide manifold block (67-7643) over the dowelpins with the inlet port face up.

B. Discharge Head

3. Insert the discharge head (67-5700) into theclamp cylinder socket with the quick connectsocket facing 45 toward the console.

NOTE: When discharge heads are install-ed for the first time, wet the O ring with

calibration fluid for easier installation.

4. Insert the plastic tube with the quick connectplug into the discharge head quick connect socket.

C. Injector

5. Slip the front support (67-6605) over the rails.

6. Place the injector in position so the lower bodyrests on top of the semicircular front support67-6605 and the fuel connectors are aligned withtheir ports in the manifold block.

7. Guide the spring and tappet follower of the injec-

tor into the manifold block center bore.

Fig. 3-9. Manifold

Fig. 3-10. Accessories in Place

cDischarge HeadeFront Support dQuick Connect

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8. Install male quick connect into the inlet port ofthe manifold block.

9. Push supply hose quick connect over male quickconnect in manifold block.

10. Push one end of the two-foot plastic tubing over90 drain tube (fill tube) (67-5292) and the otherend over the barbed elbow at the OUT port on themanifold.

Quick connect, plastic tubing and fill tube arepart of the calibrator Basic Accessories.

11. Insert the open end of the fill tube into the draintray center hole.




14. With injector clamped wait until the CLAMPMONITOR timing light goes out (after about 1second).

15. Release the HOLD TO OPERATE button andallow the CLAMP/UNCLAMP lever to returnto the center position.

NOTE:For positive and safe clamping theabove procedure must be followed in the

sequency described above.


Fig. 3-11. Injector In Place


Fig 3-13. Front Panel

13 CLAMP

12 HOLD TOOPERATE


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3.6 MOUNTING INJECTOR TYPE 8.2LITER

Make sure cam 77-0610 is installed in cambox. Injec-tor holder set 67-8525, which includes adapter, twoangle spacers, a spacer block, and an injector holder,is required.

NOTE: The injector must be clamped whentappet roller is against the cam base circle.(When the white painted area of the flywheel

is showing in the opening on front of theflywheel case). In the rare case that the cam-

shaft stopped with the roller at high cam,raise flywheel cover and turn flywheel in

either direction. Tappet roller will slide down

to cam base circle.

A. Spacer Block

1. Attach the spacer block to the cambox over thetwo dowel pins.

NOTE:Make sure the spacer block is flushagainst the push rod guide.

B. Discharge Head

2. Install the discharge head (67-5696) into theclamp cylinder socket with the quick connectsocket facing 45 toward the console.

NOTE: When discharge heads are installedfor the first time, wet the O ring with cali-bration fluid for easier installation.

3. Insert the plastic tube with the quick connectplug into the discharge head quick connect socket.

C. Injector

4. Install the injector into the injector holder byhand pushing until the mounting slots on boththe injector and the holder are aligned.

5. Then secure with the keys straight edge towardsthe injector.

This will prevent the injector from moving outduring testing.

6. Place the injector holder with the injector overthe rails.

Fig. 3-14. Spacer Block and Discharge Headin Place

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

aPush Rod Guide aSpacer Block

Dowel Pin 2Quick Connect bDischarge Head

eKey

dInjector Holder

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7. Install male quick connect plug on top of injectorholder. Then push supply hose quick connectover male quick connect.

8. Attach the two-foot plastic tubing (part of

77-0585) to the barbed elbow at the bottom of theinjector holder.

9. Insert the other end of the tubing into the draintray center hole.




12. With injector clamped, wait until the CLAMPMONITOR timing light goes out (after about 1second).

13. Release the HOLD TO OPERATE pushbuttonand allow the CLAMP/UNCLAMP lever to re-turn to the center position.

NOTE:For positive and safe clamping theabove procedure must be followed in the

sequency described above.


3.7 TESTING

WARNING

Do not open cambox cover while main

drive motor is running. Make sure that the

Flywheel has stopped turning beforeopening cambox cover, to prevent being

splashed by hot lubricating oil.


Fig. 3-17. Front Panel

11 CLAMP

10 HOLD TOOPERATE


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CAUTION

Do not start Main Drive with Supply Hoseconnected to the Manifold Block (or 8.2L

Injector Holder) and with injector notclamped. This will cause calibration fluid

to spray out of the block.

NOTE: When starting the main drive forthe first time, run it for only a few

seconds after pressure develops to make

sure that all fuel connections are tight.

1. With the injector clamped as described previ-ously, and calibration fluid temperaturebetween 99-101F, press the START MAINDRIVE button. As soon as this button isdepressed and the camshaft is turning, makecertain that rail pressure gauge shows 35 psi.

NOTE:If main drive motor wont start,check the flywheel cover. It must betightly closed for the interlock safety

switch to allow the main drive motor tooperate.

2. If necessary, set the fuel pressure (regulatorlocated inside the frame, accessible after thefront doors are opened) so that RAIL PRES-SURE gauge indicates 35 psi.

3. Wait several seconds until trapped air escapes

from discharge head as seen in plastic tubingleading to flow meter.

4. Depress START METER button on the console.The button light will come on.

The fuel delivery display will show cumulativereadings until 100 strokes are completed, thenthe reading will stay on until the next up-date.The readings will be updated automaticallyevery 100 strokes. When starting the machinecold, let the injector run and deliver fluid tothe flowmeter for 30-60 seconds before starting

to record readings.

5. After injector and machine are warmed uprecord the fuel delivery display readings. Thereading is in MM3/STROKE, which is equiva-lent to cc/1000 strokes. To obtain a goodreading take at least 3-5 readings.

6. When testing is complete, press the red STOPbutton on the left hand operators table.

Fig. 3-18. Testing Injectors

aSTART MAIN DRIVEfSTOP

eDisplay of Fuel OutputaFlywheel Cover bRAIL PRESSURE

dSTART METER

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3.8 UNCLAMPING INJECTORS

CAUTION

Before you start unclamping the injectormake sure to wait until the camshaft

comes to complete rest.

Use the unclamping procedure which applies to thetype of injector you are testing; (a) Types 53, 71, 92,or 149 and (b) Type 8.2 liter.

A. Unclamping Injector Types 53, 71, 92, & 149

1. Press and hold the HOLD TO OPERATE button.

2. While holding the button down, move theCLAMP/UNCLAMP lever to the UNCLAMPposition and let the hydraulic cylinder com-pletely retract.

3. Release the HOLD TO OPERATE pushbuttonand allow the CLAMP/UNCLAMP lever to re-turn to its center position.

4. Remove injector.

Fig. 3-19. Unclamping Injectors

bUNCLAMP

a HOLD TOOPERATE

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B. Unclamping Injector Type 8.2 Liters


2. While holding the button down, move the CLAMP/UNCLAMP lever to the UNCLAMP position andlet the hydraulic cylinder completely retract.

3. Release the HOLD TO OPERATE pushbuttonand allow the CLAMP/UNCLAMP lever to re-turn to its center position.

4. Remove key from the injector holder slot anddisconnect fuel supply hose. Slide injector withholder to the right.

5. Place the two angle spacers from the injectorholder set (67-8525) over the rails.


7. While holding the button down, slowly movethe CLAMP/UNCLAMP lever toward theclamp position to gradually extend the clamp-ing cylinder until the injector holder buttsagainst the angle spacers next to the cambox.Continue to hold the CLAMP/UNCLAMP leveruntil the injector pops out of the injectorholder.

8. While still holding the HOLD TO OPERATE but-ton down, move the CLAMP/UNCLAMP lever to

UNCLAMP position to retract the cylinder.

9. Release the HOLD TO OPERATE button andallow the CLAMP/UNCLAMP lever to return tothe center position.

3.9 SHUTTING DOWN CALIBRATOR

1. Turn off power at On-Off Switch/Circuit Breaker.

2. Wipe oil spills and splashes from console andoperators table.

3. Return all accessories to their locations.

Fig. 3-20. Unclamping Injector Type 8.2L

e Angle Spacers

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IMPORTANT NOTE:

The DD5 Calibrator is designed and built to meet all the test requirements imposed by the injectormanufacturer. It incorporates a positive displacement flowmeter which generates digital signals withhigh resolution. This type of system is recognized in the industry to be the most accurate measurementmeans for this application.

Tests conducted at Bacharach, GM - Rochester Product Division and Detroit Diesel Corporation (DDC)indicate that injector output measurements obtained on production-type calibration equipment at GM/RPD may be different from those obtained on other makes and models of calibrators. In particular, it hasbeen determined that Master Injectors marketed by Kent Moore all read higher on Bacharach DD%$Calibrators, by the amount shown below. Therefore, when checking Master Injectors, the fuel output asread on the digital readout of the DD5 Calibrator will be higher than the stamped values by the amountsshown:

Injector Type Difference In Reading (mm3/str)53 2.071 2.592 4.6

8.2L 2.3149 3.9

The recheck limits (as given by DDC) of Master Injectors on any calibrator are 2% of stamped value.As an example for type 71 Master Injector:

Stamped Add Correct Tolerance (2%)Value: Value

72.0 + 2.5 = 74.5 73.0 76.0

Therefore, for a type 71 Master Injector stamped as 72.0, the correct delivery value (fuel output) shouldbe 73.0 - 76.0 mm3/str on a Bacharach DD5 Calibrator.

This information is being provided with the full knowledge and agreement of the Detroit DieselCorporation.

Any questions should be referred to the factory: Bacharach, Inc.621 Hunt Valley CircleNew Kensington, PA 15068Service ManagerTel: 724-334-50000

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INJECTOR CALIBRATOR DD5 MAINTENANCE AND ADJUSTMENT


CAUTION

Do not attempt to make any adjustments

or repairs to the calibrator without first

disconnecting the main power line at thewall.

4.1 MAINTENANCE SCHEDULE

CHECK THESE DAILY:

1. If calibration fluid is low, add enough calibra-tion fluid to bring the level up to the F on thedipstick. Use Bacharach Calibration Fluid67-5598 (15 US Gallon).

2. If cambox oil is lower than 3-3/4 inch from thetop of the cambox, add enough SAE 30W motoroil to bring the level up.

NOTE:Dont overfill, BEARINGDAMAGE may result.

CHECK, CHANGE OR CLEAN THESE EVERYTHREE MONTHS (or after 120 operating hours,whichever occurs first):

1. Calibration fluid - Replace

2. Suction fuel filter - Replace

3. Final stage filter - Replace

4. Flowmeter transducer strainer - Clean

5. Cambox oil - check and replace if necessary

This schedule is only a guideline; maintenance willdepend on the working environment and the clean-liness of the injectors. See the following sectionsfor procedures.

4.0 MAINTENANCE AND ADJUSTMENT

Fig. 4-1. Calibration Fluid Level

Fig. 4-2. Cambox Oil Level

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MAINTENANCE AND ADJUSTMENT INJECTOR CALIBRATOR DD5


4.2 CHANGING CALIBRATION FLUID AND FILTERS

Calibration fluid change periods will depend on thetype of service. Inspect fluid periodically forcontaminants and viscosity. The fluid must bechanged when viscosity is above 3.1 centistokes

(cst) at 100 F (38 C). To check viscosity use ViscorCup (Bacharach P/N 77-0391).

At the same time the fluid is changed, changesupply and final stage filters.

1. Remove the rear panels of the calibrator.

2. Drain the old fluid using the drain valves, oneon each side of the reservoir.

3. Lift the lid of the reservoir and inspect itsbottom. Wipe clean if necessary.

4. Close both drains of the reservoir.

5. Through the dipstick port, fill the reservoir tothe F mark on the dipstick with new fluid.Use Bacharach part number 67-5598.

NOTE:It is a good idea to fasten a tag tothe reservoir giving the date the fluid waschanged.

6. Unscrew the suction filter cartridge from its

header, discard, and replace with a new onefilled with fluid.

7. Unscrew final stage filter cartridge from itsheader, discard, and replace with a new onefilled with fluid.

NOTE:Fasten tags on both filter car-tridges giving the date they were changed.

8. Remove and clean flowmeter transducerstrainer.

Fig. 4-3. Reservoir Drains

Fig. 4-4. Suction Filter

Fig. 4-5. Flowmeter Strainer

hFlowmeter Strainer

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Fig. 4-6. Front View, Doors Open

Fig. 4-7. Flowmeter Cavity

Fig. 4-8. Flowmeter (End View)

4.3 CHANGING CAMBOX OIL

After three months or 120 hours of operationwhichever occurs first, Check for proper level andpossible contamination. If oil change is necessarydrain oil from cambox and refill using the followingprocedure:

1. Open drain plug on bottom of cambox,accessible after left-hand cabinet dooris open, and allow old oil to drain out.

2. Wipe inside of cambox clean.

3. Reinstall drain plug.

4. Fill the cambox with enough SAE 30Wmotor oil to bring the level up to within3-3/4 inch from the top (or about 1-1/2inch from the bottom). See Fig. 4.2.

4.4 CLEANING AND LUBRICATING

The DD5 calibrator will remain in good workingcondition with just ordinary cleaning procedures.It is important, however, to avoid spilling ordropping contaminants into the drain where theycan mix with the calibration fluid. For the samereason, injectors should be cleaned before testing.

The calibrators mechanical parts are largely self-

lubricating and therefore no special lubricatingprocedures are required. Both motors are sealedand lubricated for life.

4.5 REFILLING FLOWMETER CAVITY

1. Turn off power, the piston will not move byhand while power is still on.

2. To locate the assembly, remove the top rearpanel.

3. Move encoder arm/piston assembly in eitherdirection to extreme end of travel.

4. Examine cavity for between 1/4 and 3/8" level(from the bottom of the cavity) of lube oil.

5. Use SAE 30W lube oil to maintain level.

6. Move the encoder arm/piston assembly to theapproximate center of its travel.

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4.6 TROUBLESHOOTING CHARTS

TROUBLESHOOTING CHART FOR MECHANICAL PROBLEMS

Fault Possible Cause and Remedy

Clamp action faulty May lack unlocking pressure - Press HOLD TO OPERATE button and listen

for pump reliefs ("putt" sound).1. If after three putts, cylinder will still not move, there may be insufficient

hydraulic pressure.(a) Check intensifier hydraulic circuit for leaks.(b) Check hydraulic pressure at the cylinder (Section 4.7)

2. If there is noputting, check air pressure gauge for shop air to the calibra-tor and make sure solenoid valve and air release valve are operating.

Calibration fluid 1. Cold water supply may be turned off - Turn on supply.temperature too high 2. Water flow through calibrator may be disrupted - Disconnect return line

with HEATER lamp off at console and observe for presence of water flow.3. Temperature control system may not be operating properly - See Section

1.4 for proper operation.

TROUBLESHOOTING CHART FOR ELECTRICAL PROBLEMS


Motor trips off 1. Motor starter (M1) overload relay trip setting may be too low - Adjustintermittently trip load control to the number calculated by multiplying the service

factor times the motor full load amps (both found on the motor nameplate).

2. Line voltage may be out of specification - Correct line voltage as required.3. Vibration-induced intermittent interlock may be occurring - Check S4, S3,

M1, or M10L (See Figure 5-15B).4. Main motor may be defective - Replace or repair.

Main motor will not 1. Flywheel cover may be open - Close coverstart 2. Interlock switch (S3) may be out of line or defective - Reposition or

replace (Section 4.12)3. Motor starter reset button may have tripped - Reset M1 button (Section

4.8)4. Fuse F-1 (2 Amp) may have blown - Replace (Section 4.9) and investigate

cause.5. STOP button may be defective - Repair or replace

Calibration fluid 1. Fuse F-5 (5 Amp) may be blown - Replace (Section 4.9) and investigate

temperature unstable 2. Temperature controller may be defective - Replace3. Potentiometer R1 may be defective - Replace4. Heaters (HTR1 or HTR2) may be defective - Replace5. Cooling water solenoid may be defective - Replace6. Calibration fluid in reservoir may be low - Increase fluid level7. Temperature Sensor may be defective - Replace8. Temperature Gage may be defective - Replace9. Cooling water supply may be absent - Connect and turn on water supply10. Clamp valve not in neutral - Fix problem

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INJECTOR CALIBRATOR DD5MAINTENANCE & ADJUSTMENT


Flowmeter display 1. Sun shines on transducer (rear panel off) makingoptical detectors inop-inoperative erative - Keep the sun from hitting the transducer.

2. Loose connector - Retighten.

3. Optical detector improperly adjusted or defective - Readjust (Section 4.11)or replace.

4. Bypass solenoid (L8) may be defective - Replace.5. Relay K1 may be defective - Replace.6. Tranducer may be defective - Replace.7. Display P.C. board may be defective - Replace*.8. Main P.C. board may be defective - Replace*.

Erratic flow readings 1. Encoder wheel bent or slots obstructed - Replace or clean as required(Section 4-11)

2. Loose or broken wiring or shields - Replace or repair3. Leak in discharge line including discharge head - Repair4. Electrical noise generated by other shop equipment - Isolate Circuit

Flowmeter display 1. Air in calibration fluid system - Bleed air from Cal. Fluid Bleed Port.indicates flow beyond 2. Optical Detector on camshaft may be defective - Replace (Section 4.11)injector capability 3. Main P.C. board may be defective - Replace*.

Flowmeter displays 1. Connector to main P.C. board may be loose - Reconnectall zeros; will not 2. Flowmeter limit switches may be tripped - Remove power and repositiondisplay flow readings piston adapter block to center of cavity

3. Flowmeter transducer electrical connectors loose - Reconnect.4. Bypass solenoid (L8) may be defective - Replace5. Detector #1 or #2 on flowmeter transducer may be defective - Replace.

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

4.7 HYDRAULIC SYSTEM/INTENSIFIER

A. Checking Hydraulic Pressure

To make sure that sufficient hydraulic pressure isapplied to the hydraulic cylinder locking sleeve:

1. Install a 0-5000 psi gauge at the gauge/bleedport (Fig. 4-9).

2. When holding the HOLD TO OPERATE but-ton, check the pressure reading. Pressure mustbe 3700-4000 psi.

3. If pressure is less than 3700 psi, check for airand hydraulic leats between the hydraulicpump and the cylinder. If over 4000 psi, reducethe air pressure. After removing the gauge,make sure to bleed air from the system andrefill. See Section B below. Fig. 4-9. Front Panel, Table Top

1Gage/Bleed Port 5Bleed Port

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B. Filling Intensifier and Bleeding Air fromSystem

4. Add oil to intensifier reservoir, if necessary(see Section 2.4 & Fig. 2-14).

5. Use 3/16 inch hex to "crack" plug at the bleed

port (Fig 4-9).

6. Press and hold HOLD TO OPERATE buttonand let some oil flow past the loosened plug.

7. Allow air to escape through port until oil flowsfreely.

8. While the oil flows, tighten the plug, thenrelease the button.

9. Use caution to observe that reservoir does notempty during bleeding.

10. Replenish oil in the reservoir immediatelyafter bleeding.

4.8 RESETTING SWITCHES

A. Resetting the Motor Reset Button

In the event of a motor overload condition:

1. Disconnect Main Power to calibrator.

2. Remove the electrical box cover and press themotor reset button (Fig. 4-10).

B. Resetting Flowmeter Limit Switches

If the flowmeter displays all zeros or will notdisplay flow readings, one of the limit switchesmay be tripped (i.e. the piston is stuck in itsextreme position) see Figure 4-11.

3. Remove power by switching the On-Off Switch/circuit breaker to OFF.

4. Reposition flowmeter piston so that theadapter block is centered in the cavity.

5. Restart the calibrator (with injector deliveringfluid).

6. If the flowmeter again displays all zeros or willnot display flow readings, check the opticaldetectors. They may have to be cleaned orreplaced.

Fig. 4-10. Main Motor Reset

Fig. 4-11. Limit Switches

Limit Switches

fOptical Detectors

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

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

7. Restart the calibrator. If the flowmeter stillwill not work, check the main circuit board. Itmay have to be replaced.

4.9 CHANGING FUSES (Figure 4-12, 4-13, and 5-15)

NOTE:Disconnect Main Power to cali-brator before removing panels.

F-1 (2 Amps): This fuse is in the main power circuitfor all control circuits. If this fuse blows, theoperators console will indicate the following:

Power Indicator (Red): ONHeaters Indicator (Amber): ON or OFFLED Display (Red Dot): OFF

All Clamping Functions: OFFMain Drive Start: OFF

F-3/F-4 (4 Amps): Both fuses F-3 and F-4 are forspecial voltage options for 380 and 460 VACoperation. These fuses control input to Trans-former T-3. If either fuse blows, the operatorconsole will indicate the following:

All power: OFF

F-2 (0.4 Amps): This fuse controls the flowmetertransducer circuit. If fuse blows, the operatorsconsole will indicate the following:

Power Indicator (Red): ONHeaters Indicator (Amber): ON or OFFLED Display (Red Dot): OFF (blank)Main Drive Start: ONFlowmeter Transducer piston: Inoperative

F5 (5 Amps): This fuse controls the calibrationfluid heaters circuit. If this fuse blows, the follow-ing will be effected:

Heater power: OFFCooling water supply circuit power: OFF

Heater lamp DS1 (Amber) on theoperators console: OFF

F1 F3 & F4 (Hidden)

F2 F5

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4.10 ADJUSTING AIR PRESSUREREGULATOR

Required air pressure is set at the factory toproduce the correct pressure for unlocking thehydraulic cylinder.

1. Check regulator setting. It must be 60 +5 0psi (4.1 bar). The air pressure regulator isbehind the lower rear panel.

2. To adjust air pressure regulator, lift the redring above the regulator adjustment ring.

3. Hold the ring up while adjusting.

4. Push the red ring back down to lock thesetting.

4.11 ADJUSTING OPTICAL DETECTORON CAMSHAFT

The optical detector (60-7000) is mounted on across bar of the table top on the underside of theencoder wheel (67-6414). The encoder wheel is athin disk which passes through a slot in thedetector.

1. If the encoder wheel rubs the sides of the slotin the detector, loosen the four screws thatsecure the cross bar to the table top.

2. Adjust the detector forward or back until theencoder wheel rides through the center of theslot.

4.12 ADJUSTING FLYWHEEL COVERINTERLOCK

1. Loosen the two screws that secure the switchto the rear cover.

2. Adjust Interlock Microswitch position so that

the switch is actuated when the flywheel coveris closed.

Fig. 4-14. Air Pressure Regulator

Fig. 4-15. Inside Flywheel Cover

Fig. 4-16. Flywheel Cover Interlock

bInterlock Microswitch

Optical Detector

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4.13 REPLACING DRIVE BELT

In the rare case that the drive belt must be re-placed:

NOTE:Turn off Main Power tocalibrator.

1. Switch the On-Off Switch/Circuit Breaker tothe OFF position.

2. Lift the flywheel cover.

3. Open the hinged side door.

4. Remove the two hex head cap screws thatsecure the optical detector assembly to itssupport angle and carefully slide the opticaldetector assembly away from the encoder

wheel.

5. Carefully slip new drive belt over encoderwheel and onto camshaft pulley.

6. Loosen the four hex head cap screws thatsecure the drive motor to its support plate.

7. Slide drive motor toward left side of calibratoruntil it is possible to slip drive belt onto themotor pulley.

8. Adjust the belt fit by sliding the drive motor to

the right side of the calibrator. The belt shouldbe installed with a snug fit, neither too tightnor too loose. The belts positive grip eliminatesthe need for initial tension.

9. With the belt fitted as above and the pulleysaligned with each other, tighten the four hexhead cap screws securing the drive motor to itssupport plate.

10. Reinstall the optical detector assembly to itssupport angle and slowly rotate the encoderwheel making sure that it does not rub the

optical detector assembly on either side.

11. Close the flywheel cover and switch the On-OffSwitch/Circuit Breaker to ON.

12. Operate the Calibrator and check for correctpulley and belt alignment.

Fig. 4-17. Replacing Drive Belt

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4.14 ADJUSTING CALIBRATION FLUIDTEMPERATURE

The calibration fluid temperature is factory set at99 F-101 F. This range is recommended by DDA.If necessary the temperature may be adjusted bythe following procedure:

1. Turn ON Calibrator and allow the heaters towarm the calibration fluid as indicated by theHEATER indicator light being on.

NOTE:It will take 20-30 minutes for theimmersed heaters to bring the calibration

fluid up to the preset temperature range.

NOTE:Make certain to loosen potentio-meter locknut before adjustment and

retighten after the desired temperature isindicated on the panel mounted gauge.

2. After HEATER indicator has extinguished,loosen locknut and adjust TEMPERATUREcontrol potentiometer, (Fig. 4-18), to therequired temperature. DO NOT turn thepotentiometer very far. One complete turnequals approximately a 45 F change, 1/8 turnfor a 5.5 F temperature change. Turn CW toincrease and CCW to decrease temperature.

3. Allow the automatic temperature controlsystem sufficient time to bring calibraion fluid

to the new temperature setting. Note thetempeature gauge reading and make any fineadjustments necessary to achieve the requiredset point. Wait until heater indicator cycles ONand OFF at least two times before tighteningthe adjustment locknut.

4.15 MOTOR STARTER OVERLOADRELAY ADJUSTMENT

1. Find the operating volts located on the name-plate of the calibrator.

2. Locate the FLA (Full Load Amps) and SF(Service Factor) for the corresponding voltage,which can be found on the main drive motornameplate.

Fig. 4-19. TEMPERATURE ControlPotentiometer

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3. The maximum dial setting on the MotorStarter Overload Relay is calculated by multi-plying the FLA value times the SF. Turn theoverload adjustment dial to that setting.

4. Set the A (auto), H (hand) switch to H (un-locked position).

4.16 FLOWMETER TRANSDUCERREPLACEMENT

The flowmeter transducer assembly (67-7650) is aprecision instrument, and is non-repairable in thefield. If troubleshooting indicates a problem withthis Unit, replace it by performing the followingsteps:

1. Disconnect the flexible tubing at both quickdisconnects.

2. Disconnect the electrical connectors.

3. Remove the four bolts, washers and nuts thatsecure the base of the transducer to the consolebase through vibration mounts. Then carefullyremove the transducer.

4. Install a new or rebuilt unit following thepreceding steps in reverse order.

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NOTES

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INJECTOR CALIBRATOR DD5 PARTS LISTS AND DIAGRAMS


5.0 PARTS LIST AND DIAGRAMS

5.1 BASIC ACCESSORIES

The following items are part of 77-0585 (Fig. 5-1)

Part # Qty Description

05-4516 1 Key, Woodruff (spare)03-6063 2ft Tubing, Tygon 3/8 x 1/4 ID77-0568 1 Paint, Azure Blue77-0569 1 Paint, Midnight Blue67-6469 1 Barring Tool77-5712 1 Push Rod Lock67-5292 1 Fill Tube

5.2 INJECTOR ACCESSORIES

The following items are part of 77-7013 (Fig. 5-2)

103-5400 3 Quick Connect Plug 1/8 NPT (Not Shown)

67-2431 1 Seal, Discharge Head67-5696 1 Discharge Head (53, 71, 92)67-5697 1 Seal, Discharge Head67-5700 1 Discharge Head (149)67-5708 1 Push Rod Extension (149)67-6372 1 Cam (149)67-6605 1 Front Support (149)67-6606 1 Front Support (53, 71, 92)

67-7643 1 Manifold Block Assy (149)77-0613 1 Manifold Block Assy(53, 71, 92)

67-8525 1 G.M. 8.2L Accessories06-6826 4 Pegboard Hooks06-6828 4 Pegboard Hooks (One Shown)05-5109 6 O-Ring, Manifold Block05-5113 6 O-Ring, Manifold Block77-0866 2 Fuel Connector (92 Marine [NS])77-0912 1 Push Rod (92 Marine [NS])77-0913 2 Support Ass'y (92 Marine [NS])

NOTE:The DD5 is shipped with Cam

77-0610 (for the 53, 71, 92 & 8.2L injectors)mounted in the cambox.

Fig. 5-1. Basic Accessories

Fig. 5-2. Injectors Accessories

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PARTS LISTS AND DIAGRAMS INJECTOR CALIBRATOR DD5


5.3 SPARE PARTS LIST

This list contains parts that may fail after extended use, and can be purchased through outside vendors.Use thediagrams in Section 5.6 to locate the Figure # and I.D.# (in balloons), and reference that numberto this list for the Bacharach part number, or a common vendor and part number.

Fig.#/ Bacharach Description System/ Vendor VendorID# P/N Location P/N

5-3/144 03-1535 Male Conn. 1/4 NPTx1/4 Tube Various Superior U1-4B5-3/297 03-2912 Nilo-Seal, Flexible, 1/4 OD Various Imperial Eastman 44-NF5-3/298 03-2913 Nilo-Seal, Flexible, 3/8 OD Various 66-NF5-3/299 03-6355 Nilo-Seal, Semi-Rigid, 1/4 OD Various Imperial Eastman 44-SN5-3/301 03-5105 Hose, Low Press., Rubber #4 Various Aeroquip 2556-45-3/302 03-5106 Hose, Low Press., Rubber #6 Various 2556-65-3/303 03-5108 Hose, Low Press., Rubber#10 Various 2556-105-3/305 03-5118 F. Swivel Fit., 7/16-20 1/4 Hose Various 4797-4B5-3/306 03-5120 F. Swivel Fit., 5/8-18 3/8 Hose Various 4739-6B5-3/307 03-5121 F. Swivel Fit., 9/16-18 3/8 Hose Various 4741-6B5-3/308 03-5125 F. Swivel Fit., 7/8-14 5/8 Hose Various 4797-10B5-3/313 03-6013 Hose Low Press. Clear #6 Various Food & Beverage Type B-44-35-3/315 103-5399 Quick Disconnect Socket Various Hansen Mfg. 3000-1/4 NPT

5-4/1 67-2643 Gasket Cal. Fluid Bacharach, Inc. --5-4/2 67-5426 Reservoir Heater (240 Volt) Bacharach, Inc. --5-4/3 67-6141 Temperature Sensor Bacharach, Inc. --5-4/4 67-6170 Thermostat Bacharach, Inc. --5-5/1 67-3443 Pressure Gauge (0-160 psi) Bacharach, Inc. --5-5/2 77-0597 Manifold Block Bacharach, Inc. --5-5/7 03-4052 Pilot Operated Check Valve Snaptite CAV 10-N2P-15 A5-5/8 03-4173 Adjustable Relief Valve Norgren V12-400-NNL5-5/15 104-0586 Pressure Switch Sigma-Netics Inc. 723-VQ6R-70N5-6/8 03-4233 2-Way Cal. Fluid Skinner-Lancer 705N3A1A5-6/9 03-6063 Tygon Tube (F4040), 1/16wall Various ASCO 1/4 ID, 3/8 OD5-6/14 07-1636 Filter Element, Final Stage P/O 07-1635* LHA Inc. SPE50-35-7/3 67-6902 Gear Pump Cal. Fluid Bacharach, Inc. --5-7/14 03-4180 Relief Valve Sun Hydraulics RPEC-JEN-FEA

5-7/17 04-3993 Motor 1/3 HP, 230V, 60Hz Dayton 5K6025-7/18 04-3995 Motor 1/3 HP, 220V, 50 Hz General Electric 5KH36LN488(G)X5-7/19 05-3400 Flexible Coupling T. B. Woods 3J5-7/20 05-3450 Coupling Sleeve T. B. Woods 3JE5-7/23 06-6205 Pressure Gauge (0-300 psi) U.S. Gauge 1460065-8A/155 03-4173 Adjustable Relief Valve Pump & Motor Norgren V12-400-NNL5-8A/158 03-4222 2-Way Solenoid Valve Cooling Water Skinner V52DA2077,5-8/190 04-4109 Motor 5 HP (60 Hz) Electrical U.S. Motor E6585-8A/191 05-2121 Timing Belt 50 Hz Standard Parts 480H1005-8A/196 04-4078 Motor 5 HP (50 Hz) U.S. Motors --5-8A/198 05-2114 Timming Belt 60 Hz Standard Part 450H1005-8B/33 67-6430 Intensifier Assy Cal. Fluid Bacharach, Inc. --5-8B/236 07-1576 Air Press. Regulator Norgren B07-202-A1KAU5-8B/237 07-1618 Filter Element. Suction P/O 07-1617* Michigan Fluid Pwr. S-285-9/9 60-7000 Optical Detector Assy Cal. Fluid Bacharach, Inc. --5-9/28 67-6416 Directional Control Valve Bacharach, Inc. --5-9/16 104-0534 Switch Electrical General Electric CR104A81155-9/19 104-0540 Switch Pushbutton (Red) Allen Bradley 800T-B6M5-10/15 104-0524 Switch Arrow Hart OB-A-15-10/17 104-0536 Alco Switch T2125(9)5065-10/18 104-0537 N. O. Contact Block F-505-10/18 67-6205 Dial Thermometer (40-100 F) Bacharach, Inc. --5-10/50 67-6779 Pressure Gauge (0-100 psi) Bacharach, Inc. --5-10/51 76-6910 Main P.C. Board Assy Bacharach, Inc. --5-10/61 77-0586 Display P.C. Board Assy Bacharach, Inc. 5-10/71 204-4593 Potentiometer, 6 Ohm, 4 Watt Clarostat 58C2

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INJECTOR CALIBRATOR DD5 PARTS LISTS AND DIAGRAMS


Fig.#/ Bacharach Description System/ Vendor VendorID# P/N Location P/N

5-10/187 04-3520 Lamp, 28V Electrical Standard Part ASA #7575-10/188 04-3584 Neon Lamp AMP 380628-25-10/189 04-3585 380628-45-10/192 04-3591 , Amber 380627-45-10/194 04-3795 Hour Meter, 60 Hz Stemco Inst. 710-00735-10/195 04-3796 Hour Meter, 50 Hz 710-00335-10/267 104-2003 Transformer Stancor P-63775-11/4 67-7650 Transducer Assy Bacharach, Inc. --5-11/9 04-5187 Relay, 120V, 60Hz (3PDT) Potter Brumfield KVP14A95-120V5-11/10 04-5255 Relay, 120V, 60Hz (Delay) CLA-43-700015-11/156 03-4213 3-Way Solenoid Valve ASCO 8320B130 24/605-11/159 03-4254 Strainer (Complete) ASCO 8600A15-11/181 04-2649 Fuse - 0.4 A Bussman Mfg. MDL - 4/105-11/182 04-2715 Fuse - 5 A MDA - 55-12A/17 67-6142 Temperature Controller Bacharach, Inc. --5-12A/267 See 5-10/2675-12B/All See 5-10/Same ID #5-12C/9 60-7000 Optical Detector Assy Bacharach, Inc. -5-12C/158 See 5-8A/158

5-12C/260 104-0486 Limit Switch Micro Switch BZ-2R0-A25-12D/4 See 5-11/45-12D/156 See 5-11/1565-13A/46 67-6548 High Pressure Fuel Line Bacharach, Inc. --5-13A/18 See 5-10/185-13A/All Others See 5-3/Same ID #5-13B/All See 5-3/Same ID #5-14/All See 5-3/Same ID #5-18/3 404-2709 Fuse 2A Little Fuse Inc. MDA-25-18/4 404-2717 5A Bussman Mfg. FNQ-55-18/6 104-1946 Transformer 330/400/416 General Electric 9T51B1715-18/7 104-1944 Transformer 230/460, 50/60Hz Westinghouse Elect. MTC1F08955-18/8 104-1906 Transformer 240/480, 60Hz General Electric 9T51B115-18/9 104-1913 Transformer 240/480, 50/60Hz 9T51B511

5-18/16 04-1308 Circuit Breaker THQC2115WL5-18/41 104-0089 Starter 208/230V A.E.G. XLS27-A-0-N5-18/42 104-0090 Starter 460V A.E.G. XLS175-A-0-L-

AX-NC * P/O = Part of

5.4 ASSEMBLY DRAWING LIST

Fig.# Page Description Fig.# Page Description

5-3 Index5-3 5-4 Tubing & Hose List 5-12C 5-32 Electrical Wiring Connections

5-4 5-5 Calibration Fluid Reservoir Assy 5-12D 5-16 Electrical Wiring Connections5-5 5-6 Clamping System Assy 5-13A 5-18 Calibration System Interconnections5-6 5-7 Secondary Fuel (Filter Stage) Assy 5-13B 5-19 Calibration System Interconnections5-7 5-8 Calibration Fluid Pump & Motor Assy 5-14 5-20 Pneumatic & Water Interconnections5-8A 5-9 Front & Left Side Views 5-15A 5-21 Electrical Diagram5-8B 5-10 Front & Left Side Views (View C-C) 5-15B 5-22 Electrical Diagram5-9 5-11 Top View 5-15C 5-23 Electrical Diagram5-10 5-12 Front View (Top Panel) 5-16 5-24 Fluid & Pneumatic Diagram

5-11 5-13 Rear View (Top Panel) 5-17 5-25 Calibration Fluid System Diagram

5-12A 5-14 Electrical Wiring Connections 5-18A 5-26 Electrical Control Box

5-12B 5-15 Electrical Wiring Connections 5-18B 5-27 Electrical Control Box

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Documents

77-9075 DD5