® INSTRUCTION 77-9045 AUDIT PROCEDURES FOR INJECTOR CALIBRATOR CD3 USING CD3 AUDIT KIT Part Number 67-7707 Installation/Operation/Maintenance Rev. 1 - February, 1994 Bacharach, Inc. Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 800-736-4666 • Website: www.bacharach-inc.com • E-mail: help@bacharach-inc.com Printed in U.S.A.
WARRANTY Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material and manufacture and will conform substantially to Bacharach Inc.’s applicable specifications. Bacharach’s liability and Buyer’s remedy under this warranty are limited to the repair or replacement, at Bacharach’s option, of this Product or parts thereof returned to Seller at the factory of manufacture and shown to Bacharach Inc.
CONTENTS Warranty Contents ............................................................................................................................................ i Important Notes .................................................................................................................................... ii l.0 1.1 1.2 1.3 1.4 Introduction .................................................................................................................................
IMPORTANT NOTES RELIEF VALVE l. CROSS FITTING Before auditing your CD3 calibrator, determine whether or not your calibrator has a relief valve to adjust the injector supply pump pressure. CD3 calibrators manufactured after November 1984 incorporate this valve. See photograph at right. The relief valve fits on the end of a length of plastic tubing leading from a brass cross fitting at the injector supply pump.
CD3 AUDIT KIT 1.0 INTRODUCTION INTRODUCTION The Bacharach Injector Calibrator Model CD3 calibrates and tests mechanical unit injectors manufactured by Diesel Technology Corporation (used in Detroit Diesel engines (DD)) and by Cummins Engine Company. The CD3 has been adjusted, set, and tested at the factory to ensure accurate test results. It is a precision machine and must be handled accordingly.
INTRODUCTION CD3 AUDIT KIT The test and measurements that can be performed with the Audit Kit are: • Calibration fluid viscosity • Calibration fluid temperature • Injector supply gear pump pressure • Injector supply inlet pressure • Body-to-seat clamping force • Plunger-to-body clamping force • Discharge head performance • Flowmeter performance Additional tests needed for a complete audit are: • Speed check of the calibrator camshaft • Stroke count check • Plow test using DD master in
CD3 AUDIT KIT INTRODUCTION • Digital tachometer (hand held). Photo-electric unit preferred, mechanical (contact type) acceptable (readability: ±1 digit) • Cummins injector, flow code 178A • Master injector kit, Kent Moore part no. J-26298 (53,71,149) • Master injector, Kent Moore part no. J-29898 (8.2L) • Two fresh 9 volt alkaline batteries Duracell M1604, Eveready 522 or others meeting NEDA1604A specifications). Operating life of the batteries is approximately 6 continuous hours.
INTRODUCTION CD3 AUDIT KIT 3. Replace fluid and filters in the calibration fluid system. NOTE: Save approximately 2 quarts of calibration fluid from the same batch as fluid in step 3. Store in a clean container to use when checking viscosity (Section 2.2). 4. Make sure all calibration fluid lines are intact and clean. 5. Replace any worn components such as belts, pulleys, and couplings. 6. Check and fill, if necessary, the lube oil in the air-driven hydraulic pump. 7.
CD3 AUDIT KIT 1.4 INTRODUCTION PRE-AUDIT CHECKLIST All responses to the following checklist should be “YES”.
INTRODUCTION CD3 AUDIT KIT NOTES Page 1-6 Bacharach, Inc.
CD3 AUDIT KIT 2.0 CUMMINS INJECTORS CUMMINS INJECTORS This section describes procedures designed to adjust the CD3 for accurate testing of Cummins injectors. These procedures must be performed in the sequence listed here. After doing the viscosity check (Section 2.2), complete the rest of the procedures while the fluid and the machine are warm. While performing these procedures, be certain all fluid connections for each test are intact. 2.
CUMMINS INJECTORS CD3 AUDIT KIT Test 5. Set up the calibrator for running a Cummins 3/8 PTD (or similar) injector per the CD3 calibrator instruction manual. 6. Turn circuit breaker on side of calibrator ON. 7. Press the START button. 8. Aim tachometer lightbeam at perforated window and read RPM. (Consult tach. instructions if any problems with reading occurs.) 9. Record reading. 10. Press the STOP button. Figure 2-1. Using Tachometer ËCAMSHAFT æCENTER HOLE 11. If RPM is 1050 ±1 rpm, skip to step 13. 12.
CD3 AUDIT KIT CUMMINS INJECTORS 5. Remove wire in center terminal of the switch and reconnect it to right terminal screw of switch (as viewed from rear of the calibrator). ÑTACHOMETER Test 6. Set up calibrator for running a Cummins 3/8 PTD (or similar) injector per the CD3 calibrator instruction manual. WARNING HAZARDOUS ROTATING EQUIPMENT. Do not reach over the pulley to operate the START or STOP buttons. Walk around to the front of calibrator.
CUMMINS INJECTORS CD3 AUDIT KIT d. If problems still exist, check the drive shaft, pump shaft or motor shaft binding and replace necessary parts. ÛOPEN ½ INCH 14. If speed is normal, turn circuit breaker OFF. 15. Reinstall the wire on the interlock limit switch in its original position at the center screw. 16. Reinstall the pulley cover. 17. Turn the power switch on the side of the calibrator to ON. 18. Push the START MAIN DRIVE button on the front of the calibrator. 19.
CD3 AUDIT KIT CUMMINS INJECTORS 2. Immerse the Viscor cup and temperature transducer in the fluid in the container. 3. Allow a minimum of one hour for the temperature of the fluid, cup, and transducer to stabilize at room temperature. 4. Connect the temperature sensor cable to the clamp force and temperature indicator. Test 5. Follow the instructions supplied with the Viscor cup. 6. Return contents of the container to the fuel reservoir, clean the equipment and return the items to the Audit Kit case. 7.
CUMMINS INJECTORS CD3 AUDIT KIT ÐTEMPERATURE æ104° F 4. Set up calibrator for a Cummins PTD injector. (See the CD3 calibrator instruction manual.) 5. Install a Flow code 178A injector. 6. Operate the calibrator for 15 minutes. Test 7. After 15 minutes, turn on the clamp force and temperature indicator and observe the temperature of the fluid. It should be 104°F ± 1°F, while the injector is running. 8. If the clamp force and temperature indicator plus the temperature gauge read the same (104°F ± 1°F): a.
CD3 AUDIT KIT CUMMINS INJECTORS b. Hold the pointer with your fingers and adjust the pointer screw to read the same as the clamp force and temperature indicator. c. Replace the gauge cover. NOTE: When set properly, temperature indicator and temperature gauge will read the same (within ± 1°F). 14. If the temperature varies more than ± 1°F: a. Check the calibration fluid level. It should be at FULL on the dipstick. b. Check the water flow at the water outlet.
CUMMINS INJECTORS CD3 AUDIT KIT Equipment Required • ËHIGH PRESSURE æLINE Test gauge set Set-up 1. Remove the injector, push rod link, and push rod extension. 2. Open the door on the left side of the calibrator. 3. Connect the test gauge set to the high pressure line quick connect. The fitting is located at the pump driven by the main drive motor shaft. 4. Close the valve on the test gauge (black handle across valve body). NOTE: Be certain that the test gauge hose does not interfere with drive belts.
CD3 AUDIT KIT CUMMINS INJECTORS 11. If, after rerun, pressure is not between 400 and 410 psi, adjust the relief valve: ÐOPEN VALVE a. Stop the main drive motor. b. Open the valve on the test gauge set. c. Follow the clear plastic tubing from the fitting at the high pressure pump to the calibration fluid tank under the calibrator. d. Lift the pressure relief valve (on the end of the plastic tubing) out of the reservoir. e. Adjust the set screw from the open end of the relief valve with a 5/32 in.
CUMMINS INJECTORS CD3 AUDIT KIT Three tests need to be performed on the discharge head: • • • Upstream leakage Pressure drop Downstream leakage Equipment Required (for All Three Tests) • • • • • Test gauge set Dummy injector Connecting tubing with quick connects Splash shield cup with hose Stopwatch 2.5.1 Upstream Leakage Test Set-up ÊFLOWMETER æTUBING 1. Unclamp the body from the seat, if clamped. 2. Disconnect flowmeter tubing from the top of the discharge head. 3.
CD3 AUDIT KIT c. CUMMINS INJECTORS If pressure is still low after checking out the gauge, there must be a leak. Find and correct it before continuing with the procedure. 10. If pressure is between 400 and 410 psi: a. Check for external leakage of discharge head, especially around the adjustment screw, and sealing nut. NOTE: Older Units contain a locknut and metal-rubber sealing washer, these should be replaced with the new sealing nut supplied with the Audit Kit.
CUMMINS INJECTORS CD3 AUDIT KIT 4. Install the dummy injector. 5. Clamp the dummy injector body to the seat. 6. Connect the test gauge set to the quick connect fitting on the right side of the dummy injector. 7. Close the valve on the test gauge set. 8. Start the main drive. (Push the START MAIN DRIVE button.) Test 9. Open the pressure test gauge set valve completely. Pressure should be 150 psi +20, -0 psi with fluid flow down through the outlet fitting.
CD3 AUDIT KIT j. CUMMINS INJECTORS Tighten the sealing nut while preventing the Allen screw from moving. 12. Reinstall the discharge head and dummy injector. 13. Reclamp the injector body to the seat. 14. Start the main drive (push the START MAIN DRIVE button). 15. Recheck pressure drop as in step 9. 16. If pressure is not within limits, repeat Steps 11 through 15 (except for replacing the sealing nut on the discharge head). 17. Stop the main drive (push the STOP button). 18.
CUMMINS INJECTORS CD3 AUDIT KIT 8. Record the time for the pressure to drop from its highest reading to 150 psi. 9. If the pressure does not drop below 150 psi in more than 30 seconds, skip to step 11. 10. If the pressure drops below 150 psi in less than 30 seconds: a. Check for leaks at sealing surface between dummy injector cone and discharge head. b. If leaks are not evident, replace discharge head. 11. Disconnect the connecting tubing from the dummy injector. 12. Disconnect the test gauge set. 13.
CD3 AUDIT KIT CUMMINS INJECTORS Equipment Required • • • • • Cummins Flow code 178A injector Graduated cylinder Container Stopwatch Paper and pencil Set-up 1. Remove lower rear panel. 2. Install and run the injector per the CD3 calibrator instruction manual. 3. Locate flowmeter return tubing. Pull the tubing out of the reservoir, and direct the fluid flow into the container. ÐSELECT 50 æSTROKES 4. Start the main drive motor. 5. Set the RAIL PRESSURE gauge to exactly 100 psi. 6.
CUMMINS INJECTORS CD3 AUDIT KIT 15. Read and record the contents of the graduate while it is sitting on a level surface. Be sure to read the bottom of the meniscus. 16. Repeat the test three times, cleaning the graduate for each test. Although the graduate scale is in ml or cm³ (cc) and the flowmeter display indicates mm/stroke, the numbers should be within ±5. ×READ BOTTOM OF MENISCUS For examples if the average display reading is 150.3 mm/stroke, the graduate reading should be between 145.3 and 155.
CD3 AUDIT KIT CUMMINS INJECTORS 6. While holding the HOLD TO OPERATE button, push the BODY TO SEAT CLAMP button on the right hand side operator’s control panel. NOTE: The BODY TO SEAT clamp monitor located on gauge panel will appear green when the body to seat clamp is engaged. 7. Release both buttons. 8. To unclamp the load cell, press the yellow button on the left hand side of the operator’s control panel. Test 9. Turn on the clamp force and temperature indicator. 10. Clamp the body to the seat. 11.
CUMMINS INJECTORS 2.8 CD3 AUDIT KIT PLUNGER TO BODY CLAMP FORCE TEST The plunger to body clamping force simulates the force by which the Cummins injector is held in the engine. This force has an influence on the flow output of the Cummins injector. The lower the force, the higher the injector output and vice versa. The influence varies with the type of injector and deviation from the required force.
CD3 AUDIT KIT CUMMINS INJECTORS 8. Release the HOLD TO OPERATE button and allow the lever to return to the center position. 9. Repeat steps 2 through 8 (clamping and unclamping) five times. 10. Connect load cell assembly to the clamp force and temperature indicator and turn on display. Test 11. Clamp the plunger to the body. 12. Record the reading on the clamp force and temperature indicator after 2 seconds. ×ADJUST æCLAMP FORCE 13. Unclamp the plunger from the body. 14.
CUMMINS INJECTORS CD3 AUDIT KIT 17. Remove the load cell assembly and turn off the clamp force and temperature indicator. 2.9 INJECTOR SUPPLY PRESSURE The injector inlet pressure of 100 psi (for Cummins injectors) has the greatest effect on injector output flow of all test parameters. The higher the inlet pressure, the higher the injector fuel output.
CD3 AUDIT KIT CUMMINS INJECTORS 12. Purge air from the line and tester by momentarily depressing the bleeder valve pin (quick connect) located 90° from the fluid inlet. Test NOTE: During the test, keep the weight (top portion of the dead weight tester) spinning to reduce friction and increase accuracy. Be certain no leakage occurs around the fuel arm connection to the dummy injector. 13. Slowly turn PRESSURE REGULATOR knob clockwise until the dead weight begins to rise. 14.
CUMMINS INJECTORS CD3 AUDIT KIT 23. Repeat steps 21 and 22 two more times and take the average of the three readings. It must be between 176 and 179 cc(ml). 24. If volume is below 176 cc(ml), check for obstruction in the orifice located in the dummy injector or for a leak in the supply system. 25. Stop the calibrator (with the STOP button.) 2.10 STROKE COUNT CHECK The following test is a verification that each update occurs after the prescribed number of strokes 50 or 100).
CD3 AUDIT KIT 3.0 DETROIT DIESEL INJECTORS DETROIT DIESEL (DD) ENGINE INJECTORS All the procedures described in this section are necessary to ensure accurate testing of Diesel Technology Corp. injectors used in Detroit Diesel engines (commonly refered to as DD injectors). 3.1 CALIBRATOR RPM TEST This test ensures that the injectors are driven at the correct speed. Because the main motor is synchronous, the speed of the camshaft depends only on the incoming power frequency and the belt rating.
DETROIT DIESEL INJECTORS CD3 AUDIT KIT Test 7. Aim tachometer lightbeam at the perforated window and read RPM. (Consult the tachometer instructions if any problems with the reading occurs.) 8. Record reading. 9. Press the STOP button. 10. If RPM is 2000 ±5 rpm, skip to step 12. 11. If RPM is not 2000 ±5 rpm: a. Make sure the motor matches the line frequency (see specifications on the nameplate inside left side door). ËCAMSHAFT æCENTER HOLE b.
CD3 AUDIT KIT DETROIT DIESEL INJECTORS 5. Remove the wire on the center terminal of the switch and reconnect it to the right terminal screw of the switch (as viewed from the rear of the calibrator). ÒTACHOMETER 6. Set the main drive belt for testing DD injectors. 7. Set up the calibrator for running a DD injector test as per the CD3 instruction manual. WARNING HAZARDOUS ROTATING EQUIPMENT. Do not reach over the pulley to operate the START or STOP buttons. Walk around to the front of calibrator.
DETROIT DIESEL INJECTORS CD3 AUDIT KIT 16. Reinstall the wire on the interlock limit switch in its original position, at the center screw. ÜOPEN ½ INCH 17. Replace the pulley cover. 18. Turn the power switch on the site of the calibrator to ON. 19. Push the START MAIN DRIVE button on the front of the calibrator. 20. While the calibrator is operating, open the pulley cover. NOTE: For older units use a sliding pulley cover, slide the cover 1/2 inch toward the back of the stand.
CD3 AUDIT KIT DETROIT DIESEL INJECTORS Skip this test if you have already done it for Cummins injectors, otherwise follow the procedure in Section 2.8. 3.6 DD MASTER INJECTOR FLOW TEST Equipment Required • • Master injectors, Kent Moore part J26298 for 53, 71, and 149 injectors Master injector, Kent Moore part J29898 for 8.2L injector Set-up 1. Set up the calibrator to run DD injectors following the procedures given in the CD3 Instruction Manual. Figure 3-5. DD Master Injectors Test 2.
DETROIT DIESEL INJECTORS CD3 AUDIT KIT The recheck limits (as given by DDC) of Master Injectors on any calibrator are ±2% of stamped value. As an example, for the type 71 Master Injector: Stamped Value 72.0 + Add 2.5 = Correct Value 74.5 Tolerance (2%) 73.0 - 76.0 Therefore, for a type 71 Master injector stamped as 72.0, correct delivery value (fuel output) should be 73.0-76.0 mm³/str on a Bacharach CD3 Calibrator.
CD3 AUDIT KIT DETROIT DIESEL INJECTORS Test ÍDISPLAY 5. Using the stopwatch, note the time between flashes of the strokes indicator which appears in the MM³/STROKE display. The flashes should be at 3.0-second intervals. 6. Repeat step 5 three times. 7. If the stroke interval average is not 3.0 seconds consult the CD3 manual. 8. Turn off the main drive. (Push the STOP button.) ÊSTROKES SET TO 100 Figure 3-6. Stroke Count Check Instructions 77-9045 Bacharach, Inc.
DETROIT DIESEL INJECTORS CD3 AUDIT KIT NOTES Page 3-8 Bacharach, Inc.
CD3 AUDIT KIT 4.0 POST AUDIT CHECKLIST POST AUDIT CHECKLIST Checklist for completed audit YES NO Calibration fluid viscosity is per chart supplied with the Viscor cup. _____ _____ Calibration fluid temperature is 104°F + 1°F. _____ _____ Gear pump pressure is between 400 and 410 psi. _____ _____ Body to seat clamp force is more than 167 lbs. _____ _____ Plunger to body clamp force is 380 lb ± 10 lbs. _____ _____ Injector supply pressure is exactly 100 psi.
POST AUDIT CHECKLIST CD3 AUDIT KIT NOTES Page 4-2 Bacharach, Inc.
CD3 AUDIT KIT PARTS LISTS 5.0 SPARE PARTS 5.1 MAJOR ASSEMBLIES Item Description Part no. 1 2 3 4 5 6 7 8 Dead weight tester assembly Test gauge set Viscor cup with instructions Dummy injector assembly Clamp force and temperature indicator Temperature transducer assembly Load cell assembly Splash Shield Cup (consists of): Plastic Closure Poly.
PARTS LISTS CD3 AUDIT KIT 5.2 INDIVIDUAL REPLACEMENT PARTS Item Description Part no. 1 2 3 4* 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19* 20* Case, without inserts (tap and bottom plate) Graduated cylinder, 250 ml (cc) Gauge adjusting tool Quick connect socket on dead weight tester Load cell push rod adapter Load cell adapter Load cell discharge head adapter Connectors, str.
