67-9268

Bacharach, Inc.625 Alpha Drive, Pittsburgh, PA 15238-2878

Phone: (412) 963-2000 • FAX (412) 963-2091 • Web: www.bacharach-inc.com

® Registered Trademark of Bacharach, Inc.Printed in U.S.A.

INSTRUCTION 67-9268

Technician Series Model7.5 & 10 HP Fuel Injection Pump

Calibrating Stands

Installation/Operation/MaintenanceRev. 4 – April 1999

Technician 7.5 & 10 Contents

Instruction 67-9268 Bacharach, Inc. Page i

TABLE OF CONTENTS

Page

1.0 INTRODUCTION ............................................................................................................................ 1-1

1.1 Specifications ...........................................................................................................................1-1

1.1.1 General ......................................................................................................................1-11.1.2 Main Drive ................................................................................................................1-11.1.3 Calibration Fluid Supply System ............................................................................1-11.1.4 Instrumentation .......................................................................................................1-2

1.2 Optional Accessories ................................................................................................................1-2

2.0 INSTALLATION ............................................................................................................................. 2-1

2.1 Stand Preparation and Hook-up .............................................................................................2-1

2.1.1 Leveling .....................................................................................................................2-12.1.2 Electrical Hook-Up (Wiring) ....................................................................................2-1

2.3 Filling Reservoir ......................................................................................................................2-22.4 Basic Accessories ......................................................................................................................2-2

3.0 OPERATION ................................................................................................................................... 3-1

3.1 Control & Light Functions ......................................................................................................3-1

3.1.1 Console Panel (Figure 3-1) .......................................................................................3-13.1.2 Front Panel (Figure 3-2) ..........................................................................................3-33.1.3 Side Panels (Figure 3-3) ...........................................................................................3-3

3.2 Tachometer / Counter Assembly .............................................................................................3-33.3 Calibration Fluid System ........................................................................................................3-3

3.3.1 Calibration Fluid Temperature Control (TEMP. ADJ.) ..........................................3-43.3.2 Front Panel Connections (Figure 3-2) .....................................................................3-43.3.3 Waste Tank ...............................................................................................................3-5

3.4 Water Cooling System .............................................................................................................3-53.5 Graduates .................................................................................................................................3-5

3.5.1 Reading the Graduates (Figure 3-5) ........................................................................3-53.5.2 Draining the Graduates (Figure 3-6) ......................................................................3-6

3.6 Accumulator Arm Assembly ....................................................................................................3-63.7 Flexible Anti-Backlash Coupling ............................................................................................3-63.8 Correct Use of Alignment Gauge ............................................................................................3-63.9 Typical Operating Sequence ....................................................................................................3-73.10 Shutdown Procedure ...............................................................................................................3-83.11 Mounting Injection Pumps and Test Injectors .......................................................................3-8

Page ii Bacharach, Inc. Instruction 67-9268

Contents Technician 7.5 & 10

4.0 MAINTENANCE & TROUBLESHOOTING ............................................................................... 4-1

4.1 Maintenance .............................................................................................................................4-1

4.1.1 Belt Tensioning .........................................................................................................4-14.1.2 Lubrication (Figure 4-1) ...........................................................................................4-14.1.3 Calibration Fluid ......................................................................................................4-14.1.4 Graduates (Care/Cleaning) ......................................................................................4-24.1.5 Adjustment of Magnetic Pickup ..............................................................................4-24.1.6 Tach/Counter Replacement ......................................................................................4-34.1.7 Removal of Flexible Coupling ..................................................................................4-34.1.8 Flexible Coupling Installation .................................................................................4-44.1.9 Motor Starter Overload Relay Adjustment .............................................................4-6

4.2 Troubleshooting .......................................................................................................................4-7

4.2.1 Electrical ...................................................................................................................4-74.2.2 Mechanical ................................................................................................................4-8

5.0 PARTS LISTS .................................................................................................................................. 5-1

5.1 Belts, Filters, Etc. ....................................................................................................................5-15.2 Electrical Components.............................................................................................................5-15.3 Instruments .............................................................................................................................5-25.4 Miscellaneous Parts .................................................................................................................5-25.5 Optional Accessories ................................................................................................................5-2

APPENDIX A – PUMP MOUNTING DIAGRAMS ............................................................................... A-1

APPENDIX B - INJECTOR ACCUMULATOR ACCESSORIES ....................................................... B-1

Technician 7.5 & 10 Contents

Instruction 67-9268 Bacharach, Inc. Page iii

WARNINGS AND CAUTIONS

WARNINGS

DO NOT attempt to make any adjustments or repairs to the electrical compo-nents of the Technician Stand without first disconnecting the main power lineat the wall. Many connections within the Stand carry lethal voltages. Anywork done to the electrical system should be performed by qualified personnel.

DO NOT operate the Technician Stand with the flexible coupling mountedand no injection pump attached, this is extremely hazardous and will perma-nently damage the coupling.

Use the flexible coupling guard at all times.

DO NOT depress the run button without being aware of the speed controlselection and setting.

Use of any adapters and/or couplings, not approved by Bacharach, Inc., tomount injection pumps to the Technician Stand may be dangerous and couldvoid the warranty. Bacharach approved couplings and mounting adapters aredesigned specifically to work with both the Technician 7.5 and 10.

CAUTIONS

DO NOT apply electrical power or attempt to operate the Technician Standuntil all steps in Section 2 are completed.

To maintain a free flow of cooling water, do not install a valve or any restric-tion in the water drain hose.

To prevent calibration fluid heater burn-out, make certain that the Calibra-tion Fluid HEAT switch is OFF when power is applied to the TechnicianStand with the fuel reservoir empty.

Make certain that there is 1" clearance between the degree wheel and thecoupling guard. Failure to have sufficient clearance could damage the degreewheel (Figure 4-11).

The flexible coupling rear flange lock nuts must be checked for tightnessperiodically (at least once per month).

Periodically check all hoses and connections to insure safe operation of theTechnician Stand.

DO NOT leave the Technician Stand unattended while the drive system isrotating.

Page iv Bacharach, Inc. Instruction 67-9268

Contents Technician 7.5 & 10

NOTES

Technician 7.5 & 10 Introduction

Instruction 67-9268 Bacharach, Inc. Page 1-1

1.0 INTRODUCTION

The Bacharach Technician Series Model 7.5 and10 HP Fuel Injection Pump Calibrating Stands aredesigned for testing and calibrating light to me-dium duty diesel fuel injection pumps used onengines employed in the construction, automotive,power generation, and farm equipment fields. Itslow cost, compact design and simple operationmake the Technician Stand an ideal choice for anew or expanding diesel fuel injection shop.

The anti-backlash, flexible, pump coupling isdriven by an AC motor coupled to a flywheel.Controls for pump rotation selection, speed set-tings, run, and stop are located on the consolepanel. The speed setting control (potentiometer)can vary the drive speed between 70 and3500 RPM (nominal).

The components located on the Technician Stand’sfront panel are: the digital tachometer/strokecounter, Calibration Fluid Supply Temperature,and the Calibration Fluid Vacuum/Pressuregauges. The gauges have English and metricscales. The calibration fluid collection and measur-ing system consists of a swiveling single blockaccumulator, attached to either side of the Stand,feeding into 8 graduates of 160 cc capacity. Thecalibration fluid reservoir has a spout with a builtin dipstick for measuring fluid level.

1.1 Specifications

1.1.1 General

(a) Dimensions Width - 28" (.71 m)Height - 68" (1.73 m)Depth - 40" (1.02 m)

Weight Dry - 1200 lbs (545 kg)

(b) Electrical requirements:Refer to Table 2-2.

(c) Water Consumption: Cold tap at approxi-mately 1.2 gpm (4.5 liters/min.), gravitydrain.

1.1.2 Main Drive

(a) AC adjustable frequency electric motor.

(b) Rotary dial speed control adjustable from70–3500 RPM.

(c) Flywheel moment of inertia: WR2 = 1145 lbin2 (0.336 kgm2).

(d) Backlash free flexible coupling, laminateddisc design (Light Duty).

1.1.3 Calibration Fluid Supply System

(a) Fluid is either supplied under pressure tothe injection pump or drawn from thereservoir under suction by the supply pumpthat is mounted on the injection pumpunder test.

(b) Thermostatically controlled calibrationfluid reservoir [capacity: 13 gallons (50 li-ters)] complete with four 500 watt heaters,cooling coil, temperature sensor, overheatsafety switch with solid-state temperaturecontroller. Calibration Fluid temperaturecontrolled to ±2 °F under normal operatingconditions.

(c) Large 10 micron submersed reservoir filter.

(d) Automatic temperature control of calibra-tion fluid to ±2 °F, heated by electricsubmersible heaters, and cooled by cold tapwater that flows through copper-finnedtubing in the reservoir.

(e) Transfer pump driven by a 1/3 horsepowermotor at a rate of 150 GPH (9.5 liter/min)at zero pressure, valves for controlling fuelsupply pressure and for suction testing ofinjection pumps with integral transferpumps.

2 Bacharach, Inc. Instruction 67-9268

Introduction Technician 7.5 & 10

1.2 Optional Accessories(Not Supplied, see Section 5.5)

(a) Final Stage Filter and Gauge Kit: (Cus-tomer installed) contains a 2 micronspin-on type filter, hoses, 0–100 psi (0–7 kg/cm2) gauge and hardware.

(b) Pressure Lubrication System: Self con-tained with motor driven lube oil supplypump, reservoir, filter, hoses, and hard-ware. This unit conveniently attaches tothe side of the Stand. Recommended forpumps requiring pressurized lube oilsupply (AMBAC Model 100 and someothers).

(c) Portable High Pressure Timing Unit: Selfcontained with motor driven high pressurepump, reservoir, filter, hoses and hard-ware. Required for timing and phasingmany in-line fuel injection pumps. Formore information, ask for Leaflet 1035.

1.1.4 Instrumentation

(a) Dual mode digital tachometer and strokecounter: Automatic shift from tachometerto stroke count; accuracy ±1 RPM, ±1 count.

(b) Compound pressure/vacuum gauge: Rangeof 0–30" Hg (0-76 cm Hg) vacuum and0–100 psi (0-6.9 bar) pressure, both mea-sured in the fuel supply line.

(c) Fuel inlet temperature gauge: Range of40–140 °F (5–60 °C).

(d) Eight collection graduates: 160 cc clearacrylic pyramidal design with 0.5 cc subdi-visions from 0–35 cc and 1 cc subdivisionsfrom 35–160 cc.

Technician 7.5 & 10 Installation


2.0 INSTALLATION

CAUTION

DO NOT apply electrical power or attemptto operate the Technician Stand until allsteps in this section are completed.

2.1 Stand Preparation and Hook-up

The Technician Stand is shipped bolted to a pallet.Remove these bolts; then use a lift truck to removethe Stand from the pallet.

CAUTION

Take care that the forks of the lift truck donot damage the four heavy-duty levelingpads that protrude from beneath the Stand.

The Stand should be installed with sufficientsurrounding space on the sides and in the rear(approximately 18 inches) to permit removal of itsaccess panels for periodic lubrication, maintenanceand/or inspection of the Stand.

2.1.1 Leveling

The Stand must be leveled to permit accuratereading of the graduates. Four heavy-duty levelingpads are provided, one in each corner of the frame.Use a carpenter’s level, across and in parallel withthe pump mounting rails, and adjust the level jacknuts to position the Stand level.

2.1.2 Electrical Hook-Up (Wiring)

Fuse the Stand’s circuit breaker wall panel to NECor local code. Table 2-1 will assist in selecting thecorrect fuse size.

Table 2-1. AC Panel Fuse Size

Stand Model / AC Input Amps (Time Delay Fuse)

Technican 7.5: 230 VAC, 3 ph., 60 Hz 35 460 VAC, 3 ph., 60 Hz 20

Technicain 10: 230 VAC, 3 ph., 60 Hz 45

Before attempting to wire the Technician Stand,refer to Figure 2-2. Make certain to follow thatportion which refers to the exact voltage, phaseand frequency noted on the electrical nameplatelocated at the rear of the Stand.

NOTE: At this point, it is suggested toremove the lower front and rear panels.

Referring to Table 2-2 and Figure 2-1, connect theAC mains to terminal block TB1. Connect a groundwire to the ground terminal. Note that wire size(AWG) will vary with types of insulation, length ofconductors, etc. Consult NEC codes.

CAUTION

To prevent the possibility of burning outthe calibration fluid heaters with the fuelreservoir empty, make certain that theCalibration Fluid HEAT switch is off whenpower is applied to the Stand.

Table 2-2. AC Mains Current and Wire Size

Stand Volts/Hz Motor 3∅∅∅∅∅ Wire SizeNo. HP Amps AWG

67-7683 460/60 7.5 18 1067-7682 230/60 7.5 32 867-7696 230/60 10 40 8

2.2 Cold Water Hook-up

Two connecting points for water are provided atthe lower left rear of the Stand. Cold tap waterinput should be connected to the upper bulkheadadapter after installing a ¼-NPT fitting to accom-modate the cold water supply. A manual shutoffvalve is suggested for connection upstream of theinlet fitting.

The cold water return connection (drain) is locateddirectly below the inlet bulkhead adapter andrequires a ¼-NPT fitting for a drain hose connection.

CAUTION

Do not install any valves on the waterreturn drain line.

A hose (or pipe) ½" inside diameter (minimum)should be provided for the unrestricted return ofcooling water to the drain. After the water inlet

Installation Technician 7.5 & 10

Page 2-2 Bacharach, Inc. Instruction 67-9268

and drain have been connected to the Stand (andthe water turned on), inspect all connections forleaks. For operating details of the cooling systemrefer to Section 3.4.

2.3 Filling Reservoir

Fill the calibration fluid reservoir (filling tube located inthe lower front panel) with approximately 13 U.S. gallons(50 liters) of calibration fluid that meets SAE J967 (ISO4113), see Section 5.1 for ordering a 15 gal. drum..

NOTE: Use calibration fluid approved bythe fuel injection pump manufacturer only.Most recommend SAE J967 (ISO 4113).

Figure 2-1. Electrical Chassis

2.4 Basic Accessories

The individual accessories supplied with eachStand are listed in the Accessories Drawing67-6323 enclosed with this Instruction.

GroundTerminals

Main PowerInput Terminals

Fuses (F1 & F2)460 VAC Only

Main PowerCable Inlet

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Installation Technician 7.5 & 10


Figure 2-3. Calibration Fluid System

2 Optional Final Stage Filter and Gauge Kit (see Section 5.5) shown in enclosed area.

Technician 7.5 &10 Operation


3.0 OPERATION

3.1 Control & Light Functions

The following is a description of the control andlight functions for the Technician Stand.

NOTE: The numbers in the text refer to thenumbers on the corresponding figures.

3.1.1 Console Panel (Figure 3-1)

1. SUPPLY Switch (Calibration Fluid): Activatesthe calibration fluid supply pump.

2. Calibration Fluid Indicator: Lit when theSUPPLY switch is ON.

3. HEAT Switch (Calibration Fluid Heater):Activates the calibration fluid automatictemperature control system.

4. Calibration Fluid Heater Indicator: Lit whenthe calibration fluid is being heated.

NOTE: The Calibration Fluid Heaterindicator will cycle on and off duringnormal operation.

5. TEMP. ADJ. Control (Temperature Adjust-ment): Sets calibration fluid temperature inthe calibration fluid reservoir.

6. PUMP ROTATION Switch: Controls thepump’s direction of rotation.

7. STOP Button: Shuts down the main drive anddisconnects power to the controller. Onceactivated, the button is locked, and must beturned counterclockwise before it will unlock.

8. Stop Indicator: Lit while the main drive systemis in the STOP or unpowered state.

9. RUN Button: Starts the drive shaft rotating.

10. Run Indicator: Indicates that power is con-nected to the main drive motor, and the driveshaft is rotating.

11. SPEED Control: Sets speed (RPM) of the driveshaft.

Figure 3-1. Console

2 4 8 10

1 3 5 6 7 9 11

DRIVE SYSTEM

SUPPLY

OFF OFF

HEAT

ON ON

TEMP ADJ.

CCW

PUMP ROTATION

CW

STOP

CALIBRATION FLUID

RUN SPEED

Operation Technician 7.5 & 10


Figure 3-3. By Pass & Shut Off Valves

12 13

14 16

15

17

18 20

19 19

22

21

Figure 3-4. Tach / Counter

Figure 3-2. Front Panel

TEMPERATURE

CAL. FLUIDSUPPLY RETURN

CAL. FLUID

VACUUM/PRESSURE

CAL. FLUID TOFLOWMETER

TO FINALSTAGE FILTER

CAL. FLUIDFROM FINALSTAGE FILTER RETURN

CALIBRATION FLUID SUPPLYVACUUM/PRESSURE

TECHNICIAN 7.5

TEMPERATURECALIBRATION FLUID SUPPLY



3.1.2 Front Panel (Figure 3-2)

12. CALIBRATION FLUID SUPPLY VACUUM/PRESSURE Indicator: A compound gauge thatindicates either positive or negative pressure(vacuum) of the calibration fluid in the fuelsupply line (just behind the front panel).

13. CALIBRATION FLUID TEMPERATUREIndicator: Displays the temperature of thecalibration fluid (just behind the front panel).

14. CAL. FLUID TO FLOWMETER: Measures thecalibration fluid return flow rate of rotarydistributor type pumps.

15. Graduates: Measures the fuel delivery of eachpump cylinder/outlet, which is routed from theaccumulator block.

16. TACH/COUNTER: A dual purpose unit consist-ing of a digital tachometer and a preselectablestroke counter. The stroke-cycle controls aremounted on its front panel.

17. Flowmeter Input: Routes fluid to theflowmeter.

18. CAL. FLUID SUPPLY Fitting: Providescalibration fluid to the pump.

19. CAL. FLUID RETURN Fitting: Routes calibra-tion fluid back to the calibration fluid reser-voir.

20. TO/FROM FINAL STAGE FILTER Fittings:Routes calibration fluid to and from the finalstage filter (Optional Accessory).

3.1.3 Side Panels (Figure 3-3)

21. Bypass Valve (Left hand side of Stand): Allowsoperator to adjust Cal. Fluid Pressure.

22. Shut Off Valve (Left hand side of Stand):Restricts or stops Cal. fluid flow to the pump.

23. DRAIN Valve (Right hand side of Stand,Figure 3-6): Operating this lever drains thegraduates.

3.2 Tachometer / Counter Assembly(Figure 3-4)

The TACH/COUNTER assembly in conjunctionwith a magnetic pick-up and 120-tool gear providespeed indication and revolution (stroke) counting.The pick-up and gear are located in the rear of theStand. The gap between pick-up and gear is factoryset to .006 inches ± .001.

The TACH/COUNTER assembly is built into theupper right-hand-front panel of the Stand. Thisassembly processes the signals that it receivesfrom the magnetic pick-up assembly and indicatesthe results on its 4-digit LED display. This unitincorporates a 4-digit thumbwheel SELECTSTROKE switch for preselecting strokes. Indicatorlights show the assembly’s mode of operation –either TACH MODE (tachometer) or COUNTMODE (counter).

COUNT MODE is started by preselecting anynumber of strokes in the SELECT STROKEcounter from 5 to 9999 and depressing the STARTCOUNT (draw) switch. If necessary, the count canbe stopped by the INTERRUPT (cancel) switchafter the draw cycle has begun.

The TACH/COUNTER assembly in its TACHMODE continuously indicates drive shaft revolu-tions per minute that is updated every 1 second.

3.3 Calibration Fluid System(Figures 2-3 and 3-2)

This system consists of a fluid reservoir, wastecollector, motor-driven gear pump, SHUT OFFVALVE, BY PASS VALVE, check valve, primaryfilter, necessary plumbing and instrumentation.

Calibration fluid is drawn from a submerged filterin the reservoir. Fluid is either supplied underpressure to the injection pump, or drawn from thereservoir under suction by the supply pump that ismounted on the injection pump under test. If fluidis to be supplied by the Stand’s supply pump to theinjection pump under test, then the one-way checkvalve is closed. Manual adjustment of the calibra-tion fluid pressure is done using the BY PASSVALVE (Figure 3-3). Maximum available pressureis approximately 75 psi.



If the calibration fluid is drawn out of the reservoirwith the Stand’s supply pump switched off, thefluid passes through the check valve and out theSHUT OFF VALVE to the injection pump undertest. In this mode, the BY PASS VALVE must beclosed (fully clockwise). Closing the SHUT OFFVALVE completely or partially (Figure 3-3) willstop or restrict the flow to the pump under test andcreate vacuum upstream of the shut off valve. Thisvacuum is indicated by the CALIBRATION FLUIDSUPPLY VACUUM/PRESSURE gauge. If re-quired, calibration fluid can be circulated throughthe final stage filter (an optional final stage filterkit available for customer installation).

There are two CAL. FLUID RETURNs availableon the front panel. They are both routed directly tothe reservoir. The calibration fluid delivered by theinjection pump and injected into the accumulatorchambers is discharged into the graduate rackhousing and returns by gravity to the reservoir bya separate line.

The reservoir is divided into three compartmentsby baffles. This permits maximum mixing of hotand cold calibration fluid and provides for stabi-lized fuel temperature under all operating condi-tions. The cooling compartment contains a coil offinned tubing through which cold tap water flowsfor cooling purposes when required. All fluidreturns from the pump and the test injectors arediverted into this compartment.

The temperature of the fluid entering the reservoiris generally higher than that in the reservoir. Theheating compartment contains four immersedelectrical heaters that provide heat to the calibra-tion fluid when necessary. The thermostat ismounted above the heaters. The main compart-ment contains the submersible primary filter. Thethree compartments are interconnected to permitfluid flow from the cooling compartment past thecooling coil into the heating compartment past theheaters and thermostat into the main compart-ment and out through the filter into the system.

A overheat thermostat is wall mounted on thereservoir to detect possible overheating of thecalibration fluid. This could occur if the automatictemperature controller malfunctions.

The temperature of the calibration fluid is mea-sured in the supply piping (manifold) behind thefront panel and is indicated by the CALIBRATIONFLUID SUPPLY TEMPERATURE gauge mountedin the upper right side of the front panel.

3.3.1 Calibration Fluid Temperature Control(TEMP. ADJ.)

Heating of the calibration fluid is accomplished byfour 500 watt immersed electric heaters. Cooling isprovided by cold water flowing through finnedtubing immersed in the fuel reservoir. The thermo-stat either switches on the heaters or admits coldwater for cooling. The thermostat is set at thefactory for a calibration fuel inlet temperaturerange of 102–106 °F. Readjustment may be neces-sary for specific pumps and particular test condi-tions.

When adjusting the thermostat on the frontconsole, the injection pump should already bewarmed up and the whole system at operatingtemperature. To maintain close control of thecalibration fluid temperature, it is recommendedthat the supply pump operate during all tests,whenever this is possible (open BY PASS VALVEfully counterclockwise). Increased fuel flowthrough the reservoir will increase the frequencyof the heating/cooling cycle and thereby supplycalibration fluid at a uniform temperature undermost operating conditions.

To readjust temperature setting after completewarm-up, observe CALIBRATION FLUID SUP-PLY TEMPERATURE gauge, then turn Calibra-tion Fluid TEMP. ADJ. thermostat adjustment onthe front console CW to increase or CCW to de-crease. Adjust by small increments only.

CAUTION

Allow 10–15 minutes for calibration fluidsystem to stabilize.

3.3.2 Front Panel Connections (Figure 3-2)

CAL. FLUID SUPPLY accepts 5/8" ID hose (#10)that is required for testing Cummins PT pumps.For other applications, suitable reducers aresupplied for use with 1/2" ID (#8) or 3/8" ID (#6)rubber or PVC hoses.

NOTE: Use PVC hoses for supply undervery low pressures (below 10 psi) andreturn. In all other cases use rubber hoses.

The two CAL. FLUID RETURNs accept 1/2" ID (#8)hoses and are provided for return of calibrationfluid to the reservoir. All connecting points, gaugesand controls are well identified by



nameplate and the calibration fluid system isrepresented on the front and left-hand panel byinterconnecting lines and symbols.

3.3.3 Waste Tank

The drain pan is connected to a waste tank. Bypreventing the spillage in the drain pan fromreturning to the calibration fluid reservoir, thepossibility of contamination is greatly reduced.Check the waste tank level periodically, anddiscard the waste fluid as required.

The waste tank is located at the lower left rear ofthe Stand and is accessible without removing therear panel. Remove drain hose and then slide tankto rear for removal.

3.4 Water Cooling System

The cooling system will automatically shut off theflow of cooling water when the power is off. Thissystem consists of a cooling coil, a solenoid valve,and necessary plumbing. The cooling coil is in-stalled in the calibration fluid reservoir.

The solenoid valve is a normally-closed, 2-wayvalve. When energized, it permits cooling water toflow through the calibration fluid reservoir andthen to the drain. This solenoid is energized whenthe Calibration Fluid HEAT switch is ON, andwhen the temperature control calls for cooling.

With the Calibration Fluid HEAT switch "ON", theheaters or solenoid valve can be energized. Whenthe solenoid is energized, cooling water will flowthrough the coil in the calibration fluid reservoirand the heaters are shut-off.

When the temperature drops below the set point,the thermostat provides a current path throughthe normally closed safety thermostat, applyingcurrent to the heaters. This causes the watersolenoid to de-energize and the heater light tocome ON. By this action, cooling water is blockedfrom flowing through the reservoir’s cooling coil,thus allowing the calibration fluid temperature toincrease up to the set point previously establishedat the TEMP. ADJ. potentiometer located on thefront panel.

3.5 Graduates

The Technician Stand contains a number of uniquefeatures. The graduates are of clear molded plastic,with 160 cc capacity. Graduations are every 1ccexcept in the range from 0–35 where 0.5 cc gradua-tions can be read. The pyramidal shape features ahigh degree of readability. An aluminum spraydeflector located at the top of each graduatediverts fluid to its back surface to minimize foamaccumulation.

The black vertical line on the rear wall of thegraduate provides a method of eliminating “paral-lax” reading error.

3.5.1 Reading the Graduates (Figure 3-5)

A black vertical stripe painted on the back wall ofthe plastic graduate serves to obtain an accuratereading line for the correct fluid level. To find theexact fluid level, move your eyes to the level of thefluid and to a position at which the distance “A” isat a minimum. At this position, the image (shownin Figure 3-5) is formed.

The thin black horizontal line resulting from theblack stripe and fluid meniscus is the reading line.Follow this line horizontally to the graduationsand read the volume in cubic centimeters (cc’s).

Figure 3-5. Reading Graduate



3.5.2 Draining the Graduates (Figure 3-6)

The graduate DRAIN lever is located on the upperright side of the Stand. To drain fuel from thegraduates after a count, push “in” the graduateDRAIN lever and move clockwise to the DRAINposition. Release the lever to allow its notch toengage the latch plate and hold the control lever inthe DRAIN position.

The graduates will continue to drain until thecontrol lever is released from the latch plate drainposition. Return the control lever to the FILLposition before starting the next count. The recom-mended drain time is 30 to 35 seconds.

Figure 3-6. Graduate Drain Lever

3.6 Accumulator Arm Assembly(Figure 3-7)

Eight nozzle clamp post assemblies (and setscrews), used to assemble the accumulator foroperation, are packed in the parts bag.

1. Align flat spot on base of post with thethreaded hole on back of accumulator.

2. Slide each nozzle clamp post into holes pro-vided for them on top of accumulator.

3. Place each set screw into a threaded hole onthe side of the accumulator block; then tightenuntil it secures the nozzle clamp post.

The accumulator arm can be mounted on eitherthe right or left side of the Stand’s front paneldepending on the injection pump’s application. Ifthe accumulator arm needs to be moved to theother side of the front panel, slide the accumulatorarm out of its mounting tube and slide it into themounting tube on the opposite side. The accumula-tor arm can be swung to move the accumulator outof the way when necessary.

3.7 Flexible Anti-Backlash Coupling(Refer to Sections 4.1.7 & 4.1.8for Removal / Installation)

The coupling is secured to the Stand drive shaft bya tapered-hub. The front (driving) flange is de-signed for direct attachment to the pump drivingcomponent (hub) without any backlash. The flangealso provides a pilot to ensure concentricity. Adrive Adapter (see Section 5.5) is available as anoptional accessory to make the flexible couplingsemirigid. The drive adapter is used only when it isnecessary to convert the flexible coupling fordriving pumps that require a tanged-type drive.

3.8 Correct Use of Alignment Gauge

For correct engagement of drive hub to the flexiblecoupling, use the Alignment Gauge that is suppliedwith the coupling.

1. Insert pins of the gauge between laminationand flanges on each side.

2. When correct engagement exists the gauge will“drag” slightly, exhibiting a slide-fit betweenthe pins on one side and the lamination andflanges on the other. Note that excessive “pull”or “push” on the lamination will permanentlydistort them, requiring their replacement.

3. To avoid distorting or damaging the laminateddisc, the flexible coupling must always beconnected to an injection pump coupling beforethe Stand is operated.

CAUTION

The rear flange lock nuts must be periodi-cally checked for tightness (at least once permonth).

It is recommended that all bolts and nuts of thecoupling be periodically checked for tightness andproper torque. There are approximately 6 Lamina-tion (see Section 5.4 for part number) on each sideof the Flexible Coupling.



3.9 Typical Operating Sequence

Before performing the following steps, ensure thatthe pump is mounted on the Stand according topump mounting diagrams or pump manufacturers’instructions (see Section 3.11), all necessaryconnections have been made, and the pump isready for testing.

1. Set all switches on the Stand to their OFF orfully CCW position.

2. Turn on water supply.

3. Turn on power to the Stand at the maindistribution panel.

4. Set main circuit breaker (CB1) on upper leftside to ON

5. Observe that the STOP (red) light is ON andthe RUN (amber) light is OFF.

6. Set the PUMP ROTATION switch to thedesired direction of pump rotation.

7. Turn BYPASS VALVE fully CCW (open).

8. Turn SHUTOFF VALVE to OPEN

9. Set the CALIBRATION FLUID SUPPLY andHEAT switches to ON before running aninjection pump. Allow enough time for thecalibration fluid to reach operating tempera-ture.

NOTE: When calibration fluid reaches itspreset temperature, the HEAT ON lampwill turn off. The calibration fluid systemwill automatically run the heater elements(HEAT lamp will be ON) or water will berouted through the calibration fluid cool-ing coil (HEAT lamp OFF) to maintain thetemperature preset by the TEMP ADJ.control. The temperature is factory adjustedto 104 ±2 °F. In the event the injectionpump manufacturer’s instructions call for adifferent temperature setting, use thecalibration fluid TEMP ADJ. to makeadjustments (reference Section 3.3.1).

10. Adjust the BYPASS VALVE to obtain thedesired calibration fluid supply pressure.

NOTE: Negative pressure (vacuum)generated by an injection pump’s supplypump (feed or transfer) can be read on thecompound gage after closing the SHUTOFFVALVE.

11. Make sure that the STOP button is in the upposition. This control remains in the downposition once it has been depressed. The buttonmust be rotated counterclockwise in order for itto release.

12. Depress and hold the RUN button until thedrive begins to turn.

13. Adjust the SPEED control to the desired RPM.The RPM will be displayed on the TACH/COUNTER.

14. Dial in the desired stroke count on theSELECT STROKE thumb wheel switches.

15. Make sure the graduate FILL / DRAIN lever isin the FILL position.

16. Depress the START COUNT switch to beginthe stroke count cycle. The graduate solenoidenergizes causing the graduates to beginfilling. The TACH/COUNTER will first displaythe stroke count during the count cycle, andthen automatically return to its tachometermode.

NOTE: The stroke count cycle may bestopped at any time by depressing theINTERRUPT switch.

17. After reading the graduates, move the gradu-ate FILL / DRAIN lever to the DRAIN posi-tion. Recommended drain time is 30 to 35 sec-onds.



3.10 Shutdown Procedure

1. Turn RPM control completely CCW (if notalready CCW).

2. Push the STOP Button.

3. Turn Cal. Fluid SUPPLY switch to OFF.

4. Turn Calibration Fluid HEAT switch to OFF.

5. Set main circuit breaker to OFF.

6. Turn OFF cold water supply.

3.11 Mounting Injection Pumps andTest Injectors

Appendix “A” is a list of Pump Connection Dia-grams available from Bacharach. These drawingswill assist the operator in mounting the fuel pumpson the Stand. For exact pump test procedure andspecifications, refer to the pump manufacturers’service literature.

Refer to Appendix “B” for a listing what adapters,spacers, bleed-off tubing, and clamps are needed tomount and hold down the test injectors. Someinjectors require no adapters, while others mayrequire one or two in order to mount them into theaccumulator.

To install a nozzle:

1. Use appropriate nozzle holder adapters and“O” Rings, as called for in Appendix “B”, on thetest injector.

2. Slide the injector into one of the accumulatorholes.

3. Slide the Nozzle Clamp under a set of posts onthe nozzle clamp post assembly so that theends rest on top of the injector. The notches ontop of the nozzle clamp should rest under theposts.

4. Screw down the clamp screw assembly so thatit holds the nozzle tight.

Figure 3-7. Injector Installation

NOZZLE CLAMP POST ASSY.

NOZZLE CLAMP

CLAMP SCREW ASSY.

NOZZLE HOLDERADAPTER

O-RING (05-5202)15/16 ID x 1-3/16 OD

O-RING (05-5162)1-3/16 ID x 1-5/8 OD

SET SCREWS

ACCUMULATORNOZZLE BLOCK

Technician 7.5 & 10 Maintenance & Troubleshooting


4.0 MAINTENANCE &TROUBLESHOOTING

4.1 Maintenance

CAUTION

Before performing any maintenance,disconnect electrical power to the Stand atthe main AC distribution panel.

4.1.1 Belt Tensioning

The electric motor drive belt stretches in the firstfew hours of operation. Check for proper tension atthe mid-position. Slack should not exceed 1/2 inchwhen compressed by hand.

To tighten electric motor drive belt:

1. Remove rear access panel

2. Loosen electric motor mounting bolts andmove complete assembly to tighten belt

3. Retighten mounting bolts to 10 lb-ft torque.

4.1.2 Lubrication (Figure 4-1)

Lubrication of the two main drive shaft bearings isrecommended after each 1000 hours of operationor once a year, whichever occurs first. The follow-ing lithium-base greases have been found to beacceptable for this application.

Socony-Mobil Armvac-781Texas Company Multifak 2 (E-P)-1990Shell Oil Co. Alvania 2

To grease the main drive shaft bearings mountedon the brackets, remove the rear access panels.

4.1.3 Calibration Fluid

The fluid should be replaced whenever any one ofthe following events occur:

(a) After every 200 hours of operation.(b) Viscosity increases to 3.2 cst (based on

SAE J967 (ISO 4113)) or more.(c) Every three months or 200 pumps.

Figure 4-1. Main Drive Shaft Grease Fittings

Fill reservoir with 13 U.S. gallons (50 liters) of therecommended calibration fluid. Most fuel injectionpump manufacturers recommend SAE J967 (ISO4113) calibration fluid.

Replace primary filter every second fluid replace-ment. To replace primary filter:

1. Drain calibration fluid reservoir with thesupply (transfer) pump.

2. Connect drain hoses to both drain valves.

3. Open both valves and drain residual calibra-tion fluid in reservoir from both sides.

4. Remove screws securing the calibration fluidreservoir to the frame.

5. Lower the calibrating reservoir to the floor.

6. Pull out all return hoses and remove the lid.

7. Loosen and remove the filter retainer andslide out the filter.

8. Replace the filter with new filter and reas-semble the reservoir in the reverse order.


Maintenance & Troubleshooting Technician 7.5 & 10

Replace the optional final stage filter every secondfluid replacement. The final stage spin-on filter islocated behind the front panel. To replace filter,use an automotive-type filter spanner wrench. Forcorrect part numbers of primary and final stagefilters, see Sections 5.1 and 5.5.

4.1.4 Graduates (Care/Cleaning)

Proper maintenance of the Graduates necessitatesperiodic removal. Remove the rear access panel,then proceed with the following:

1. Loosen the two socket head set screws in thedrain arm assembly.

2. Remove the drain arm from the drain rod.

3. Remove the upper right-hand side panel.

4. Remove two socket head cap screws from drainarm mounting plate.

5. Remove graduate drain hose.

6. Pull the eight individual accumulator hoses fromfront panel and drape them in the rear of Stand.

7. Remove two quick connects from graduatesolenoid.

8. Remove four hex nuts from graduate mountsand remove complete assembly.

9. Remove the fill tube holder assembly byremoving the set screw and lock nut on the endopposite the fill solenoid.

10. Remove three hex nuts holding the graduateretainer bracket in place (located at the top ofgraduates).

11. Slide retainer from the welded stud.

12. Graduates may now be serviced.

NOTE: When cleaning graduates, adetergent solution must be used. Do notuse solvents.

Reassemble in the opposite order of disassembly upto Step 4, then proceed with the following toproperly set (bias) the graduate DRAIN lever.

1. Use vise grips on the drain rod assembly andturn until the graduate drain valves areraised to their maximum drain position asviewed from the front.

2. Keep the drain rod assembly in this position,then slide the drain lever mechanism onto theend of the drain rod shaft.

3. Align the detent into the drain position andsecure drain arm to rod by tightening two setscrews.

4. Check results by shifting from DRAIN toFILL position, then remove the vise grips.

4.1.5 Adjustment of Magnetic Pickup(Figure 4-2)

The gap between the magnetic pickup and the 120tooth gear is factory set to .006 inches.

The general indication that the gap setting is outof tolerance, or that the magnetic pickup is defec-tive and must either be reset or replaced is exem-plified by an erratic RPM display on the TACH/COUNTER. To adjust the magnetic pickup gapsetting, use the following procedure:

1. Turn main circuit breaker to OFF.

2. Remove the rear panel to gain access to themagnetic pickup.

3. Loosen locknut on magnetic pickup body andadjust until the gap between the top of theteeth and the pickup is .006 in. (±.001 in.).

4. Manually rotate the flywheel one full turnmaking certain that all teeth clear the pickup.Use a dial indicator to check for concentricityaround the gear. If the encoder gear is eccen-tric, loosen the three hex head cap screwsthat secure the gear to the hub. Readjust thegear and retighten the screws.

5. When proper gap setting is achieved, tightenlocknut, then recheck for concentricity.

6. Check Stand for correct RPM indication witha hand held tachometer, especially at lowspeeds (around 70 RPM). If RPM is incorrect,refer to Section 4.2 Troubleshooting.



Figure 4-2. Magnetic Pick-Up

4.1.6 Tach/Counter Replacement

No attempt should be made to repair this unit inthe field. If unit becomes inoperative with mainswitch ON, check for tight electrical connections.

1. Use a voltmeter set on the appropriate rangeand check that 230 VAC (approximate) ispresent between Terminals 1 and 2 at rear oftach/counter.

(a) If input voltage is present, it may indicatethat the unit is defective.

2. Another possible malfunction could be adefective magnetic pick-up. Check the inputsignal between Terminals 7 & 8 forapproximately 2.5 volts peak to peak.

(a) If signal is present, the tach/counter isdefective.

To replace this assembly:

1. REMOVE POWER TO STAND.

2. Remove the rear access panel.

3. Use a 3/16" socket wrench with extension andremove the four hex nuts from the rear of thetach/counter housing.

4. Disconnect and tag wiring after noting theexact position of each connection.

5. Remove complete assembly by pulling for-ward and out from the front panel.

NOTE: Make certain to insulate all wiringconnections.

4.1.7 Removal of Flexible Coupling(Figures 4-3 & 4-4)

Figure 4-3. Shoulder Bolts

1. Locate and remove the four shoulder boltsfrom the rear flange

2. Remove the front flange and centering ringassembly.

3. Remove the three hex head cap screws fromthe tapered hub.

4. Install these screws into the tapped holes tojack the hub from the rear flange.

5. Use the barring tool to facilitate hub removal,while gradually tightening each screw insequence. Then slide hub off shaft.

6. If difficulty is encountered during hubremoval, wedge a screwdriver into hub slot torelieve tension on the shaft. Caution: Excessiveforce will split the hub.



Figure 4-4. Removing Hub from Rear Flange

7. Slide the rear flange and degree wheelassembly off the shaft by pulling forward.

4.1.8 Flexible Coupling Installation(Figures 4-5 thru 4-11)

1. Insert hub into tapered inside diameter ofrear driven flange.

2. Align the three bolt holes in hub with thethree tapped holes in the driven flange andassemble loosely with three 1/4-20 bolts andlockwashers supplied with hub.

3. Slide the complete hub and rear flangeassembly over the drive shaft.

4. Slide hub and flange assembly along shaftuntil 1-3/16" remains between endd of driveshaft and hub.

NOTE: Reference dimension of 1-3/16" isdesigned to provide a final clearance of about3/4" between degree wheel and front panelafter hub is torqued to final specification.

5. Alternately tighten the three hex head capscrews in 50, 25, 25 and 8 lb-in. increments inrotational order. This will draw the drivenflange to the tapered hub uniformly. All threecap screws will have a final torque of108 lb-in. (Figure 4-6).

Figure 4-5. Flexible Coupling

Figure 4-6. Tightening Hub Cap Screws

NOTE: When properly installed, thetapered hub will remain stationary on theStand drive shaft and the drive flange willbe drawn into correct alignment with it.The distance between front face of degreewheel disc and degree wheel vernier shouldbe within ± 1/64 when cap screws aretightened to final torque.

6. With the rear flange and degree wheel se-curely installed, check the front face of thedriven flange for perpendicularity using a dialindicator against the top face of the flange(Figure 4-7).

7. Install the dial indicator using a bracketaround one of the Stand rails.



Figure 4-7. Checking Rear Flange Assembly

8. Bar coupling over one full turn and check thatdeviation does not exceed ±0.002 from theperpendicular plane (“wobble”).

NOTE: To prevent damage to the dialindicator, make certain that the stem isheld as it passes over the milled slot in theflange. The total misalignment must notexceed 0.002 ". Should it exceed this, loosenthe three hex cap screws and retighten themin the same manner as detailed in Step 5.After retightening, check for misalignment.

Figure 4-8. Placing Beveled WashersBetween Laminations & Rear Flance

9. Install four beveled washers over the shoulderbolts protruding through laminated discs (Fig-ure 4-8).

10. Refer to Figure 4-9. Horizontally align thefour shoulder bolts protruding through thelaminated discs with the holes in the rearflange.

11. Place lock nuts (one at a time) into each of theslots in the rear flange.

12. Tighten each bolt gradually until a finaltorque of 13 lb-ft is achieved (Figure 4-10).

Figure 4-9. Placing Lock Nuts intoSlots on Rear Flange

Figure 4-10. Tightening Shoulder Bolts



CAUTION

Use Flexible Coupling Guard at all timeswhen flexible coupling is in operation.Never operate Stand without flexiblecoupling connected to a pump.

Make certain that there is 1" clearancebetween the degree wheel and the couplingguard. Failure to have sufficient clearancecould damage degree wheel (Figure 4-11).

Figure 4-11. 1" Between Wheel & Guard

4.1.9 Motor Starter Overload Relay Adjustment(Figure 4-12)

1. Find the operating volts located on thenameplate of the Stand.

2. Locate the FLA (Full Load Amps) for thecorresponding voltage (step 1), which can befound on the main drive motor controllername plate.

3. The dial setting on the Motor Starter Over-load Relay is equal to the FLA value.

Figure 4-12. Typical Motor Starter withOverload Relay



4.2 Troubleshooting

Before attempting to troubleshoot, determine if theproblem is electrical and/or mechanical.

1. Electrical Problems

(a) Blown fuses or heaters, removingpower to one or more circuits.

(b) Relay contacts dirty/sticking or vibrationproblems.

(c) Extreme line voltage drops (or transients).

(d) Faulty switches.

2. Mechanical Problems

(a) Broken, worn or loose belt.

(b) Loose parts due to vibration.

(c) Dirt/oil buildup on sensitive parts.

(d) Starved system due to clogged filter.

(e) Fluid leakage due to worn seals or looseparts.

4.2.1 Electrical

Symptom Possible Cause Remedy

1. Graduate fill solenoid does not energize Defective fill solenoid. Defective If 230 VAC absent betweenwhen COUNT button is depressed. relay in tach/counter (SOL1)(TACH). Pins 3 & 4 when COUNT is

depressed, replace FILLTest Points: solenoid SOL.1.Terminal strip rear of tach/counterPins 3-4. Check for 230 VAC If 230 VAC present between 3(Tolerance: 197-253 VAC). & 4 when COUNT is depressed,

replace defective tach/counter.

2. Motor Overload Relay trips. Improper Motor Overload Relay Readjust using Section 4.1.9.setting (M1).

orImproper line voltage. Verify the incoming line voltage

meets specifications.or

Loss of a phase voltage. Investigate & correct problem.or

Motor overload. Troubleshoot & correct problem.or

Faulty motor (B1). Replace motor.

3. All systems function except Stop Button not reset. Rotate Stop Switch CCW tomain drive motor. allow button to return to the

up position (reset).or

Stop Switch bad (SW5). Replace.or

Motor starter bad (M1). Reset or replace.or

Control Relay Bad (K1). Replace.or

Motor controller bad (MC). Replace.or

Run button bad (SW6). Replace.



4.2.1 Electrical (Cont.)


4. No calibration fluid temperature control. Low fluid level. Add fluid.or

Temp. Sensor bad (S1). Replace.or

Plug disconnected (P1). Reconnect.or

Cooling solenoid open (SOL2). Replaceor

Overheat thermoswitch bad (TS1). Replace.or

Temp. Controller failed (TC). Replace.

5. Motor and drive function at low and Braking resistor open (BR1 or BR2). Replace.high speeds but trips out upon ordeceleration with light loads. Braking resistor wire(s) loose. Tighten.

6. Tach does not read RPM or Count. Magnetic pickup defective Replaceor Misadjusted. or Readjust.

7. Calibration fluid heating time slow. Heater(s) defective (HTR1-4). Replace.or

Water solenoid valve stuck open Repair or replace.(SOL2).

4.2.2 Mechanical


1. Air in Calibration Fluid Supply line. Low fluid level. Check and replace.or

Loose connection(s) in system. Tighten as required.or

Shut Off Valve leaky or defective. Repair or replace.or

Supply pump shaft seal leaking. Repair or replace.

2. Excessive vibration when main drive Stand is not level and/or on rubber Make corrections.motor is running. pads (under leveling screws).

3. Calibration temperature in reservoir No water supply. Troubleshoot.not stable. or

Water supply valve stuck closed. Repair or replace.or

Controls set wrong. Reset.or

Calibration fluid pump inoperative. Troubleshoot.

Technician 7.5 & 10 Parts Lists & Diagrams


5.0 PARTS LISTS

5.1 Belts, Filters, Etc.

Part # Description Qty/Stand

07-1614 Calibration Fluid Filter Cartridge - 10 micron Purolator 63104-02 or AC PF347 ................................... 105-2122 Main Drive Belt ......................................................................................................................................... 105-5107 Graduate 0-Ring S-7-3 (LT1) ................................................................................................................... 867-0094 Hose Assy. (Cal. Fluid Pump Inlet) ........................................................................................................... 167-4269 Hose Assy. (Cal. Fluid Pump Outlet) ........................................................................................................ 167-4517 Hose Assy. (Cal. Fluid Return to Reservoir) ............................................................................................. 367-4521 Hose Assy. (From Cal. Fluid Reservoir Outlet) ........................................................................................ 103-2912 Cal. Fluid Supply Pressure Gauge Connection (Plastic Line) ............................................................... 3 ft.03-2913 Nylon Tubing 3/8 0.D. ............................................................................................................................ 4 ft.03-5108 Hose (Cal. Fluid Waste) ........................................................................................................................ 2 ft.03-5109 Hose (Graduate Drain) ........................................................................................................................... 4 ft.03-6063 Graduate Flexible Vinyl Tubing .............................................................................................................. 1305-6304 Oil-Seal (For Cal. Fluid reservoir thermoswitch) ...................................................................................... 167-5598 Cal. Fluid (15 Gal. Drum) ......................................................................................................................... 1

5.2 Electrical Components(Reference Pages 2-2 and 2-3 for Component Designations Shown in Parenthesis)

04-3585 Indicating Light (Amber) .......................................................................................................................... 304-3584 Indicating Light (Red) (LT2, LT3, LT4) .................................................................................................. 167-5426 Heater 240V 500W (Cal. Fluid Reservoir) (HTR1-HTR-4) .................................................................... 404-1311 Circuit Breaker (Mounted On Side Panel) (CB) ....................................................................................... 104-2719 Fuse (F1 & F2) 460 Volt Stand Only ........................................................................................................ 2

104-0348 Switch (ON/OFF) Cal. Oil Supply/Heat (SW2) ....................................................................................... 167-6142 Temperature Controller Assy. (TC) .......................................................................................................... 167-6244 Graduate Solenoid Assy. (TC) .................................................................................................................. 167-6141 Temperature Sensor (Cal. Fluid Reservoir) (S1) ...................................................................................... 167-6887 Supply Pump/Motor Assembly 230V/60 Hz/1 Phase (B2) ....................................................................... 103-4222 Solenoid Valve (Water) (SOL2) ............................................................................................................... 2

104-0084 Motor Starter (M1) 7.5 HP, 230 Volt Stand Only ..................................................................................... 1104-0085 Motor Starter (M1) 7.5 HP, 460 Volt Stand Only ..................................................................................... 1104-0098 Motor Starter (M1) 10 HP, 230 Volt Stand Only ...................................................................................... 1

04-4062 Main Drive Motor (B1) 7.5 HP, 230 and 460 Volt Stands Only .............................................................. 104-4120 Main Drive Motor (B1) 10 HP, 230 Volt Stand Only ............................................................................... 177-1122 Motor Controller (MC) 7.5 HP, 230 Volt Stand Only (Consult Factory for Programming Procedure) .. 177-1136 Motor Controller (MC) 7.5 HP, 460 Volt Stand Only (Consult Factory for Programming Procedure) ... 177-1130 Motor Controller (MC) 10 HP, 230 Volt Stand Only (Consult Factory for Programming Procedure) .... 104-5258 Control Relay (K1) .................................................................................................................................... 1

204-9411 Breaking Resistor (BR1 & BR2) 7.5 HP, 230 Volt Stand Only ................................................................ 2204-9412 Breaking Resistor (BR1 & BR2) 7.5 HP, 460 Volt Stand Only ................................................................ 2204-9413 Breaking Resistor (BR1 & BR2) 10 HP, 230 Volt Stand Only ................................................................. 2

04-9992 Arc Suppressor (Supply Pump Motor, Heaters, Water Solenoid, Control Relay) (RC2, RC3, RC4, RC5) ... 404-9993 Arc Suppressor (Motor Starter, Graduate Fill Solenoid) (RC1, RC6) ...................................................... 2

104-0357 Switch (Cal. Fluid Pump) (SW3) ............................................................................................................... 1104-0336 Switch (Rotation) (SW4) ........................................................................................................................... 1


Parts Lists & Diagrams Technician 7.5 & 10

104-0554 Contact Block, Normally Closed (Stop Button) (SW5) ............................................................................ 1104-0555 Contact Block, Normally Open (Run Button) (SW6) ............................................................................... 2104-0557 Button, Black (Run) *Does Not include Electrical Contact Block ........................................................... 1104-0558 Button, Red (Stop) *Does Not include Electrical Contact Block .............................................................. 1

04-4872 Potentiometer (Speed Control) (R1) .......................................................................................................... 1204-4593 Potentiometer 6 ohm, 4 watt W.W. (Temperature Adjust) (R2) .............................................................. 1

67-6170 Thermoswitch (Cal. Fluid Reservoir) (TS1) .............................................................................................. 1

5.3 Instruments

67-6204 Tachometer/Counter Assy. ........................................................................................................................ 167-6258 Magnetic Pick-up Assy. ............................................................................................................................ 167-6205 Temperature Gauge, 3 1/2" Dial Size, Range 40°-140°F (5°-60° Celsius) ................................................ 167-6206 Compound Gauge, 3 1/2" Dial Size, Range 0-30" Hg, (0-76 cm Hg VAC), 0-100 psi., (0-7 kg/bar) ...... 167-6845 Sho-Rate “150” Flowmeter (Return Flow Meter) ..................................................................................... 1

5.4 Miscellaneous Parts

02-8201 Panel Fasteners (L-handle Type Latch) South Co. #61-20-107-11......................................................... 1167-1120 Bulkhead Fitting (Cal. Fluid Inlet) ............................................................................................................ 103-2727 Bulkhead Fitting (Cal. Fluid Returns) ...................................................................................................... 206-8151 Leveling Pad, 1/2-13 Stud (Fabcel #HD-300) ........................................................................................... 405-1405 Rear Drive Shaft Bearing, 1-1/2" ............................................................................................................... 167-6278 Front Drive Shaft Bearing, 1-1/2" (Modified) ........................................................................................... 167-5512 Graduate Assy. (Includes Valve Assy. 67-0346) ...................................................................................... 8

104-6532 Knob (Speed Control) ................................................................................................................................ 105-9519 Shock Mount (Electrical Chassis) ............................................................................................................. 403-4248 Shutoff Valve (Ball Valve 3/4 FPT) ............................................................................................................ 167-2643 Gasket (Cal. Fluid Heaters) ....................................................................................................................... 167-0346 Graduate Valve Assy. ................................................................................................................................ 867-7702 Flexible Coupling Assy. ........................................................................................................................... 167-5433 Cooling Coil .............................................................................................................................................. 1

900-2654 Waste Can ................................................................................................................................................. 1

5.5 Optional Accessories

67-7610 Final Stage Filter and Gauge Kit ............................................................................................................... 107-1606 Final Stage Filter Element ......................................................................................................................... 167-7227 Pressure Lubrication System ..................................................................................................................... 172-7010 Portable High Pressure Timing Unit ......................................................................................................... 167-3541 Drive Adapter (Tanged)............................................................................................................................. 1

Technician 7.5 & 10 Appendix A

Instruction 67-9268 Bacharach, Inc. Page A-1

Listing of Pump, Mounting Diagrams for BacharachCalibrating Stands*

Dwg. No. Pump Male/Model/Application

67-9186C Ambac APE6BB (Mack)67-9196C Ambac APE6BB, APE6Z67-9185C Ambac APE8VBB, including

‘Short Housing’ and APE8VG67-9078B Ambac APF1A, APF1B67-9156D Ambac 100 - Navistar77-9041D Ambac PSB12BT (MIL.)67-9080B Ambac APE.A67-9285C Ambac PSB6A (Mil.)67-9410D Ambac 100 - Allis Chalmers77-9070D Ambac PSU, 2/4 (M50)

67-9076B Bosch PES6P/Navistar DT817B,C67-9077C Bosch PES8A75C/Navistar Trucks67-9079B Bosch EP/VA - Navistar/Farm67-9151C Bosch PES6P/John Deere67-9129C Bosch PES6A/John Deere67-9311D Bosch EP/VE - VW Rabbit67-9439D Bosch PES4M/MB 190D67-9424D Bosch PES6MW - Navistar (I)46667-9451D Bosch EPVE/CDC77-9083D Bosch P7100/Mack

67-9081B CAV NN (Mack/Scania)67-9153C CAV Roto Diesel/John Deere67-9276C CAV DP1567-9305D CAV Roto Diesel/John Deere67-9341D CAV-DPA67-9428D CAV-DPA Case/Cummins77-9121D CAV-DPC

77-9082D Cummins PT - Flowconsole77-9085D Cummins PT - Flowmaster

* This is a complete list of Pump Mounting Diagrams.Useonly those that apply to the Technician Stand.

Dwg. No. Pump Male/Model/Application

67-9134C Caterpillar 1 10067-9139C Caterpillar 167367-9140C Caterpillar 167467-9141C Caterpillar 169367-9229D Caterpillar - Sleeve Metering 3208 (V8)67-9228D Caterpillar - Sleeve Metering 3304, 330667-9238D Caterpillar 340667-9252D Caterpillar 3408/341267-9440D Caterpillar 3406 B New Scroll Type67-9444D Caterpillar 3306 B New Scroll Type

67-9253C Diesel Kiki PES6A (Navistar/Nissan)

77-9142D Nippondenso NB(EP-9)

77-9086D Simms P5184/1

67-9125C Stanadyne DM/John Deere67-9177C Stanadyne DM/Allis Chalmers67-9176C Stanadyne DM/Allis Chalmers (Oiler &

Bracket Installation)67-9287C Stanadyne DB-2 - GM 5.7L/V8, 4.3L/V667-9342D Stanadyne DB, DC67-9399C Stanadyne DB2 - Navistar, 6.9L/V8,

7.3L/V867-9400C Stanadyne DB2 - Allis Chalmers 43367-9401C Stanadyne DB2 - Onan 2.3L, 3.4L,

DB4 John Deere67-9402C Stanadyne DB2 - Waukesha VRD220,

VRD33067-9395C Stanadyne DB2 - GM 6.2L/V867-9445D Stanadyne DB2 - John Deere77-9053C Stanadyne DB2 - Teledyne Continental

2.7L

APPENDIX A – PUMP MOUNTING DIAGRAMS

Page A-2 Bacharach, Inc. Instruction 67-9268

Appendix A Technician 7.5 & 10

NOTES

Technician 7.5 & 10 Appendix B

Instruction 67-9268 Bacharach, Inc. Page B-1

APPENDIX B - INJECTOR ACCUMULATOR ACCESSORIES

The following is a list of injectors by manufacturer and the accumulatoraccessories needed to run them on the Technician Stand. **

INJECTOR ACCUMULATOR ACCESSORIES APPLICATION TABLE

Test Injector Nozzle Nozzle Nozzle NotesHolder Clamp

Mfg. Type/Size Adapter Adapter Holder

AMBAC DN12DI2, ADN8S2 67-6693* ——— 77-0756*& Bosch Orifice Type SAE/ISO " ——— "

(all ‘S’ Size)

AMBAC AKF130.................. " 77-0830 " MilitaryAKN212........ " 77-0770 77-0829

AMBAC Horizontal Inlet " 67-0449* 77-0756*(MACK) Vertical Inlet " " "

Bar Stock " " "AKN..(4 Valve Head) " 67-6245 "

Bosch ‘Low Dead Volume’ ——— 77-0625* " Mack (for(1 688 901 101) P1700 pumps)‘Low Dead Volume’ 67-6693* ——— " EPVE-CDC(1 688 901 027)‘T’ Size ——— ——— "

Caterpillar IP 1715 ——— 67-6684 " Early Style(Obsolete)

1U5500 (was 6V 9470) ——— 77-0771 "

Zexel "T" Size (105780-8130) ——— 77-0512 "(Diesel KIKI) "Low Dead Vol.","S" Size 67-6693* ——— "

* These parts can be found in the Basic Accessory Kit.** This is a complete list of Injector Accumulator Accessories.

Use only those that apply to the Technician Stand.

Page B-2 Bacharach, Inc. Instruction 67-9268

Appendix B Technician 7.5 & 10

NOTES

© Copyright 1997 Bacharach Inc.

WARRANTY

Bacharach, Inc., warrants to Buyer that at the time of delivery this product will be free from defectsin material and manufacture and will conform substantially to Bacharach’s applicable specifica-tions. Bacharach’s liability and Buyer’s remedy under this warranty are limited to the repair orreplacement, at Bacharach’s option, of this Product or parts thereof returned to Seller at the factoryof manufacture and shown to Bacharach’s reasonable satisfaction to have been defective; providedthat written notice of the defect shall have been given by Buyer to Bacharach within one (1) yearafter the date of this product by Bacharach.

Bacharach warrants to Buyer that it will convey good title to the Product. Bacharach’s liability andBuyer’s remedy under this warranty of title are limited to the removal of any title defects or, at theelection of Bacharach, to the replacement of this Product or parts thereof that are defective in title.

The warranty set forth in paragraph 1 does not apply to parts the Operating Instructions designateas 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 FROMBACHARACH’S 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 unless in writing, signedby a duly authorized officer of Bacharach.

A

67-9268

Documents

calibration fluid system

console panel figure

trademark of bacharach

panels figure

panel connections

alpha drive

main drive

optional accessories