TM-9-4910-604-14-and-P

TM-9-4910-604-14-and-P
TM 9-4910-604-14&P
TECHNICAL MANUAL
OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT
AND GENERAL SUPPORT MAINTENANCE MANUAL
INCLUDING REPAIR PARTS LIST
FOR
TEST SET, DIESEL INJECTOR
(BACHARACH INSTRUMENT COMPANY)
(NSN 4910-00-317-8265)
HEADQUARTERS, DEPARTMENT OF THE ARMY
OCTOBER 1981
WARNING
The force of the spray from a feel injection nozzle is sufficiently great to penetrate the skin. Fuel oil in the blood stream
can cause blood-poisoning. Keep hands away from injectors and nozzles when they are being tested.
TM 9-4910-604-14&P
This manual contains copying material
Technical Manual
HEADQLARTERS
DEPARI MENT OF THE ARMY
Washington DC, 15 October 1981
No. 9 4910-604-14&P
Operator’s, Organizational, Direct Support
and General Support Maintenance Manual
Including Repair Parts List
For
TEST SET, DIESEL INJECTOR
(NSN 4910-00-317-8265)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find-any mistakes or if you know of a way to
improve the procedures, please let us know. Mail your letter, DA Form 2028
(Recommended Changes to Publications and Blank Forms), or DA Form 2028-2, located
in the back of this manual direct to: Commander, LIS Army Armament Materiel Readiness
Command, ATTN: DRSAR-MAS, Rock Island, II. 61299. A reply will be furnished direct
to you.
NOTE
This manual is published for the purpose of identifying an authorized commercial manual for the use of the personnel to
whom this diesel injector test set is Issued.
Manufactured by: Bacharach Instrument Company
625 Alpha Drive
Pittsburgh, PA 15238
Procured under Contract No. DAAA09-75-C-6725
This technical manual is an authentication of the manufacturers’ commercial literature
and does not conform with the format and content specified in AR 310-3, Military
Publications. This technical manual does, however, contain available information that is
essential to the operation and maintenance of the equipment.
TM 9-4910-604-14&P
INSTRUCTIONS FOR REQUISITIONING PARTS
NOT IDENTIFIED BY NSN
When requisitioning parts not identified by National Stock Number, it is mandatory that the following information be
furnished the supply officer.
1-
Manufacturer’s Federal Supply Code Number - 05083
2-
Manufacturer’s Part Number exactly as listed herein.
3-
Nomenclature exactly as listed herein, including dimensions, if necessary.
4-
Manufacturer’s Model Number -
5-
Manufacturer’s Serial Number (End Item)
6-
Any other information such as Type, Frame Number, and Electrical Characteristics, if applicable.
7-
If DD Form 1348 is used, fill in all blocks except 4, 5, 6, and Remarks field in accordance with AR 725-50.
Complete Form as Follows:
(a) In blocks 4, 5, 6, list manufacturer’s Federal Supply Code Number - 05083 followed by a colon and
manufacturer’s Part Number for the repair part.
(b) Complete Remarks field as follows:
Noun:
(nomenclature of repair part)
For:
NSN: 4910-00-317-8265
Manufacturer:
Bacharach Instrument Company
625 Alpha Drive
Pittsburgh, PA 15238
Model:
Serial:
(of end item)
Any other pertinent information such as Frame Number, Type, Dimensions, etc.
ii
TM 9-4910-604-14&P
TABLE OF CONTENTS
INSTRUCTIONS ....................................................................................................................................................
GENERAL FACILITIES ..........................................................................................................................................
APPLICATION OF TOOLS ....................................................................................................................................
CONNECTOR SET 44 INSTRUCTIONS ...............................................................................................................
TEXT FIXTURE AND NOZZLE TESTER INFORMATION ....................................................................................
TESTING INJECTORS ..........................................................................................................................................
MAINTENANCE AND OPERATING INSTRUCTIONS ..........................................................................................
DIESEL NOZZLE TESTER-GENERAL REMARKS ...............................................................................................
OPERATING PROCEDURE ..................................................................................................................................
USE OF OUTLETS ................................................................................................................................................
LEAKAGE AND DISCHARGE VALVE REPLACEMENT .......................................................................................
STARVATION AND FILTER REPLACEMENT ......................................................................................................
SPECIAL TEST OILS.............................................................................................................................................
PARTS LIST FOR NOZZLE TESTER....................................................................................................................
INJECTOR TEST SET WARNING ........................................................................................................................
INSTALLING SEAT BLOCKS ................................................................................................................................
PREPARING FOR TEST .......................................................................................................................................
INJECTOR TESTS .................................................................................................................................................
ADDITIONAL TESTS FOR NEEDLE VALVE INJECTORS ...................................................................................
MAINTENANCE .....................................................................................................................................................
PARTS LIST FOR TEST FIXTURE .......................................................................................................................
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TM 9-4910-604-14&P
INSTRUCTIONS
FOR USE OF
NOZZLE-INJECTOR CLEANING TOOLS
These tools are intended as cleaning aids and should be used only to remove foreign particles or deposits
detrimental to operation of fuel injection nozzles. Proper lapping blocks for removal of heat and other surface
discolorations or small pits on flat sealing surfaces are available as separate items.
Such operations as lapping valve seats and regrinding nozzle valves are special operations, requiring more tools
than provided, and, unless operator is equipped to do such work, should not be attempted.
Injectors should be dismantled and cleaned in accordance with manufacturer’s recommendations, both as to
cleaning methods and tools. Cleanliness is all important and no detail, however small, should be neglected to insure and
maintain clean air, oil and surroundings. Dirt particles too small to be seen without magnification are still large enough to
cause serious damage to fuel injection equipment.
GENERAL FACILITIES
A separate room for fuel injection work, supplied only with clean, filtered air, is preferable. If this is done, and
room air is maintained at pressure slightly above atmosphere, airborne dirt cannot enter from outside atmosphere. If
separate room specification cannot be met, choose isolated corner in shop; this corner should be kept clean and shop
traffic kept to minimum .
Be as clean as possible; use clean tools; keep work bench clean; wear shop coats or coveralls, heavily starched
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TM 9-4910-604-14&P
to minimize lint problems. Keep all openings on nozzles capped. Use paper towels as mats on which parts can be placed.
Use only clean fuel oils and solvents. Two or three porcelain or glass trays are best to use for holding solvents and fuel oil.
Minimum of two trays, one for solvent-and one for clean fuel oil, is suggested. A piece of brass screen, placed on half-inch
blocks, will hold parts in bath and allow dirt particles to settle on bottom of tray.
Ordinary wooden work bench surfaces tend to accumulate dirt and grease; steel bench tops may damage tools or
nozzles if they are accidentally dropped. Acceptable and preferred surfaces are linoleum, masonite or varnished hardwood
tops. Use copper or fibre jaws on vise; grip injector only on vise flats. Use only proper wrenches to dismantle and
assemble injector parts in clean fuel oil or preservative and assemble wet; avoid handling, particularly lapped surfaces.
Nozzle injector servicing after cleaning includes complete testing. Tests generally include adjustment to correct
opening pressure, observation of spray form, check for leakage and chatter to indicate freedom of movement of nozzle
valve. These operation, s are performed with aid of suitable testing equipment. If injector is to be stored, use special test
oils to minimize oxidation and gumming which sometimes occur when regular fuel oil is used. Flush injector thoroughly to
insure test oil penetrating to and coating all surfaces of unit.
CAUTION: Never, under any circumstances, interchange nozzle bodies and valves. Best way to eliminate even
accidental interchanging is to dismantle one nozzle body and valve at a time: clean and reassemble it before working on
another. This will avoid confusion and prevent subsequent trouble.
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APPLICATION OF TOOLS
Bristle Brushes:
Codes 66-0016
66-1062
For INJECTORS:
Use to clean rack hole in injector body. Also use as general purpose brush on all
injectors where size permits.
Honing Stone:
Code 66-0017
For NOZZLES, and INJECTORS:
Use to deburr cleaning needle, seat scraper, pressure chamber scraper, cleaning
drills, and so forth. Use also to sharpen cleaning needles to wedge-type point or
two-fluted reamer.
Spray Tip
Cleaner:
Codes 66-0018
66-1109
For INJECTORS:
After clogged and dirty orifices in spray tip have been opened, clean dirt from
axial hole in spray tip. Dirt pushed into spray tip while cleaning orifices should be
removed.
Bristle Brush:
Code 66-0019
For NOZZLES;
Use to clean interior of nozzle holder, nozzle cap, nut and other regions not
readily accessible to wire brush.
For INJECTORS:
Use to clean interior of injector body. If necessary soak parts in solvent to soften
carbon and lacquer.
Pin Vises:
Codes 66-0021
(0-.062")
66-0068
(.052-.125")
For NOZZLES, and INJECTORS:
Use to hold cleaning drills and needles when cleaning orifices. Also use to hold
small injector parts when they are being lapped. For example, Pin Vise, Code
66-0068, is recommended to hold I-H check and reverse check valves in this
operation.
Inspection
Magnifier:
Code 66-0023
For NOZZLES, and INJECTORS:
Use to closely inspect orifices and other critical parts. Magnetic base holds
magnifier mounting post vertical. Lens and protector are removable from post for
additional inspection facility and packing convenience.
Tallow:
Code 66-0029
For NOZZLES and INJECTORS:
Use to clean lacquered and stained valves. Soak heavily lacquered valves in
solvent before attempting to clean with tallow. Tallow can be also applied to
cleaning sticks and polishing sticks to clean pintle orifice and nozzle valve seat.
If this is done, excess tallow should be removed and seat polished before
assembly of nozzle.
Brass Wire
Brush:
Code 66-0030
For NOZZLES:
Use to remove carbon, rust spots and similar deposits from external surfaces of
nozzle holder, nozzle nut. and nozzle body, and from external surfaces of injector
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TM 9-4910-604-14&P
Brass Wire
Brush:
Code 66-0030
(cont’d)
body, top plate and cup. Alternate soaking in fuel oil or carbon solvent and brushing may
be necessary. Do not brush mating lapped surfaces; do not brush nozzle body or injector
cup in vicinity of orifice more than necessary to remove dirt. Never use power-driven wire
wheels.
Pressure Chamber
Scrapers:
Codes 66-0047
66-0050
For NOZZLES:
Insert hooked end of scraper into nozzle body and rotate scraper to clean pressure
chamber gallery in nozzle body. Flush with clean fuel oil and blow dry with clean
compressed air. Remove burrs and sharpen end of scraper with smooth-cut file when
necessary.
Cleaning Drills
Codes 66-0048
66-0049
For INJECTORS:
Use to clean all dirt and foreign particles from interior of injector cup. This is to be done
after orifices have been cleaned. Hold in finger tips and rotate, pushing just hard enough
to perform necessary cleaning operations.
Pressure Chamber
Scraper:
Code 66-0050
Refer to Code 66-0047
Polishing Sticks:
Codes 66-0059
66-0060
66-0086
66-0087
For NOZZLES:
Using stick which most closely fits bore of nozzle body and after other cleaning
operations on body have been completed, polish valve seat with polishing stick which has
been previously soaked in fuel oil. This operation is best done by rotating nozzle body or
stick in a chuck at not more than 100 revolutions per minute and holding other part in
hand, applying light pressure to give seat desired polish. Refinish conical end of stick with
file when necessary.
Pintle Cleaning
Block:
Code 66-0061
For NOZZLES:
Insert pintle end of nozzle valve into slot in cleaning block, squeeze sides of block with
one hand and rotate nozzle valve to clean stopped sections of pintle. Insert into conical
hole; rotate and push slightly to clean conical area of valve. Soak valve, if necessary, in
suitable carbon solvent to loosen stubborn deposits.
Valve Seat
Scrapers:
Codes 66-0062
66-0069
For NOZZLES:
Insert end of scraper which best fits bore of nozzle body and rotate scraper by hand to
clean seat area of gum and foreign deposits. Nozzle body should be previously soaked
in carbon solvent. Resharpen scraper with smooth-cut file when necessary.
Centering Sleeves:
Codes 66-0063
66-0064
66-0065
66-0066
66-0067
66-0111
For NOZZLES:
Use to align nozzle in nozzle cap in assembling nozzle holder. Before beginning to
tighten nozzle cap nut, install centering sleeve between nozzle and nozzle cap nut; then
tighten to torque specified by equipment manual. This automatically centers nozzle in
assembly.
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TM 9-4910-604-14&P
Replace protective plug on end of centering sleeve when not in use.
Pin Vise:
Code 66-0068
Refer to Code 66-0021
Valve Seat:
Scraper:
Code 66-0069
Refer to Code 66-0062
Nozzle Seat
Scraper:
Code 66-0072
For NOZZLES:
Use to clean seat in nozzles. Scraper should be used with very light pressure and
rotated only enough to clean carbon from seat. Use hone to keep wedge sides and end
sharp and square, free of burrs.
Burring Tool:
Code 66-0075
For INJECTORS:
Use to deburr sharp corner of valve seat. Chamfer of 0.002" to 0. 005" is recommended.
To use stone, hold between forefinger and thumb and rotate, applying light end pressure.
Wiper Pad:
Code 66-0076
For NOZZLES:
Use as polishing pads to apply tallow to nozzle valve for cleaning purposes. If possible,
nozzle valve should be inserted in rotating chuck for this operation.
Orifice Cleaning Stick:
Code 66-0077
For NOZZLES:
Use cleaning sticks to clean orifice in nozzle body through which pintle protrudes. Insert
stick into orifice and clean with combined rotary and pushing motion. Cleaning sticks
should be soaked in fuel oil prior to use.
Spray Tip
Driver and
Bushing Cleaner:
Code 66-0078
For 71 INJECTORS:
1. Use to drive sticking spray tips out of injector nut.
2.
Use to clean bushing by sliding tissue paper through axial slot and wrapping
around shaft. Bushing is then cleaned similar to gun barrel. Soak in solvent or clean fuel
oil.
3.
Use as assembly pilot by placing body seal and all parts of spray tip assembly
except injector nut on top of bushing. Use long rod to hold parts in position with one hand
and slide injector nut down over rod with other hand and then by switching hands
carefully, move injector nut over spray tip assembly and screw onto injector. body.
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TM 9-4910-604-14&P
Injector Nut Tip
Seat Reamers:
Codes 66-0079
66-0081
66-1108
For INJECTORS:
Use to remove carbon from spray tip seat and boss of injector nut. On reamer with
adjustable collar, set collar before using to permit 0. 005" clearance under stop when
reamer is inserted in new injector flute. On reamer with fixed collar, be certain when
re-sharpening to remove equal amount of material from collar.
Injector Spray
Tip Driver:
Code 66-0082
For 110 INJECTORS:
Use to drive sticking spray tip out of injector nut.
Injector Bushing
Cleaner and
Assembly Pilot:
Code 66-0083
For 110 INJECTORS:
1. Use to clean bushing by sliding tissue paper through axial slot and wrapping around
shaft. Bushing is then cleaned similarly to gun barrel. Soak in solvent or clean fuel
oil.
2. Use as assembly pilot by placing body seal and all parts of spray tip assembly
except injector nut on top of bushing. Use long rod to hold parts in position with one
hand and slide injector nut down over rod with other hand and then by switching
hands carefully, move injector nut over spray tip assembly and screw onto injector
body.
Polishing Sticks: Refer to Code 66-0059
Codes 66-0086
66-0087
Bristle Brush:
Code 66-1062
Refer to Code 66-0016
Cleaning
Needles
and Drills:
For NOZZLES, and INJECTORS:
Use needles to clean and open up clogged orifices. Needle should be inserted in pin vise
with 1/16"protruding for first cleaning operation. For subsequent operations, needle
should be relocated to extend about 1/8", and cleaning operation should be repeated until
all orifices are fully open. If orifices are badly plugged, soak piece in solvent, and with
needle extruded only 1/32" from end of pin vise, tap gently with small mallet and rotate
needle; repeat, extending needle in small increments, until orifice is fully open.
Use cleaning drill for cleaning axial hole in spray tip after orifices have been cleaned. Dirt
which is pushed into center hole can thus be removed.
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GENERAL INFORMATION
MODEL YJH TEST FIXTURE and NOZZLE TESTER will test injectors for Series A, H, NH, or NVH engines. By
using accessories provided, complete tests may be made on injector and inlet tube under field or shop conditions.
NOZZLE TESTER is also used to test hydraulically-operated, differential-pressure type nozzles as covered in instruction
pamphlet on NOZZLE TESTER.
Several tests are necessary to determine condition of injector. Before proceeding with injector and inlet tube tests,
injector should be tested for clogged orifices in tip.
For permanent installation, fasten test fixture to bench with 3/8" bolts; for portable use (field service trucks, etc.),
stand may be used without permanent fastenings. For all injector tests described in following paragraphs, FLEXIBLE
CONNECTOR (1) may be attached to either upper or lower connection of DISCHARGE BLOCK (2) on TESTER (3) by
simultaneously engaging right-hand threads on DISCHARGE CONNECTION and left-hand threads on FLEXIBLE
CONNECTOR with dual-threaded CONNECTOR NUT (4), tightening securely. Left-hand threads are on rounded end of
CONNECTOR NUT. CAP NUT (5) is tightly screwed on discharge connection not in use. GAUGE VALVE (6) should be
fully open during all tests.
TESTING INJECTORS
BACK PRESSURE TEST
After injector tip has been cleared of clogged orifices, place CLAMP SLEEVE (7) on top housing of injector
(remove wire bale on NH injectors) and set injector in place on REVERSE FLOW BLOCK (8) making certain that
PLUNGER STUD (9) does not protrude below PRESSURE SCREW (10) and that PRESSURE SCREW clears CLAMP
SLEEVE when seating injector in REVERSE FLOW BLOCK. Simplest method of doing this is to hold injector vertically in
seat and turn PRESSURE SCREW down into CLAMP SLEEVE.
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TM 9-4910-604-14&P
FLEXIBLE CONNECTOR (1) is attached to REVERSE FLOW BLOCK with second CONNECTOR NUT (4). Screw DRIP
TUBE (11) into injector drain line hole. This test set-up is illustrated by Figure 1.
Using TESTER, maintain pressure of 2, 000 psi. (sixteen hundred psi. for A injectors), pumping as required.
Fuel flow through DRIP TUBE should be caught in BURETTE (12) provided and should not exceed six cubic centimeters
per minute at 2, 000 psi.; flow in excess of this rate indicates worn plunger or barrel and injector should be returned to
factory for repair or replacement. For accurate measurements, do not meter fuel until at least one drop has been
observed at DRIP TUBE.
Fuel at inlet connection indicates leakage past injector body check valve. Leakage of one or two drops per minute
past injector body check valve is permissible since design of valve is such that when leakage causes unsatisfactory
operation of this part an almost continuous flow of oil will result.
FIG. 1 Back Pressure Test
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INLET FUEL CONNECTION TESTS
Prepare inlet connection for test by removing brass connection and strainer screen from inlet connection.
Assemble ADAPTER (13) to inlet connection and attach LOW PRESSURE GAUGE (14) with UNION CONNECTION (15)
as illustrated in Figure 2. Attach FLEXIBLE CONNECTION (1) to LOW PRESSURE GAUGE with CONNECTOR NUT (4).
Using TESTER (3), determine that opening pressure of check valve in inlet tube is within limits specified in engine manual;
opening point of valve is best determined by pumping slowly.
FIG. 2 Inlet Connection Opening Test
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Fuel inlet connection check valve is checked for leakage (Figure 3) by screwing end of inlet connection normally
screwed into injector body into female threads of ADAPTER (13) and connecting ADAPTER to FLEXIBLE CONNECTOR
(1) with CONNECTOR NUT (I). There should be no leakage at 2, 000 psi.
FIG. 3 Inlet Connection Leakage Test
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TM 9-4910-604-14&P
INJECTOR FLOW AND CUT-OFF TESTS
Figure 4 illustrates set-up to determine opening pressure of injector and inlet tube in series. Using ADAPTER
(13), connect FLEXIBLE CONNECTOR (1) to inlet connection with LOW PRESSURE GAUGE (1L) in system. Opening
pressure of inlet tube and injector inlet valve in combination should be 10 to 15 psi. Higher than opening pressure of inlet
connection check valve. STUD (16) is mounted on yoke on top of stand and engages hole in injector body housing; spray
can be caught in CUP (17).
FIG. 4 Injector Inlet Connection Opening Pressure.
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TM 9-4910-604-14&P
Figure 5 shows test set-up to observe plunger cut-off characteristic.
Mount SPACER BLOCK (18) on REVERSE FLOW BLOCK (8); set injector in conical seat on top of
SPACER BLOCK; screw down HANDLE (19) until injector plunger is firmly seated against bottom of
injector barrel. Connect injector and inlet tube assembly to FLEXIBLE CONNECTOR (1) with INLET
TUBE ADAPTER (13) and CONNECTOR NUT (4). There should be no leakage at tip of injector or
injector body at test pressure of 2, 000 psi.
FIG. 5 Plunger Cut-Off Test
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MAINTENANCE AND GENERAL OPERATING INSTRUCTIONS
All necessary operating instructions and maintenance information concerning
NOZZLE TESTER are in separate instruction pamphlet. Parts for the
MODEL YJH TEST FIXTURE or NOZZLE TESTER are replaceable.
Minor leakage is permissible at seat of REVERSE FLOW BLOCK (8), provided required fuel
pressure can be maintained by slowly pumping NOZZLE TESTER. Care should be given to proper
insertion of injector in conical seal since damage to both seat and injector tip result if injector is not
properly seated. High forces are not necessary since seal is obtained by rubber O rings in conical seat of
REVERSE FLOW BLOCK. Rings are replaceable, and for user’s convenience, extra 0 rings are supplied
with each stand.
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TM 9-4910-604-14&P
INSTRUCTION DEAWINO
(DO NOT USE FOR ORDINRINO PARTS)
BLOCK FITTING (8), using lower connection for
conventional tests on hydraulically-operated
nozzles; use upper connection for leakage
rate measurements.
7. Install CAP NUT (9) on connection not In
use and tighten all connections.
8. Note opening pressure, leakage and spray
form, service injection nozzle according to
engine builder’s recommendations.
9. In general, nozzle should be serviced to
obtain:
(a) Correct opening pressure.
(b) Proper spray appearance during rapid
pumping.
(c) No leakage at 100 psi below opening
pressure. (300 for pintle type nozzles).
(d) "Chattering" under extended pumping.
GENERAL REMARKS
Series 65-000 Nozzle Test Pump,
can be used
interchangeably with nozzle testers of earlier design on
connector sets and test fixtures which have been
developed for specific Diesel engine applications.
OPERATING PROCEDURE
1.
2.
3.
4.
5.
6.
Bolt NOZZLE TESTER (1) to bench with
3/8’ bolts; for portable use, mount on
wooden or metal base similar to type
illustrated in Figure 1.
Slide tubular end of PUMP HANDLE (2)on
HANDLE SHOE (3) in base of NOZZLE
TESTER. Solid shaft in telescoping PUMP
HANDLE may be extended or telescoped,
depending on pressures needed.
Remove COVER (4) of FUEL SUPPLY cup
(5) with combined twisting and pulling
motion; fill SUPPLY CUP with testing fluid.
Open GAUGE VALVE (6).
NOZZLE TESTER is self-priming; several
strokes may be necessary to evacuate
entrapped air. Although not necessary,
VENT SCREW (7) in side of housing and
directly behind lower discharge fitting can
be opened for through venting and as
priming aid.
Attach
nozzle
and
connector
to
DISCHARGE
USE OF OUTLETS
DISCHARGE BLOCK ASS Y (8) has two discharge
outlets to facilitate various tests which are required by
nozzle and injector manufacturers. When nozzle under
test is connected to the lower connection, closing the
GAUGE VALVE (6) isolates prolonged pumping when
flushing nozzle or checking spray form. Using upper
connection and closing the GAUGE VALVE (6) isolates
the GAUGE and Nozzle from the NOZZLE TESTER,
permitting accurate measurement of leakage rates or
pressure drop. CAP-NUT (9) must be tightly screwed
onto connection not in use.
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LEAKAGE AND DISCHARGE VALVE
REPLACEMENT
STARVATION AND FILTER REPLACEMENT
Fuel starvation may be caused by several
causes. Series 65-000 Nozzle Tester uses improved
paper type filter; oil is forced through filter by
atmospheric pressure and pump suction. Dirty filters can
cause nozzle tester to starve for lack of fuel; in addition,
leaking O-rings or gaskets in reservoir and filter
assembly may also cause starvation. CENTER ROD
ASSEMBLY (15) with can over filter enables fuel level to
be pumped to bottom of can before refilling is required.
Filter in, OIL SUPPLY CUP (5), should be
replaced at least annually. Appearance of filter and fuel
starvation, especially during sustained rapid pumping,
are symptoms of dirty filter. Special care should be used
to prevent unfiltered oil from entering NOZZLE TESTER
(1) and fittings while replacing filter. Replace filter as
follows:
1.
Remove COVER (4) and empty OIL SUPPLY
CUP (preferably by inverting NOZZLE TESTER).
2.
Unscrew CENTER ROD (15); pull filter off
CENTER ROD. Be careful not to lose gaskets and
spring which seal top side of filter unit. 3. Install new
filter and reassemble in reverse order.
Minor leaks may develop occasionally. They are usually
easy to find and service. If GAUGE (10) indicates that
TESTER will not hold pressure, test tightness o, f
threaded connections,
GAUGE VALVE (6) and
DISCHARGE FITTING (8). Use Allen wrench to tighten
socket head cap screws in DISCHARG, E FITTING. If
leakage persists, dismantle and clean DISCHARGE
Valve e as follows:
1.
Remove four SOCKET HEAD CAP SCREWS
(11) in DISCHARGE FIT’TING.
2.
Lift DISCHARGE FITTING from pump housing
and remove DISCHARGE VALVE (12).
3.
Roll O-RING (13) off DISCHARGE VALVE;
examine seat for scratches or particles
preventing O-RING from sealing; replace scored
or pitted DISCHARGE VALVE.
4.
Inspect O-RING for fraying or extrusion; it should
have slight tension when Installed; if O-RING is
not available, use S-7-8 O-RING or equivalent,
provided it is oil-resistant rubber.
5.
Reassemble, making certain that DISCHARGE
VALVE GASKETS (14) are in place; tighten CAP
SCREWS alternately to draw DISCHARGE FITTING up
evenly. Leakage past nozzle tester plunger is detected
by accumulation of fuel at base of tester housing. Some
seepage is desirable for lubrication but there should not
be visible drippage past plunger. Since plunger is lapped
into bore of nozzle tester housing, it is necessary to
return instrument to factory for repairs; the lapped fit of
the plunger is similar to Diesel fuel injection equipment
and should receive similar care.
SPECIAL TEST OILS
Careful consideration should be given to oils
used for testing since Diesel fuel oils may have
undesirable properties for nozzle test work. Oils with
noncorrosive & noncongealing characteristics are
preferred when injector being tested may be stored for
some time before being used. It is suggested that
recommendations of manufacturer by followed
concerning use and type of testing fluid.
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Instructions for Operation
and Maintenance
INJECTOR TEST SET
CODE 65-1014
for all
GENERAL MOTORS
SERIES 53, 71 and 110
UNIT INJECTORS
WARNING
The force of e spray, from a fuel injection nozzle is sufficiently
great to penetrate the skin Fuel oil in the blood stream Con cause
blood-poisoning. Kept hands away from injectors and nozzles when
they ore being tested
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GENERAL
Model YHQ Nozzle Test Fixture, used in conjunction with
Model YFL Nozzle Tester and Connector Combination
65-881, is designed to test all Series 53, 71 and 110 unit
injectors by applying factory recommended tests to
determine injector condition. Test Fixture is available
with two interchangeable Seat Blocks. One Seat Block
will test Series 53 and 71 standard and offset body
injectors. The other Seat Block is used to test Series
110 standard and offset injectors. Use of these Seat
Blocks is discussed in the titled section below. Connector
Combination 65-881 includes a Connector Tube, Nuts
and Adapter for testing the spray tip and check valve
assembly of the Series 71 needle valve unit injector while
it is connected to the Model YFL Nozzle Tester. This test
requires that the Nozzle Tester be equipped with a 5000
psi gauge as shown in Fig. 5. Servicing injectors
requires specialized equipment, facilities and trained
personnel. In all instances, actual test and repair
procedures which have been established by the engine
builder should be closely followed. Refer to the engine
manual for specific performance figures and injector
disassembly and assembly instructions. Figures 5 and 6
identify parts of the Nozzle Test Fixture and Connector
Combination referred to in these instructions. Operation
and maintenance of the YFL Nozzle Tester is covered in
a separate pamphlet, 8-I-54. Nozzle Tester is shown
mounted on Test Fixture, but if Fixture and Nozzle Tester
were purchased separately, mount Tester on Base Plate
(1) using three 3/8" 16 x 5/8" Ig. cap screws.
Nozzle Test Fixture can be permanency
mounted to bench or table top with 3/8" bolts through
holes in the Base Plate, or it may be used as a portable
tool by fastening it to bench or table with C-clamps or
similar fasteners.
INSTALLING SEAT BLOCKS
Series 53, 71 and 110 injectors, both offset and standard
body, are positioned in the Test Fixture by means of Seat
Blocks. Seat Block (2) is used when testing Series 53
and 71 injectors; Seat Block (3) is used with Series 110
injectors.
The photographs and drawings (Figs. 1 through
4) illustrate the position of the Seat Block on the frame of
the Test Fixture. The Seat Block must be located in the
proper holes so the filter caps of the injector will align
and seal properly with the Sockets (4) when the injector
is installed in the Test Fixture. Slots in the Seat Blocks
receive the injector dowel pin and guide the injector into
the Test Fixture.
With the standard body 110 injector pull out the
Shift Knob (5), away from the Test Fixture, to change
the spacing between the Sockets (4) to accommodate
the filter caps. All other injectors are tested with the Shift
Knob pushed in toward the Test Fixture Frame.
When the injector is properly positioned in the
Test Fixture the leaf spring on the Seat Block will
automatically position the injector fuel rack in the full fuel
position.
Fig. 1 Using Seat Block (2) for
Series 71 Standard Body Unit Injector
Fig. 2 Using Seat Block (2) for
Series 53 &71 Offset Body unit Injector
-21-
TM 9-4910-604-14&P
Fig.3 Using Seat Block (3) for
Series 110 Standard Body Unit Injectors
PREPARING FOR TEST
1.
2.
3.
4.
Ready the Nozzle Tester (6) for use by filling the
Fuel Reservoir (7) with clean fuel oil or
recommended test fluid.
Nozzle Tester is self priming; several strokes
5.
may be necessary to evacuate entrapped air.
Although it is not necessary, the Priming Screw
in the side of the Nozzle Tester Body and directly
6.
behind the lower discharge fitting can be opened
for thorough venting as a priming aid.
Install Seat Block in proper holes of Test Fixture
for injector under test as illustrated in Figs. 1
through 4.
Install injector by sliding in place and engaging
INJECTION TESTS
This outline of tests for injectors is principally to guide the
user in properly operating the Test Fixture to perform
recommended tests. For specific procedures, pressures
and results of observations refer to engine manual since
variation exists between different types and models of
injector.
1.
Check injector rack and plunger movement for
freedom of travel. Move Spring on Seat Block
out of position to allow full rack travel. Put rack
in no fuel position; depress Popping Handle (11)
to bottom of stroke. Slowly release Popping
Handle while moving rack back and forth.
Friction of rack indicates dirty or damaged
internal injector parts.
2.
Determine valve opening pressure of injector by
operating Nozzle Tester Handle with full, smooth
strokes; simultaneously watch Test Fixture
Gauge (12) and note pressure when injector
3.
4.
-22-
Fig.4 Using Seat Block (3) for
110 Offset Body Unit Injectors
dowel on under side of body in proper slot in
Seat Block. Check that fuel rack is against leaf
spring of Seat Block.
Connect injector to Fuel Line (8)by rotating Inlet
(Cam Handle (9) toward Nozzle Tester to move
Socket (4) against injector inlet filter cap.
Purge injector of air by operating Nozzle Tester
until clear fuel flows from outlet filter cap. Then
rotate Outlet Cain Handle (10) toward Nozzle
Tester to scale (outlet filter cap, Operate Nozzle
Tester 14) build up slight pressure in test system
and pop injector two or three times with Popping
Handle (11).
sprays fuel. The opening or pop pressure
should be 450 to 850 psi.
Determine valve holding pressure by operating
Nozzle Tester Handle to bring the pressure to a
point just below popping pressure. Quickly close
Nozzle Tester Valve (1 3) and note pressure at
which valve is closed and time the pressure drop
over specified interval. Time for pressure drop
from 450 to 250 psi should not be less than 40
seconds.
Check for leaks at high pressure at injector nut
seal ring, rack hole, plugs, filter cap gaskets and
internal lapped surfaces. Depress plunger with
Popping Handle (11 ) far enough to cover ports
in plunger bushing; to, .k handle by inserting
Lock Pin (14) in hole in Test Fixture frame.
Maintain approximately 1600 psi by operating
Tester -Handle while checking for leaks.
TM 9-4910-604-14&P
5.
Observe spray pattern using Tester Handle to
raise pressure to just below opening pressure and pop
injector several times with Popping Handle. Check for
clogged orifices and uniform spray pattern.
Before removing injector from Test Fixture,
pop with Popping Handle until no pressure is observed
on Gauge (12) to avoid fuel spray as Sockets (4) are
disconnected from injector. After injectors pass above
tests they should be flow tested and matched into sets
on a Bacharach YZR or YQT Injector Compactor.
ADDITIONAL TESTS FOR NEEDLE VALVE INJECTORS
In addition to the tests for rack and plunger freedom,
holding pressure, and spray pattern as outlined in crown
valve injector tests; needle valve injectors are also tested
for opening and holding pressure of the needle valve.
After the above tests are completed disconnect
the Fuel Line (8) at the Nozzle Tester. Install Connector
Tube N-1 (15 ) to the discharge block of the Nozzle
Tester with Nut N-4 (16). The Nuts are tapped with both
left and right hand threads. The end of the nut with the
circular
Hold Adapter N47 (17) in vise at hex and
assemble check valve, valve cage, spring and seat,
spring cage, needle valve and tip on lapped surface of
Adapter. Place injector nut over spray tip and thread it to
Adapter using 75-85 ft. lb. Of torque. Connect Adapter
with injector parts to
Connector Tube using Nut N4 as shown in Fig. 5.
Operate Tester Handle until assembly is purged of air
and needle valve has opened several times.
1.
Observe opening pressure of needle valve
shoulder has the left hand thread and is always
connected to the Tube. Engage one or two
threads of Nut on Tube then tighten Nut to
discharge block.
2.
Establish valve holding time by operating Tester
Handle to bring Gauge (18) pressure to 2000 psi
and quickly close Valve (13). Time for pressure
drop from 2000 psi to 1500 psi should not be
less 4han 20 seconds with no drops of fuel
collecting at spray tip.
Open Valve and allow pressure to bleed off before
removing Adapter from Connector Tube. After injectors
pass above tests they should be flow tested and
matched into sets on a Bacharach YZR or YQT Injector
Compactor.
MAINTENANCE INFORMATION
Replacement parts for Fixture are available should they
4.
Leakage other than that of 2 and 3 is corrected
become necessary due to normal wear or other reasons.
by tightening connections, replacing defective parts or
Ordinarily, stand needs no maintenance. If leakage
similar repair procedures. Some care should be used
should develop, it is suggested that a dummy injector or
when installing injectors; align injector filter caps with
test block, Code 65-252 be used to locate and repair
Socket (4).
Misalignment may cause Sockets to
leak.
permanently damage seals to such an extent that seals
Test block is connected in system at Socket (4)
need to be replaced. Extra seals are supplied with Test
on Test Fixture in same manner as unit injector. Using
Fixture and are installed by unscrewing Socket Cap (19),
Nozzle Tester, build up system pressure to 1500 psi.
removing old seal and installing new one. When this is
Close Pump Valve; leakage should be less than 60 psi
done, new seals should be ordered from factory.
per fifty seconds from 1500 psi. If Gauge indicates
Nozzle Tester can also be used to test nozzles
leakage in excess of this, locate as follows:
of _ hydraulically- operated, differential- pressure type.
1.
With clean, compressed air, blow dry all joints
To do this, optional gauges of required ranges are
where leakage may occur and inspect for seepage.
available. On stands so equipped, these nozzles are
Lacking compressed air, use clean cloth or tissue paper.
tested by disconnecting Fuel Line (8) at Nozzle Tester
2.
If seepage appears at Sockets, turn Cam Handle
and attaching nozzle as indicated in instruction bulletin
to be certain that trouble is not due to insufficient force
on Nozzle Tester. Keep Cap Nut (20) tightly screwed on
between Socket and test block.
when discharge outlet not in use.
3.
Make certain Pump Valve is tightly closed.
-23-
TM 9-4910-604-14&P
Fig. 6 Model YFL Nozzle Tester mounted on Test Fixture with Series 71
Offset Body Unit Injector installed
-24-
TM 9-4910-604-14&P
-25-
By Order of the Secretary of the Army:
E. C. MEYER
General, United States Army
Chief of Staff
Official:
ROBERT M. JOYCE
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with Special List.
*U.S COVERNMENT PRINTING OFFICE:1995-388/40039
PIN: 049862-000
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