TM 9-4910-409-12 DEPARTMENT OF THE OPERATOR ARMY AND AND DIESEL NOZZLE TRIAL MODEL MANUAL REPAIR SPECIAL TESTER TOOL FUEL INSTRUMENT CONNECTOR PARTS LISTS) INJECTOR (BACHARACH YFL) MANUAL ORGANIZATIONAL MAINTENANCE (INCLUDING TECHNICAL INDUS- COMPANY (4910-255-8641) SET 44 WITH (BACHARACH PART NUMBER 65-275) (4910-955-5517) AND CONNECTOR B11020498) HEADQUARTERS, SET (ORD DWG (4910-955-5516) DEPARTMENT OF OCTOBER 1963 THE ARMY
Changes in force: C1 TM 9-4910-409-12 C1 HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D.C., 25 June 1973 Change No. 1 Operator and Organizational Maintenance Manual (Including Repair Parts and Special Tool Lists) TESTER, DIESEL FUEL INJECTOR NOZZLE (BACHARACH INDUSTRIAL INSTRUMENT COMPANY MODEL YFL) (4910-255-8641) WITH CONNECTOR SET 44 (BACHARACH PART NUMBER 65-275) (4910-955-5517) AND CONNECTOR SET (ORD DWG B11020498) (4910-955-5516) TM 9-4910-409-12, 29 October 1963, is changed as follows Page 2.
By Order of the Secretary of the Army: CREIGHTON W. ABRAMS General, United States Army Chief of Staff Official: VERNE L.
TM 9-4910-409-12 Technical Manual No. 9-4910-409-12 HEADQUARTERS, DEPARTMENT OF THE ARMY WASHINGTON 25, D. C., 29 October 1963 OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOL LISTS) TESTER, DIESEL FUEL INJECTOR NOZZLE (BACHARACH INDUSTRIAL INSTRUMENT COMPANY MODEL YFL) (4910-255-8641) WITH CONNECTOR SET 44 (BACHARACH PART NUMBER 65-275) (4910-955-5517) AND CONNECTOR SET (ORD DWG B11020498)(4910-955-5516) Paragraph C HAPTER 1 . Section I. II. 2. CHAPTER I.
CHAPTER 1 INTRODUCTION Section I. 1. Scope a. This technical manual contains instructions on operation and maintenance of the diesel fuel injector nozzle tester for the operator and instructions for organizational maintenance of the nozzle tester by personnel of the using organization. b. Appendix I contains a list of current references, including supply manuals, forms, technical manuals, and other available publications applicable to the nozzle tester. c.
inspected, to be repaired, or to be used in repair. Properly executed forms convey authorization and serve as records for repair or replacement of materiel in the hands of troops and for delivery of materiel requiring further repair to shops in arsenals, depots, etc. The forms, records, and reports establish the work required, the progress of the work within the shops, and the status of the materiel upon completion of its repair. b. Authorized Forms.
l–Fuel reservoir assembly A–Fuel reservoir B–Center rod assembly C–Fuel reservoir cover 2–Hydraulic pressure gage 3–Discharge block assembly A–Data plate B–Valve handle C–Hydraulic pressure gage valve assembly D–Upper discharge outlet E–Lower discharge outlet F–Cap nut assembly 4–Body and plunger assembly A–Handle shoe B–Pump handle assembly C–Vent screw Figure 1. Nozzle tester.
CHAPTER 2 OPERATING INSTRUCTIONS Section I. SERVICE UPON RECEIPT OF MATERIEL 7. Purpose a. When a new or reconditioned nozzle tester is first received, it is the responsibility of the officer in charge to determine whether the materiel has been properly prepared for service by the supplying organization and to be sure it is in condition to perform its function. For this purpose, inspect all assemblies and parts to be sure they are properly assembled, secured, cleaned, adjusted, and/or lubricated. b.
12. Hydraulic Pressure Gage 13. Pump Handle Assembly and Handle Shoe The hydraulic pressure gage (2) indicates the amount of pressure applied when testing the various types of nozzles. The dial has a range of O to 5,000 psi (pounds per square inch) and marked in increments of 50 psi. The action of the pump handle assembly (4B) and handle shoe (4A) actuates the plunger built within the body and plunger assembly (4), and producing a hydraulic pressure which is recorded on the hydraulic pressure gage (2).
INSTRUCTIONS CONNECTOR SET 44 BACHARACH PART NO. 65-275 Figure 2. Connecting instructions.
may cause blood poisoning. Keep hands free of spray at all times. (2) Opening Pressure. Use lower discharge outlet (3E). Open the hydraulic pressure gage valve assembly (3C), operate the pump handle assembly (4B) slowly and, when nozzle begins to spray test fluid, observe the pressure indicated on the hydraulic pressure gage (2). This pressure should be compared with that specified by the engine manufacturer and nozzle adjusted, if necessary, before proceeding with further testing.
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS Section I. REPAIR PARTS, TOOLS, AND EQUIPMENT 17. General 19. Common Tools and Equipment Repair parts, tools, and equipment are issued to the operator for operating and maintaining the nozzle tester. Tools and equipment should not be used for Purposes other than prescribed and when not in use should be properly stored.
lock nuts, locking wires, or cotter pins used. (4) By “excessively worn” is me ant worn beyond serviceable limits or to a point likely to result in failure if the unit is not replaced before the next scheduled inspection. 23. Cleaning a.. General. Any special cleaning instructions required for specific components or parts are contained in the pertinent section. Cleaning instructions are as outlined in (1) and (2) below. General cleaning precautions are contained in b below. (1) Metal parts.
Table I. Preventive Maintenance Checks and Services 1st Echelon Daily Schedule Item to be inspected Paragraph reference Procedure Nozzle tester & Clean hydraulic pressure gage by wiping dirt and other foreign matter from ridges and surface of gage face. b. Clean accumulation of dirt and other foreign matter from outside surface of the fuel reservoir assembly. c.
which is peculiar to the operator’s (first echelon) maintenance operations. Table II. Troubleshooting – Continued Malfunction 27. Procedure Malfunctions which may occur with the nozzle tester are listed in table II. Upon observing any one of these malfunctions, take immediate steps to locate and correct the cause. Causes are listed opposite each malfunction and are arranged according to the ease of correction. Table II. Troubleshooting Malfunction Probable cause 1. Test fluid starvation. a.
CHAPTER 4 ORGANIZATIONAL MAINTENANCE INSTRUCTIONS Section I REPAIR PARTS, TOOLS, AND EQUIPMENT 28. General Repair parts, tools, and equipment over and above those available of the operator are supplied by the using organization for maintaining the nozzle tester. Tools and equipment should be properly stored when not in use. 29.
ther damage to a disabled component. Be careful during inspection and troubleshooting, so that damage can be avoided. 36. Scope This section covers troubleshooting which is peculiar to organizational (second echelon) maintenance operations. For troubleshooting procedures performed by the operator, see paragraphs 25 through 27. 37. Procedure Malfunctions which may occur with the nozzle tester are listed in tables II and III. In effect, table III is the continuation of table II, paragraph 27.
b. Disassembly. Remove the cover (2J) from the reservoir (2B) by using a combined twisting and pulling motion. Unscrew the center rod assembly (2G) from the body and plunger assembly (1) and remove the O-ring (2H). Slide the filter element (2D), filter washer (2E), and filter spring (2F) off the center rod assembly (2G). Remove the upper and lower filter gaskets (2C) from the filter element. Remove the reservoir (2B) from the body and plunger assembly (1) and the seal (2A) from the reservoir. c. Cleaning.
Section VI. DISCHARGE BLOCK ASSEMBLY AND HYDRAULIC PRESSURE GAGE N o t e . The key numbers shown below in parentheses in this section refer to figure 4 except where otherwise indicated.” 40. Description The discharge block assembly and hydraulic pressure gage (3, fig. 3) is mounted on the front of the body and plunger assembly (1, fig. 3) and can be removed by unscrewing four socket head cap screws (4, fig. 3).
CHAPTER 5 SHIPMENT AND ADMINISTRATIVE STORAGE AND DEMOLITION TO PREVENT ENEMY USE Section I. SHIPMENT AND ADMINISTRATIVE STORAGE 4 2 . Shipping Instructions a. Responsibility.
other convenient method). The noz zle tester so marked must not be operated while in this category. c. Inspection in Administrative Storage. Visual inspection of the nozzle tester in administrative storage must be conducted at least once each month to detect corro- sion and rust, When corrosion and rust are found, corrective action must be taken immediately. A record of these inspections must be maintained for each nozzle tester in administrative storage.
46. Destruction of the Nozzle Tester a. Method No. 1 - Destruction by Mechanical Means. (1) Open the carrying case and remove the nozzle tester, connector sets, hose, and spray collector cup. (2) Using an axe, pick mattox, sledge, or any other heavy implement, destroy the nozzle tester by smashing the body casting, fluid reservoir, and hydraulic gage, (3) Destroy the carrying case and spray collector cup by smashing. Cut the hose in short lengths, and scatter the connector sets.
APPENDIX I REFERENCES 1. General a. Military Publications. The packaging publications listed herein are available to activities requiring such publications. Forward requests for Military Specifications to Naval Supply Depot, 5801 Tab or Avenue, Philadelphia, Pennsylvania. Requisition technical manuals, technical bulletins, supply bulletins, and other publications indexed in 310 series DA pamphlets in accordance with AR 310-1. b. Commercial Publications.
5. Forms The following forms pertain to this materiel: DA Form 468, Unsatisfactory Equipment Report. DA Form 1115, Property Turn/In Tag (tag), DA Form 2028, Recommended Changes to DA Technical Manual Parts List or Supply Manual 7, 8, or 9 (cut sheet). DD Form 6, Report of Damaged or Improper Shipment (cut sheet). DD Form 250, Materiel Inspection and Receiving Report. DD Form 1149, Requisition and Invoice/Shipping Document (cut sheet). DD Form 1348, DOD Single Line Item Requisition System Document (Manual).
APPENDIX II BASIC ISSUE ITEMS LIST Section I. PREFACE 1. General This appendix is a list of basic issue list items. It is composed of those items which make up the major end items of equipment and the first echelon tools, supplies, assemblies, and repair parts that are issued with the equipment and are required for stockage. umn indicates whether unserviceable items should be returned for recovery or salvage. When no code is indicated, the item will be considered expendable.
5. Abbreviations Abbreviation dwg . . . . . . . . . ea. ............ ............ no. . . . . . . . . . . . . . . . . . . . . . . Ord . . . . . . . . . . . . . . . . . . . . Explanation drawing(s) each number(s) Ordinance 6. Suggestions and Recommendations The direct reporting of errors, omissions and recommendations for improving this technical manual by the individual user, is authorized and encouraged, DA Form 2028 will be used for reporting these improvements.
Section II. BASIC ISSUE ITEMS (1) (2) (6) (3) Source, maintenance, and recoverability code Ill”stre.t, on Federal stock No. Description MAJOR COMBINATION ---- R ~910-255-8641 TESTER, DIESEL FUEL INJECTOR NOZZLE: (05083 :YFL). ea ---- 1 ea ea ea 1 1 5 5 5 set 1 6 set 1 6 COMPONENTS OF MAJOR COMBINATION None authorized. REPAIR PARTS None authorized. TOOLS AND EQUIPMENT : T 00LS None authorized.
Figure 5. Equipment Figure 6.
APPENDIX III MAINTENANCE ALLOCATION CHART 1. Purpose The maintenance allocation chart allocates specific maintenance operation to the proper level. 2. Basis REPLACE Allocation of maintenance operations is made on the basis of time, tools, and skills normally available to the various echelons in a combat situation and influenced by maintenance policy and sound maintenance practices as outlined in AR 750-5. REPAIR 3.
Maintenance (1) Grp No. A Uocation Chart for Tester, Diesel Fuel Injector Nozzle ~>] Component and Related Operations 1 Tester, Nozzle: Service ----------------Adjust -----------------Inspect ----------------Test ------------------Repair ----------------2 Body and Plunger Assembly service ----------------Inspect ----------------Repair -----------------Rebuild(Plunger Assembly) m Ist — (1) GrP No.
APPENDIX IV REPAIR PARTS AND SPECIAL TOOL LISTS Section I PREFACE 1. General a. This appendix is a list of repair parts which may be required by the using organization for performing organizational maintenance but are not authorized to be stocked. These items are to be requisitioned as required for immediate use only. b. For prices of items of Ordnance materiel, see the appropriate supply manual of the SM 9-2 series.
3. Explanation of Columns a. Source, Maintenance, and Recoverability Code (Col. 1). (1) Materiel Numerical Codes (col. 1a). This column indicates the responsibility commodity command for the materiel. The commodity command responsible for supply of items in this list are: Code 3 5 9 10 Type materiel Chemical Materiel Engineers Materiel Ordnance Materiel Quartermaster Materiel (2) Source (col. 1b). This column indicates the selection status and source for the listed item.
Abbreviation ea.. . . . . . . . . . . . . . . F . . . . . . . . . . . . . . . . Fed . . . . . . . . . . . . . . . fl . . . . . . . . . . . . . . . ga . . . . . . . . . . . . . . . gal . . . . . . . . . . . . . . . . hex . . . . . . . . . . . . . . . hr . . . . . . . . . . . . . . . . in. . . . . . . . . . . . . . . . lb . . . . . . . . . . . . . . . . lg . . . . . . . . . . . . . . . . it . . . . . . . . . . . . . . . . max. . . . . . . . . . . . . . . ML . . . . . . . . . . . . . . . min . . . . . . . . .
Section II. REPAIR PARTS AND SPECIAL TOOLS -— ,1} (7) (2) source, mfiintenmc?, and recovembi!lty code Illustration (d) h -. 7. .C 6 z > : Federal etock No. Description ,; REPAIR PARTS FOR: Discharge Block aud Hydraulic Pressure Gage Groups 9 c o --- .----_--_.--- 9 c 0 --- ------------- 9 c 0 --- ------------- 9 c 0 --- ------------- c’ 0 --- .-_----_----- c 0 0 ----- .-----------.------------ 0 --- .
(1) (2) (3) (4) !sOur’. e, maintenance, mfl nxoveratl) I !ty’ code 111 ustrati on —r (a) (a) Federal stock No. Description REPAIR PARTS FOR – Continued Fuel Reservoir and Body and Plunger Groups — Continued 4- Socket head cap screw (05083: 65-508). I SPECIAL TOOLS None authorized. TOOLS AND EQUIPMENT : TOOLS None authorized. EQUIPMENT Appendix II of this manual oontains list of equipment required for operational and organizational maintenance.
(1) ,s C,urc, (3) (2) (i’) e. maintenanw, and recovorabtllty code Illustration —— 1, .a (h] (d) (c, ~ * > : 6 ; .r; Description : d. :? 4 (a) Federal stock No. ~, ,5 - ~ g .
1 ) (2) (3) (7) ,s ource, m~intenanre, t%.. d recover ah, i]ty CCXIC. (a) (b) Illustraticm (.) Federal stock 90. : Description :Z -i ‘~$0 : g. . ——— al 0 ~ cc CJ> ..3 a! F —— CLEANING, PRESERVING AND PACKAGINGMA TERIALS-Continued ------------- 8135-281-4112 8135-281-4113 8135-281-9067 8135-281-4115 ---- ------------- 8135-281-4120 8135-281-4121 8135-281-5105 8135-281-5106 ---- ---- ----- 8135-664-0028 5 5 ---- ---- ---- ---- 10 10 ---- ---- ---- ---- 9 .
INDEX Paragraphs Page App II & IV 3d 22,28 . . 42b 44a 44c 43c 43 b 42c 43a 42a 44 b 2 App I 42b 17 17 18 17 17 17 17 17 17 2 20 17 Basic issue items list . . . . . . . App II 22 Cleaning . . . . . . . . . . . . . General . . . . . . . . . . . . . Metal parts . . . . . . . . . . . Precautions (general) . . . . Rust removal . . . . . . . . . . Rubber parts other than electrical . . . . . . . . . . . Cleaning, preserving, and packaging materiais . . . . Cleaning precautions . . . . .
Paragraphs Organizational maintenance instructions: Common tools and equipment General . . . . . . . . . . . . . . Repair parts . . . . . . . . . . . Special tools and equipment Organizational preventivemaintenance services: General . . . . . . . . . . . . . . Services . . . . . . . . . . . . . Packing . . . . . . . . . . . . . . . . Painting . . . . . . . . . . . . . . . . Plates (data) . . . . . . . . . . . . . Preparation: Operation . . . . . . . . . . . . . . Shipment . . . . . . . . . . . . . .
By Order of Secretary of the Army: EARLE G. WHEELER, General, United States A r m y , Chief of Staff. Official: J. C. LAMBERT, Major General, United States Arrny, The Adjutant General.
TM 9-4910-409-12
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