COU EU eee CUMMINS INJECTOR TEST STAND OPERATING AND SERVICING MANUAL Ref.No. D/285 10-89Hartridge sese avec. CGPERATING & SERVONS MANUAL CUMMINS INJECTOR TEST STAND OPERATING AND SERVICING MANUAL WARNINGS 1. le 0 acl supslyaaare 55 ong a al lena, paca epee Borferming sny olnterance operations, sre te inst ba Saughe A A sitar he ‘Spang "any "aces ix aa LA* ica on tat) why 2 machin A hie the. machine I comprossed ale and ah GENERAL PRECAUTIONS You must reas the « lon & ‘Oparatng! before sttanpting to ue the machine, You mut enous that the arilng ranenants snd Intar tot out In Maintenance! (Section EA) are Tako hood of toe ana find bacton 8 Santa ven raspectivaly on te tla pagee of Section ‘Renamber that tha Hartrigga HA 285 Tast Stand ie en accurste place of agulpmant £0 ook after Ite GENERAL CONTENTS Introduetion and Speciation smeton 9 Intating ane Propacing Seetion 2 systone Desorption Section 9 parsing Seaton 4 Maintenance Section § Spares List, Section 6£8 Hartridge esa ovscw OPERATING & SERVIONG MANUAL ayES Hartridge cesa_ ovis CPERATING & SERVEING Manual SECTION 1 INTRODUCTION AND SPECIFICATION CONTENTS Page al te a Voditiostion Standards 1a Ba 13 8 1a 5 13 B £3 8 "3 & 13 5 3 ort 13 Bi 3Hartridge oese. oven ‘A. INTRODUCTION AN. GENERAL ‘The tunction of = comparator fat Cunning PT ang Detrole Diet au) “ont i teas sing fe ieee “eturers {Taur the wolume.of eaoration fla celvared can bo socurataly ‘Rearurod and chosise sgainet's mestar Inactor (rot required fot Gtinen! 22, THE HARTRIDGE HA 265, “Tho injstor 12 mounted in the hydro-pneuntic shaming hae with the oewla tip uppermost. ‘The Motor drivse the aonboe ve 8 Doly-vae “bet runsing. an ope at two. sete of diferent. sitet Bulleye to ave eposde for" teating “Curmina and Git Injeotres The rotor and earbox/slamping Nase are mounted on a base pate which ia ingulntes from the vast of the raosines The has eaulted'in reduced overall noise lavalay Fron the sams ts eriven the pump which supplie eaibration| tiuie te tee Mnjoetors “The. sigral “for the anid sate. shot Counting function on the Printad Greute Soar a taken ence every Eenthall rovatutlon teem e megratic plck-us which torasy © p09 It Bresette pully. "the carsox cattaint two cane and, an Srcent selec by’ fever to agiuate Curmins stancaré and‘! tors ee wal 26 Osteat Dios (2M) 71 typete eal 9, 28a raring te {The irlsetor solvers tho caloento athos"aresring the notering piston. chamber (curing ‘oovat oF Sireuating tarorth is piston setors returning’ fo arainy tie fastare enaures the thar stailty of she 27st, ump draws calloraton flats Te to ty inlector on fasts ‘aic'e9 thw otacing. ont, When the motor cutput button is pressed, tne metering piston cspanvor wi turn the dil inelestar to zara: neo The" baton has’ Sees od, 83 hole ) oF ealbratontiud’ from the. ijpotor on test wht boldotverou to this shanbor once apathy andthe volun ill Bo iepayed on the dial inden The temperature contro! ystsm consists of @ 450 Vet electric aatat and water operated cooler with aod. sate eoneolet, “y tthovmator Inthe. fue tanky -anauring’ that ths ston Hold tanparacare le maintained thin a lerance OPERATING & SERVICING MANUAL, ‘Ax, SERIAL NUMBER fdontticatan’ pate on tho east, panel and it ahauis awaye ‘be ‘uotea' in any" corcespensense. A tyoleal sia numbery wth ah relanation of each bot of cits or laters, To given belon. SERIAL No. Ta/0O1/A/1 eee {talod coding wil Bevraure in eararas) octiandon, ranaard Lato Machine Serial Number Guna) Produst Code Number At, APBLICABILITY = MODIFICATION STANDARDS: ‘ig oanusl ip appliable to HA 205 test stance, trom the Intsaausniir St the shina at Moditcaton Standard Bt." &" bret {naiyata of the Modification Stangarde is glven bans ws. OTAILS a Ineroducton of machina 8 ‘Foal rooorder piston (FR 13/0/1) now soe sane egneaer Srigge, ¢ Ineroduaton of maine vltoge Heater (Aso) 5 Now pure (Sundetrand ropaoes Cosappe)S) Hartridge cess avicon B. GENERAL DATA B51. DIMENSIONS AND WEIGHTS: Shipping Inforration COASE SIZE: 92 x BB x Ane {610 x 710 x S120eI) NET WEIGHT: 90019 (190K) GROSS WEIGHT: 41D (187K0) 2. ELECTRICAL SUPaLY Tho siectrieal mains cogulramant ie & SO/sOG2 eo. tr nase "supply of 1e1/KYA operating tran ay one of the comtoniy Sraliole "atoaly""wetagor. The NAT 285 "iy ited with & Eranatormor’ having. Te primary taos to satisfy all ovtags Feguirements (roter te 8898 2n3)- Ba, woToR 0.7ehp (SoH motors) oF O.8Hp (HE rctors). Single speed. standard Range: zz-240 volt’) $ phave Sore T3sfov/ory Seoceao Vor | 3 Brave Sore 732/000/0/9, 220-240 Volt 3 phaso oor 738/000/0/6 40-490 Volt 9 phase core 783/000/0/7 Motors bracketes toantnr ara of, cu viagae but ‘nacnine mired 9m, sfadvetion “excoraiag to tte sora! mune viene to ehone "ene the sonngetione to t0 terminal fauiring reploorent ges thouideontact ordering, stating weltabe Tigh voltages autaide the ‘ave NARTRIOSE LTO" vetor ba, CAMBOX Belt driven trom motor, Ineorporates camshaft runaing on ball 18 \ollae bearings: Sem Sleeve fed wiht fe movsbie by hand oF lover to align each eum wih the Toauired for tostings 158, FUEL TANK AND CALIBRATION FLUID (FUEL) SPECIFICATION fl tok oat integra 9.u.8. Gall. (si ier 2.8" Inpe Gall) Ccaliortion fale (fue 180 118 Speatiction ‘The vlscolty of thls fluid fet RAAB to 2475. santatokow afore The folowing tulee ere cesormandos en mast the 150 Fpcitoaton “end. nave “actltonat propartios."wiion anit SBtrosion onisation and guemiege Sholl-Berre Narmatla! (Franca) Sra ais Urea ina) atonal) Brugaraiee Callus 2 (Spain) OPERATING & SERVICNG MANUAL — im fs Se Figet ot OIMENSIONS: 186, CALIBRATION FLUID PUMP DDetven elrsety from ner of samba. Delivery 20.U.5, Gulls per hour (108 Mires or 30 Gall, Imp. per nour) at 1900 rom. BY. CALIBRATION FLUID PRESSURE CONTROL, 2 pressure ranges ea by valve For Curmming Injatans, 120 ps (8.26 bar) = aahctabie ‘For Datrott Diese injaciona, 40 pt (2.8 bar) - aajuetable 2B, TEMPERATURE CONTROL “Thenmlstor sensed 200 watt electric heater and water operated cosler; alta stats controler, adjusted by potanuignetan, “naineainetomparasura of the saibration lua to 05 (loa). 0, TEST SPEEDS Rear 2utlays (For Cumming injectorsys TO80 strokes por minute Front Pulteys (Par Oetolt Diesel injectors) GIO. METERING SYSTEM Positive piston steplacement metering system with eat Inateatondtepiny of injector output. Injector ouput ts measured var 86 whi Injections, The mstaring programme ie conealied BY3 propristary Hartriige 00140 slate alactranic shot counter, land te pharas 9 tne cumahatt by mean ot 9 magnets pick-up Sina peg in the reas cr ta carom poly. B11 INSTRUMENTATION Cuiput meteator ‘Prenaure Cause: “Temperature metar: (o-so2e.0+ (par 1000 atrakon) -toQpat (ont cary Green Tose chs & wey ‘Air Pressure Gauge: Ovo0pst {O-8 bat) BI2,CLAMPING HEAD ydronpneumatic with oad adfustment. Minera air Hoe praasore Sopet (en ba.2 Hartridge cese_ovson OPERATING & SERVING IWANUAL SECTION 2 INSTALLING AND PREPARING CONTENTS Au She Bogulrorete 2 : if ue 8 21. vera at BE fhlsany corny re uh Ba, Fitting the Mysrautlo Charber Bt BE Stoney mecca aHartridge cece vision A. INSTALLATION AL, SITE REQUIREMENTS “The HA 205 te dnignes for bench mounting. The neneh shou _setiaty he followeg conattons! ©) estas be sirerg rough sport he macnn — alge boats asc 1) Famous ba adele working canes roid the ©) The trian arm shou tra tom the ngree fet. 3 Atari ee SAPS Rage ut wil a wong penne of ea? a Slee ence etre / 5 Kinuincwittr apy nina Roe OF0.0U:8. os. pan ‘rine oa aa, 0,8 i. al pr ise) 1 AE ary aetna un bench Shasta nies te aches ene et nd see my Faptesete Mache Bar’ sng ene etch uo Teh wpe wee bat pce: ie bla Soube ttesaradinanee of 85070" Cooreny Siar ibipe wih gory pense ae AS, MOUNTING THE MACHINE Prion & mounting, earetully ramove all pang material. “Than the four Reble touring fot (1) supped ws the machine Should be pressed onte the basses on the cornara ofthe boxe by the lifting heok (2) which (salted at the paint of balances Feleasing tye locknut (8) and unscrewing It rom the base plats to Finally, remove the centrat restraining bat arecotad 89) Uihleh sreadisa tho hase plate suring trana‘t. (UF Une bale fa Le ‘ny the pase plate wil be unable oat’ as intended, 29 he ‘eauced noe fovals wil not be achieved.) «THE LIFTING HOOK AND BASE PLATE (Mowing Fest Shown Enlarged} OPERATING & SERVIDING MANUAL dj Fig. 2. THE TERMINAL cx IMPORTANT NOTE RE VOLTAGE CORRECTION, Each mchina Ie supplied correctly i supply ot the. rapion for wnien ty dat nly 'to” roquirad it tw “machine, eto Sisrnativs voltge, Before the machire san ‘Rkarnatva, Voltage. soe elgotcal compononte may leo icament se dotaliod Sn shoso pase achinas which aro to be cperatod shove 400 volte noriaa! will require addivenal eanponarte large eutetvanstormrts Custorers should NOT ATYCUPT to change tha machine to an Alternative veliaps supply “without soreulting ‘Lesie Martraga tinker or apent, Installation, he main supply. Reror * Hy whan the machine ia, start ooking reverse any two of the phsee connections In the maint fevmanal bons The HBtoT must not oe allowed to rom In Tevsrge for the motor dose not tern Ione Serogs aa tne allt ‘aregp the Dum gal Boaed (Fig. 204.) The HA 205 suppilod with a rae phato nxtor which may sitnar be single of dual cltaga, ‘The, equipment. e- auppieg Soirasty wired for tne voltage ana trequanoy euppis of the foolon ‘Srila the, machine le dvtinos. ita thorotore only normaly faceatary to'angok the connections |SO4z eupplioa) the brisging ane (ear) on tne twemtnal Goerd which fo locted ines the phe nang. ponal towards te tront ofthe machines. Adjaatronts st el ih wasn > Se petted fen NMeonines operating fro soHs supalian ace ted with gual Imotorsy ex wore rior, chines, operating fram. Sis Toraopt S60 vlts).Acjuatmants to tre Torminel bane Gonnectons for aileron: voltage apples may be taco as below, Maohines aperating from GoHs suppliag are now being ited with Eirolevoltge nelors. appropriate for tho destined reolen. Du Woltage “Sora” macora supplied only. W"gesehtais Th toraina board” oraging tabe (Figs 2 Glage 3. $4) should raul ahereuony 418 dust NOT 6 changed without priar oom Sith uals Horsrdge Ur, enn, t88voaer rant pana (ioe Sut) 0 ga sess tothe S02 Supa a, "Socal be Sotoactd ta ane tar pat fr wa" tn bing. fe Tho romlning motor wire; Gis vic showle hore nator ‘irae should’ be coonasted "terete "Ay Toca Ghoma in Bit Supping For high voltage (400 vette nonina) the bridging tebe enouls fe fed ordain Bia 8 FOr iw stop (200 ate Single. voltage reotors_ now being fitted sojustments to these tabs toute NOT bo rade. The wires, abiok are nunoered $1 through &2 {o"ena aro connected” ta" the eppropriats terminals st mated,Hartridge occa ovsov Special requirements: He ie ie not paca to allages” lyon oh the waco sora) plato) it wll be. nacossary erchunpe the: motor for"ane of « autebia tanger The tar ust Sanya'Ga changeo it the machine ta to b0 operaied tram a 4upBlY The Hn 246 a ited with a ranstoener T° feitege: coquirononte. Wnassstarys "rane toe 3 remove ‘tho and cho Dee to. tety Borspex dover ane move tha primary wire marke Bilarsto the appropriate tapping to wut te supaly vakage. S58 Fige 2.3 It the mishioe te to 86. operated from an. alter frectondy treincdt tat Se chads O0 nt Romp to |Ad, SOLENOIDS AND OVERLOADS sath cenit wbion controle the way, cslr naraly rauiren at follows 220/240 vate 1.6 ame 440/880 vate 10 gs changoa tram operating "ron Now volte (200 Vaal) or overioes ust be ttess Refer [9 OPERATING & SERVIONG MANUAL (eater wortage jon marked Water lal on the back of the SP "snoulds be" connected to's maine watar fn narod wate? cut shoul iow souls" boat lant 0.8 U é te golonoid valve Ie open. To "Sa ony soou when the motor Is AT, AIR PRESSURE CONNECTIONS ‘The ait line consection for te clap of the’ sichion ab showin Fige” 26, ont he ae titer ang’ water trap. and adjust the pr the conthal on the ight Na paras Ate) SG ig.2.4, THE ALTERNATIVE TERMINAL BOARD CONNECTIONS Fig.t.6. AB! CONNECTIONSHartridge ese. oviscn DPERATING & SERVICING MANUAL 8. PREPARATION FOR USE Bt. GENERAL Remove the two naunting Brackets whlch are ttaa to tho cast base to. prevent “damage ‘during. transit. On the fetchang_ sido Senn paned ath stude Ch ray anna ‘these brackets to be withdrawn. ‘Sihes wuftenty to sna The sorows which eecura the top cover during tranelt may also be removed (ese toson 8 bara. Alva) Machined parte should ne washed with saratin (korosone} to caneve protective coating and thom lightly oi. (82, FILLING WITH CALIBRATION FLUID Almay use a sultanle oalbestion tad fuel) conforning to the apookietion elven ih GENERAL DATA (coction | paray BB)= To ‘aloave the fe hanes eavoes pane! a he a tude and ite off Eneure that the inside of the fusl tank is clean then pour in coalioation Hula “urd the level le approxinataty tysin (aon) {Bove te titer os shown in gy 2.7. 9, CHECKING CAMBOX OIL LEVER « vi, tm lttand oanelcomoeed the canoer ght les can be ith’ SAE_'30 engine oll until it reaches the ‘Inve! of the sight se. The filer pug ie logted in the canton top at the rer, nantes ey ene arrow (2) etar't Figs 2.5 nd Gotach che agnt tube (1) trom the top of areule opts ‘tnd, using. s pune tye ol eaty il tha evliedar eheaun thls taba to within sie (an) of tNe (0D With"‘ealbraton fle: than top up the. oplnder "with SAE 30 Sngine ta within dia (mmm) ot the top. Refi Fobiace Whe" cover tha bleed the eysten (se seat pal 68, STORING ACCESSORIES ‘wo reeks ste provided for the storage of the adsptore and sooataoriee provided, ane tre. shown In igs tae tn 2, 79 rable the fuel aos) election of orifegs cox hevnolae in" tneee racks hove’ Been Ince “position "eons threeded,2 Hartridge ces svicon DRERATING & SEAVIONG MANUAL SECTION 3 SYSTEMS DESCRIPTION CONTENTSHartridge ese. ovsen ORERATING & SERVERS MANUAL FUEL PRESSURE: CONTROL VALVE neste earl Sire SEE [ET se racer Bo soce. by (eae. "men Tt} 7 Fd ia | am remeron | Bool PL gkses | Ally act I a I I 1 ! 1 i I ! ! ; I | | i 8 jee z ee 7 ey vere fee eee cos [cy ING SEQUENCE" for a set of schoraticHartridge cece ovsov OPERATING & SCRVICING MANUAL SECTION 4 OPERATING IMPORTANT WARNING JRE COMMENCING TO OPERATE THE TEST STAND CHECK THAT Yous CLOTHING, ESPECIAL CY SLEEVES AND NECK~TIES, [6 SAFE, ZNO Wit, NOT BECON™ CAUGUT IN ANY NOVING PARTS, "PROTECT ou HANDS WITHA SUITABLE BARRIER GROAN, THAT ALL CALIBRATION FLUID (FUEL) CONNECTIONS ARE Fiat aN SAFE, AND THAT THERE Ig ADEQUATE VENTILATION TO REMOVE FUMES. CONTENTS A USE OF CONTROLS 42 1D MOUNTING AND CONNECTING EQUIPMENT oe Al, Astor Control @utons and Isetator D1. Accessories Selection Chart ae “over 5. Selection of Garrior Blocks (Cumming) ao Shear Sbowraie Diese as ‘met Handwash 1s. Ftturg te Noseptece ~All Types ae ‘StL Calibration Fluid Preamare Selection Valve © MOUNTING PROCEDURE a9 JMG, Set Zoro Sorew: Et, Gummine Cytindricst Injector 48 £2. Cummins etange Typ injectors an 8 USE OF INSTRUMENTS ES Detnot Dieser Injectors Ble 21. pains warning Lave F CALIBRATING AND ADJUSTING PROCEDURE Fi. Caliorating Cumming Injectors Fa! Galtsnaing Detrott Gkeest'58'and 71" Injectors al Agjutting Cummins injectors BBs. Inston Cutput Olaplay (ial tngteaton) G1. Seti clamping Head Ge) Ghanging Camara SpeedHartridge cece ove. OPERATING & SERVING MANUAL Fig tit THE CONTROL PAREL Fig.4.9 THE AIR AND FEED PRESSURE SELECTION CONTROLS A. USE OF CONTROLS Al. MOTOR CONTROL SUTTONS ANC ISOLATOR (Fig-4.1) At AIR VALVE SWITCH (F13- 4.9) Fig, 4.2 THE CAM ScLECTION LEVER Flas &sA THE SLIDE LEVERHartridge cece svcow e ® 7® 2, ee e| o = eS e ©O6 Figi&.t THE UPPER FRONT PANEL CONTROLS: (Che carnahatt se (2) ean ony be fly seen sith tne panal remove). AT. AIR PRESSURE REGULATOR (Fig. 4.3) “The air pressure regulator (2) is lbuated on the right hand sige of tho machine as cortola tha prasaure ot th ait mq Alnprassure gauge (S20 Section 4B), “To aajust te pressure, aut the irs oF te Kno out Seoranse the prescure. When te pressure ta corracty as Uh “The presmuns may require asjusting daly, to oben the iat.9) “The calibration uid pressure selection valve (2) ts silat ‘on ths right hand se of the machboy ard to uous tomatoe the Pominal Feed pressure raquined for the type of inject on leat “Turntog tha valve Fuly ant-oloctonge to the 'opent position give arnominal Food prozzure of Aaleyint (2 Bkeg/em) as ress For teeing Detrott toss) injectors. Turning the valve fully ctackeige to the ta «nominal toed pnensune oF 1200/10 Co Cummins tyecties. yor") for tasting rmanufaoturerts tost procedure san bo adjusted en the fue Ee Srmasintaly priar to hs tat. (@EPER to Section 42. "PRE, eStine NETES! (8, METER OUTPUT CONTROL (9-4-1) with an injector mitted (Seaton 4. fers) ard the drive rotor running, sperats she metering unt By pressing the range ‘rater outout button ¢8), Onsw started, tne bation may be roteaced ince the metering pragramnme wih Sonne automates ane Walt hlan by dlsnlayang essing on the cal indietar Cancel the reading by geprassing thi bution again ao soun ae the ston Eaton a rinat acing ean be saken, the metering unt est bbe nitsed tm operating targennture, ity the drive maton ee hing, and.an trjeotor all feed, inact est wh be Momtng| theaugh the urdoraide of the rnstering wnt piston. Aft ts ‘itn the terpersbare ateauy, tee saveras reaaings unt they Are nas Say rere lin a vacate ting aot AMO.SET ZERO SCREW ig. 4.8) [Atter stoping he drive motor, cancel the nanding diaplayed ton the lal Insioator by prescing em meter ouput button. I Necessary dos a screwdriver t adjust the ‘zoo st! srew (6) (0 the metering unit aril unt the dat Vsteator reading is at Sera Aton a whtle, particularly If te abave adjustment hac bean rroscot tw sere,” with tne dnive mome naming are th nfeotor ‘kind, press and hole down the onego motor cup Button, ne ‘wit aneat the roading and prevent a teeah count trom Sang Revadjut tre soron (we conning hols down he tng B. USE OF INSTRUMENTS. I. MAINS WARNING LAMP ¢Fige4.9) “This red warning lamp (6) wil be laminated whenever ther 82. FLUID TEMPERATURE METER & WARNING LAMP (Fig.4.6) VAs te fealator sntich (200 Section 4 para. At) set 1911 tho theater in thes tar nl start to marm the eaoration okay the warning tarp (1 wile lturinated to inateate tant te Raster {© enter the RED (t00 Cold) sector at tye Left hand end of the fluid temperature meter (2). The tomparature of Ow calioration Mug {S rguintained by the Integrated hentar ars coshen syste © 10°F 4 Fy and to nooslo ehoula stalize tm the GREEN aece,. Nate the racale may terporarily ener the RED (ts het) senior 8 the Flontinana end cf tne meter ths tz perfectly normal IF, after the machine has bean sunning Yong enough fr the rater nanding t Mave stabillzedy the mente Ia po in tao green Teotor, sithar the rreter om the contr cineutt wil) rogaine aehust= {nent (ection Spars-cc1t).. ify with os pease a the acta {2nd of te right and necton, the warning tmp stows sorenicunly ‘ahich should be investigated (Section © para, Be). iret sacertain That me water supply iz aatiatastory (Section & paras), 6, FLUID PRESSURE GAUGE (Fa. 4.6) a tigpressure ange) songs te fos renee of the Controt Valve and adjueted an the Fast Blook (Gestion 4 para. AB raters BA, AR PRESSURE GAUGE (Fa.4.6) Bravia comeect clamping (Sect pare, G1 provid seals of this operation),Hartridge ceca ovson OPERATING & SEAVENS MANUAL 85, INJESTOR OUTPUT OISPLAY (CIAL INDICATOR} “The lal naoator gauge 5 in gradu’ 010000 are, ino bocca ue davere ot teeg strove (ar tra) altoramvely te gauge my be tro for indigo dtteries pon rpections ‘With the metering unit and injactan at operating ta ana wits the gauge sot ls 28ro, take roaaings oF be non Dy pressing the meter ouput bution (tem @ Fig.4. Incest has two manda, tie Larger rraicng ane revelation for ach lOc of autput, Bs emaltery whieh can revolve twice, making tone revetion for auch 26¢c0 OF oute. “The eral hand graduations ars ered! in tenes the bre Inner aeala, ana i {ean made more refer t the outer seal Flo. 4.10 A READING OF 220.9 ce we obtaining the Final result. ‘Some Gpleal examples ef the readings wolen might be Fig. 4.11 A READING OF 208.2 60 “the datlvary igures quoted by Cumming in thelr scheckles for sone of tar iargar injactare are far 800 wiroKee Cehcts), (horafore there igure mut rst be muliptes iy 8/4 Sod tan Compares nity the eeactngs taken, which are for 1000 stroke, Baanple: (ia Indlotor reading = 167.8 (per 1000 strokes) Cummins delivery figire = 18800 (per 600 strokes) “a Fig: 4.8 A READING OF 202.8 00& Hartridge ocsa.ovsoy OPERATING & SERVICING MANUAL C. PRE-TESTING NOTES C1. SETTING CLAMPING HEAD PRESSURE (Fig.4.18) {tte sccentil that the clamping hand prassune be ast sorractys ‘check the pressure cally, using te load cell NIA 17, aa fallow 12) Chock mat we ate presaure supply adeaunte (ome » than move te toeking avert th Lat open the all emive (Section 4 paras. AB & AG refer), 2) Spenate the air valve switch several tres © Sxpe from the system; return Sie sini 19 Bie Ww! Com) postion aoe Section # para. AA). 6) Filtre Nowspiooe NTA 106/12 (1) t tha clamping has. Fold ene to sell (2), ith ts cartaal end uppenmest bpetwoan the tappat (3) and the nosapiece and clamp (> position by presaing dovin the air valve swan. ‘© Tate exe toad eat eaclng, which shoud bein be conene 6) Unslane the load call and thon eopeat the above ts the rendinga are not correst adjust the nie pressure ©) Move the Locking lever to the right to close te ot valve and eave the air waive switch to the (ot position. It Ee tcad oat raning seeps raptcly from the blace tone 2 Teak in tha Fydraule eyatom Is present, which must be tmvostigated- NOTE: WORKSHOP TEMPERATURE MUST BE KEPT THE PRESSURES WILL CHANGE CONSIDERABLY ‘he camanart speed can be changed by moving the Poly Veo) bet from one sat of pulleys to tha obi. Loosen both the Front felts on tie noise mounting plate and slige the motor tonaree Me Chimbow to slacken the ble (roe Fig. 8-18). [Ease the belt onto me other 208 oF pulleys and tnten the bett to obtain a tension oF WP (Imm) atthe midway pobre between the pulleys.” Retighton tye motor raunting alto, mowing that (eta ony the feort air wich actually clamps the moter down, “The near pates of pulleys (8 for Cumming Injectors, the front pair i for Datrott Diet Injectors, 8, MASTER MUECTORS “The Ouremnin celioratad ta maton Injector and tha inactore under tat are entibrated by the ranfactur “The actual mounting of a ster injector tothe machine ss for the injooian ot the samme be whieh a under ents Section 5 4e gu til parteatans the monty proeadune, : THE ACCURACY GF ALL. YOUR WORK DEFENDS UPON THEM = BO NOT USE (Of, SETTING CALIBRATION FLUID PRESSURES (Fla. 4.14.) “The ealibraion fluid pressure ean he adjusted From te 840 nominal steings az required ty using one ofthe No adhIING Tefava which ara aitatad on the fue! block as snow Because the Cummins inst procedure ray require feequtnt pressure corrections toe made, de fue Block (1), so ented En the aide, projecting from a leutnout tn the righthand comer SF the tp covery for sate of accnes,,-Adaitiaralty th nigh Drenaure sevow (2) can be mahusted witnout previously removing the valve cover The oiterent nature of the Datrott tenet (GM) tat procedure aka frequane prassure corrections unnecessary, The ow (pressure adhustng serew (4) ta anly acceasible after removing {he dirced nt (8) shackan the locieut (8) before maing any adjustment th the drive motor running and an injector tad, turn she sepropmiats adjusting sew inwards (clockniee) t wersage te Sreosure or aubwarse (enti-loctnine) to dectange the pressure Ratightes the ow pressure adjusting screw tocknut and repiace eve corned mut PTD “Top Stap injectors Some PT Top Stop Instone require calibration at a seduced presoure,” Fit ST 1908 Master tnjactor (17UA-PTD) a8 tn Section 4 para? and reauce the prasaure with te high Dreszure adjusting screw (2) until an output of 1886.0. 19 abtalneds {ho wilt boat approximately GOpst, ‘Calibrate Tap-alap injectors wih te preanure uatng Sere a hi stings to ar trating normal ye injectors, RR scotare Tee (Correct Output on HA 265 Eat-basec\ Test plan Se * Mathod of canvaraion given in Section 4 para. at foot of page osposite. FigsA.14. THE PUBL PRESSURE BLOCKOPERATING & SERVIONG MANUAL a 8 u 8 © S = 5 2 s = D. MOUNTING AND CONNECTION EQUIPMENT Cree sas 069s W790 Wa boob VAN common ary 4] zye01 wan] Om OL re 11 /e08 wan SveO MOT Livee 7BS3IG LONI 3G rey uuu eztor 9/901 VLN 190k WAN Cron SAW 4 2/301 vin Loot VAN Loot wan exe Horn Lifes 7Ss310 sowlsa s2/ot VAN (eB 8) ele VAN] 1/PLL LN) auyaat win URONATA wae (KL >) Qld WORIGNTTAD SNINWND, 62/91 VIN (s6uns 2) se/ot VIN | H/EZl WIN zi /90k VIN (percwey dorg dos) O17 SNIAWAD. oe/oh VAN ean aor van |2/0/%e/et VAIN) 1/08 win BEONNTA 8/6 (ACOB 303Id @ Cid TWOIRIONTIAD SNIWAND ee/ol VIN Gone @ 12/91 WAN |e/o/r0/01 vin) zi/eat win RIEONNAG 276 (AdOS BOBIE & Gd “WORSONITAD SNIWWNO. 96/81 VEN Taare 92/96 VAN |/0/P0/91 VALNI et/s08 iN NS GSWoa (SONS, © Oud TWOIMONTIAD SNIWWNS 96/01 VIN ou 3) et/ah VAN P/0/P8/91 VIN 1/008 win ONS NIvIa _(SONTS.0, © Dud TWORIGNTTAD SNIWWNO be/at WN Gare payor win [2/0/re/3! WAN z1/eo8 wan Ge) WALLS 9NOT (SONRS 0, aig WoRIONrAS sNWWNo besok Wan Gaus =) beet vin fYvPest vin z1/o08 win (owas woraaw (oNne 10, +) Big TWORSONIAD SNIWWAD te/ob WIN (cours ©) ober van |2/a/P8/01 VAN! ziyso LN 9 Was LHOHS (SONFY.0. Bld “IVORIGNMAS SNIAWOO hides van (e6u 2) itt 96/4 VAN z1/o08 did QZONW74 SNINWND vi/ol WIN (eoaie oh/ob VIN zt/901 wun 9/P a3ONW Ia SNIWHNO Lieb WN Gonue) o1/aL VLN 21/008 WAN HAH GBONWI4 SNIAWNO Goon Wot VAN e/ok VIN zt/oot win 7 a30Nv14 SNEWWND NOISNSWIG SOSHO NINLL as1L0st3s: wo eOLWOOT (a#o920u1000) woLdvay consounuerD| NOISNELS wais SOLOS ssruosssoov, Anvio NOLLAS ES SaIs055s00¥ "10Hartridge cece ovo OPERATING & SERVIONG MANUAL bt. cconToy IDENTIFICATION OF THE ADAPTORS AND AC i cuaRT OPPOSITE NOSEPIECES: CLAMP BLOCK (DETROIT) NTA 106/14 NTA 109/14 NTA 108/1 (All Detroit) (ATL Cummins) FUEL BLOG AND PILLARS STEM OGENSION | CONNECTOR (DETROIT) (DETROIT) (@ETROIT) NTA 400/2 and ALP 70 NTA 100/21 __NTA 108/20 NTA 10077 ADAPTORS FOR CUMMINS FLANGED TYPE INJECTORS: L. TYPE H/NH & PTD TYPES J/C TYPES awa ;O oO NTA 16/6 = Stem Extension NTA 16/10 Stem Ext. (H/NH) NTA 16/13 ~ Stem Extension NTA 16/7 - Adaptors, NTA 16/28 Storm Ext, (PTD) NTA 16/14 ~ Adaptor with (Connectors) NTA 16/11 Agaptor DOWTY PP 45-11 - Seals CARRIER BLOOKS FOR CUMMINS CYLINDRICAL TYPE INJECTORS wp NTA 16/94/0/2 (Formerly NTA 18/20/0/2) NTA 129/1 NTA 14/1Hartridge ces. ovson OPERATING 6 SEAVIONG MANUAL bt. (eon) H, ADAPTORS FOR CUMMINS PTB INJECTORS (With four 'O" rings) SHORT STEM MEDIUM STEM LONG STEM *€ NTA 16/81 ~ Adaptor NTA 16/81 ~ Adaptor NTA 18/81 — Adaptor NTA 16/10 ~ Stam Extension NTA 16/21 = Stem Extension NTA 18/24 ~ Stem Extension J. ADAPTORS FOR CUMMINS PTC INJECTORS (With three ‘0! rings) CS NTA 16/19 ~ Stem Extension __NTA 18/35 — Adaptor NTA 16/26 ~ Stem Extension K, ADAPTORS FOR CUMMINS PTD INJECTORS (With tno piece bodies) ee s a WB DIA. PLUNGER BOI, PLUNGER 16 DIA, PLUNGER (‘«' type) NTA 16/29 - Locating Pin NTA 16/29 ~ Locating Pin NTA 16/29 = Locating Pin INTA 16/27 ~ Stem Extension NTA 16/23 ~ Stem Extension _NTA 114/2 - Stem Extension 40Hartridge oes ovsow CES (Fg. 418) corractrifs (9) should bes Sheet and seam oe he osepioos NTA ae the PART NUMBER IDENTIFICATION ORIFICE 1/9, NTA y08/13 3007s o.0118in NTA 108/14 2 o0Ts o.0%3in NTA 106/35 1 por cen NA 1a 4 bors 0250 2s SELEGTION OF CARRIER BLOCKS - CUMMINS ginger "Toe S70" incual plate is 'revorabie to acconacdace the irked eth tod wth ta ada panos the leak 3 Ta ang ATE injotorss tae ether alge te marked "OT Wl agcope P50 Injectors only, other than the lest WC type. looks for mounting Cummins Sirah) tn Ge vace ata ies too puted! uppermost) must bo uted for neuring PTD ype Injecares oy cals Sle MTA 12/1, wits tho aariag 19 upparnt rut Be utd for mounting Cummins L10 typ9 Inectars 4 MEASURING THE TIMING CHECK DIMENSION - DETROIT Diesel (Pip. #78) The ing stk, inansion ia toy hg matter baore uern of ihe Hh 284 orovar I Sy ot ete “conpanei Stel “no alate twin “8 = Eos (e012 ok fre figurer given ta the shert on pase 1 the stom axtoncion (1) to bottom dad contre an aie aight fam noua lca th apf, la edn Aajuae the piles lengths ex rageseary by toring tacors under tre hardened pur heads’ 2)e DS. FITTING THE MOSEPIEGE = ALL TYPES (Flo. 4.16) (roe socowing In the correct ottice (Cunmine esate only) Insort the eseptace (type “Cua s {spire t,t clanging ad wh ‘ing (3)s Fi the uppat Senjo connactor" (a) aa shown Fig.4.18 THEE TIMING CHEDK DIMENSION OPERATING © SERVIENG MANUAL Fig.4it@ THE NOSEPIECE E, MOUNTING PROCEDURE. EX, CUMMINS CVLINORICAL INJECTOR (Figa.4.17 = 4.21) Pit ee eoleetea careter bck (1) lo the side (2) as sary secur Ie with the seron (EA) and tse fast pipes tothe untons a frcestes. ETD Too Stop Injectoray sf the yltnerionl infsctor boing tasted I= Fre DTB [e sises Sony) tins inmanporatina a toe clap, revrave the ‘mension Sera and iach, then Moun as for standar PTO Injostores SECURING CARRIER BLOCKHartridge ses ovcon OPERATING & SERVIENS MANUAL CUMMINS CYLINGRICAL INJECTORS ~ CONTINUED re Fig.4.18 SELECTING STEM EXTENSION/AOAPTOR RING Ett the sstectad stam sxtension 2) and adaptor ring (4 tthe Anjecton, ita re ain (8) engaging the Lovating hole te wow On tp and K type injctons insert the locating pin (2) ml - and tnaect tna injector (7) rom Bena Fig.t. CEAMPING AND LOCKING Press the ein maitch (8) din te larry the Injector inisaty, ana remove meagitor nrg or pln if desires. Removing “The removal of inectors from the HA 285 fs the reversal of the meunting procedue but note We followings a) The cam must be set 1 Top Dead Cantre boos the Injector con be unclamped (ese Section & paras, AS & » Fig 4.21 FWVAL ENGAGEMENT8 Hartridge cece. ovson CRERATING © SERVIONG Manual 52, CUMMINS FLANGE TYPE INJECTOR! Fig.4.08 STEM EXTENSION, ies the elie (7) to enable tne injector to be cecage nm stor etenaion (0) wit ra depression ithe st @) [Sha then Loner the sige b> rest onthe injector Mange (10). the air suite (11) down t clamp the injector an, ‘paves lock iby eroving the Lover (12) to the right Fig 4.25 CLAWPING AND LOCKING Ft the calinration utd fees (19) and dratn (14) banjo con nsetiona to the injector, sneuring tat the content aide af Sah Sal (8) te th groin facen (16). Comect bs plea co ae Rersoving “The remaval of inectoes trons the HA 208 ke the meveneel of the mounting provedure, But nats tho fll {ejector can be unslamped (ese Section 4 paras. AB & rs82) Hartridge o2ce. oven CPERATNG & SERVIONS MANUAL Fig.4.7 FITTING CLAMP BLOOK AND EXTENSION TUSE 8. DETROIT OIESEL INJECTORS (Figs. 4.27 4.91)£2 Hartridge esa oven. F. CALIBRATING ANO ADJUSTING PROCEDURE ‘The following two pages outline a step by ap procedure ne to how salibrating ad testing conditions san be produced using he Haren Ha 265 Feat Stand. Read ther in conjunction with the Injector rarutasturar's servise literature wlan lye down te OPERATING & SERVONG MaANUai Betore prostoding make sure tt you Rly ursorstare te Gonnact pain of pultoye for the ype of injector on test (200 Seton test data required. The datalled sectional references, which give bd coieae SER og et a a Qe ce ey ‘nthe machine (Section « para, Ba refers Ft. GALIBRATING CUMMINS IJEDTORS 1 CHECKING RUN FIT A SPARE INJECTOR ~ NOT THE MASTER - AS OESCRIBED IN SECTIONS 40 8 4E:, 1 HANOWNEEL, Eneure that machine furne. SELEDTION VALVE . MAINS SUPPLY SWITCH Switeh One not the taps meter eplaye a reading, .. MOTOR START BUTTON “Start motor running until fluid appar fn drain pipe. 8 METER OUTPUT BUTTON Presa; the dat nalatoe will zara, then an toi Sutput rors the injector salt purge the systrn of an n METER OUTPUT BUTTON [Praas ageiny at he concluston of metering cbserve {he racing on bw cal inaiostor, Toke (a te delivery te inaction cas ‘efor t Section 4 para. tO. NH CALIBRATING THE WACHINE TO THE MASTER INJEDTOS THIS TEST SHOULD BE CARRIED OUT DAILY opexarion ACTION " ‘Carry out the Checking run (hi tte has nat already been done and chesk 2 Flt tye master injector as described tn Section 4 &4E. + agent operations & ~ 7 of (1) and check that the readings are consistent before {Shing a final reading. Also chuck tnt the temperature fo otablo, 4 CCompars the final raading with the Cumming dalivary igure forthe Spe [of injacton an tasty fe may be naseusary fo convert tha figure as shown OY the mamole given in the NOTE at te conelumon oF IRLIECTOR OUTPUT s. MoH PRESSURE: Irereane or decrease the presaure AENUSTING SREW Winerease on seoraaze the detivary Ua fir within tro ente given, OPERATION ACTION NECESSARY " ‘carry out the machina calibration (1) this proceaure has oot bean \Srsortaken prion to each days injector caitorting, om ater charging tenting 2 dittenene type of injectors Fe th Injeotor to be calibrated t the teat stand, °. ‘Repeat (2) - Operations 5 = 7 and eneure that the readings are consiotent before ting a nal reading, « 1 ne firm reading seas not fl within te Cumming stated is te Injector should be adjusted as specled by Currmnines Ue ay Lovelve changing, or wlth oVindrical injectors burnishing, the aitioe. 1 the Suiput cannot be brougrt within te neta rer to Carmine semice REFER TO Pare. AB etings ‘SECTION 4 Pare. co REFER TO68 Hartridge ces avec 2. CALIGRATING DETROIT OIESEL "52", "71" AND 192" OPERATING & SEAVIOING MANUAL REFER TO THE CHECK LIST ON THE TOP COVER ~ ALL CORRECT? (OPERATION contROL 2 FLUID PRESSURE CONTROL VALVE MAINS SUPPLY SWATCH ISOLATOR SWITCH MOTOR START SUTTON METER OUTPUT SUTTON ejector on eat orion yecessany nersn 70 comm. are. AB ial re eb ater cage Pag ue art mote ning et ld apse in rin pips, Ran. At ‘Press; the dial indicator will zerd, then an initial Para, A Saal ron te co wl are eon Betiaiy save val maior, Shisteike doivent Satie Tatthin tve manufacturer's sated Limits for each type of injoctor. ++ oye diat indicator fate to cere precisely, tt will roquire resetings rafer t Section & para. AIO. Fa, ADJUSTING CUMMINS INJECTORS Cainaricat ype “The delivery trom Curnming evindricat injectors ean be tnenanoad by sumntening te int orifice (1) of the Injeoior using the bunishing toa! HF 724 aa described below. =) Remove the sorewed plug trom the cannfan block (2) and Fit tho surmicning tock @) tn ite place, pulling out the eral knob (6 frst ‘Tum the tage Krab (6) ntl (18 9.6mm (9/899 from the tot boy. ‘Gareflly push the ama Knob {nti the Burning Bit (Gem be tale engage stent orifice, ‘Seow ths large rab inna (locke) unt te fat ge salio, the pends (snow comoletaly fling tne orice. Continue screwing tne largo Krab inwerds, as indlestec by the graduations adjacent tte paintary antl the orifiew fas bon barishes the cequired amount Tiber the burnaning operation hax been comet turn tho Tange konb antieclosgeiae, alana’ the contre spied Durmianing Bit. Flemove the toot and replace tne sanewed » 2 » ° foreign rattan on slight burrs inthe orifice; tranefora tke Ineneane the delivery by eltmtrating aso derects alone, If amounts to give an Inersase in output in mca of Boe are to be munnished withdraw Une tol and carry outs delivery test 1 the delivery ts ta9 high ta new tnfet onsice & the injector, Since the spring bend fitted round the Injector body roy obatrsct the burnisning bit, it ahoule be removes before Ring ‘he injootor to the carrier blosk, replace le before refting te injector t the engine. Fig.4.92. BURNISHING THE INJECTOR'S INLET ORIFIDE Flange Type “The inet orifiea{s 2et at an ange kn te not pore of Curnmine Shows tal, Agjstment to injactor ouput fe only possible by ttaing he orice, neon to tha tabla or Fart and Devery Values Injector. “The range will cover a "spread! of sizes 2.9, from ‘dame ronge before the correct delivery is obtained. A nescle ‘rugs fa avaliable to make netection ae Eralnes.Hartridge occa. ovson SECTION 5 MAINTENANCE IMPORTANT WARNING SERVICING OR MAINTENANCE, OTHER THAN CONSUCTING THE FAULT FINDING SEQUENCES WhEkE THE TEST STAND MUST SE OPERATING, WateQur FIRST ISOLATING THE TEST STAND FROW THE MAINS TAKE GREAT GARE WEN CONOUOTING THE FAULT FINDING SEQUENCES, STANO IS STRL LV THE TESTS FOR LECTHONIS GOMPOWENTS (OA MENTS TO BELTS CR COMPONENTS. ae CONTENTS BD! Mataring Unit Dinosie © REPAIR AND ADLUSTMENT (C2! Sanvicing tne Sasher Salanatd Valve es Sarvteing, © SLECTRICAL OIAGRAMS oat OPERATING & SERVIONG MANUAL62 Hartridge cese avecy CRERATING & SERVING MANUAL Fly.5.2. THE FLUID AND OIL LEVELS A), WEEKLY SERVICING (or 120 Fours) om Gallbration Fats ig-6.8 Fig.S.1, THE ACCESS PANELS AND COVE eee 1 aro na ittand aca pana an ones ate vat of calibration Fudd tw spprosimatsty in (Omen) A. SERVICING Gaptclyy 0.8 ea (14.8 Ultras, 2.8 fe, Gal, Al, REMOVING COVERS AND PANELS carbax OW (FI9-8.2) WARNING: ISOLATE THE MACHINE FROM THE MAINS 1b) Remove te left-hand ide pane! and aboorvs the sight LECTRICAL SUPPLY GEFORE REMOVING Slave arrow 1) on te can, Remove eps Cavers OF PANELS {arrow 1 inthe serbo tp, fill ough the oniPice ST ietaceary and replace the plug eaoun'y 8) Top Covers Firat remove the bvo wecuring eorsie ‘Storicarty SAE 30 engino att, {eiteor rani ny} frome rear Gapseitys 2.4 U.S. pine (1 tres, 2 Imp. pints). Gone in "eregeration For Use". Now Hydoaulte Gramber Of (Fig. 5.9 18°) Carefully pull the cover forwards to ‘eloase the four prase tude and URE 12) Check thatthe machin sontrals nave been et tthe Wetear. (ircamped snd Unlercea postions (sea Pipa. .4 Sr 4.5). ©) Upper tone Talat tha four seouring fasteners @ ‘The love can be sean tn te nylon sight Ube (1). The Benet trays Ginter of @ tums anticetockwtos to {lel should be Sain (7.08) rom te top of the extincers Fotease tne panel, then IF Te forwards ‘Complete wiln eye drip Way. Noto that IF the tovel na droped Lh tha cytindon wit the drain pipe must be put oak wien Calibration Mud az enor Le iivores Flu (F1g.8.9 '8") Papet: 2) There is. gaute line filter situated on the front f te achine, Remavs oe uppee and sonnucting mut (1) and SESch the mon pipe @). Now, wahdrav Be Fitter by recrowing te ane rap (2). Wash the gauze in parain 4) Lettenand Pl forward rstense each prees: (eerosane) and blow twough with an at tine. 2) Rear Access Remove the bo Nex. head K UNG screws Panet Gand the tires 298 purtsve serena and tele a © Loteand ron Theat an righthand pane ar net fot require removal for ary nore lamp lng Head Pressure |) Checke te clamping head prasuro with th toad est Machine Calionation b) Calforate te machine t the mastar injector vat a of| Wr Gp ae the injootora which art bs tasted ior 4 para, C5. Tha machina wilt require r= Calibrating 163 diffanant type of inlactor i oubeesetly Fg. 8,9A" THE HYDRAULIC CHAMBER te be tasted tae ony. Fig.6.0"8" THE LINE FILTER@ Hartridge cese_ovecn FigsG.4, THE PRESSURE CONTROL VALVE FILTER “The catioration utd preaaure control valve which ie {Bioated on tha right-hand ese oF Une mashiay te tls 1), wai (tn paraftin (korosane) ane AS. MONTHLY SERVICING (en 60 hours) sin Enter ¢Ftg.0.9) 5) Rema the access covery the ain alteration ffuld Hiter (3) let be found at tye left-hand and of the Soren na plastic wing mt (@} ar erove he ar Fite replacement, checking the oi! seals for condition. Fige0.8. THE MAIN FILTER Fig.8.6. THE AIRLINE FILTER ASSEMBLY A, OCCASIONAL SERVICING (As Inatoatad by a Visual Chesk) Airine Fuiten (F10.6.6) 2 * Shc ono he dy, enaurtrg ta the gat (Pas not Desdina perished. (Calibration Ftuld Changing ) fe ealtbraton utd ts suspacted of being contaminated, ‘rot ro longer conforming & the specification glvan Seotion | para, 6, emust be changed. Rerrove the {rain pg trora beneath (on the rightonand nse when ‘owed from tho rear) an olla te old fut to arate 1 Remove tho raan aoseas panel (Fig. 5.1) and sorrpletaly lear out the boar of he trk. Rapiace te drain Bl ‘Section 2pana, 62, Replace all overs, B. FAULT FINDING 1B), FAULT FINDING CHART syMPTom PROBABLE FAULT - (0 Machine can sat be ‘reac ane \Wirora accessories or osm selected, ‘Select and fk: correct accessories 0 a. Res warning ght Ssttaguloned, Cbs At other tactntcat Flectrical supply laolated om wall ‘Tors on appropriate ewitch or Replace appropri fuse, Section 5B68 Hartridge oesa_nvscn OPERATAG & SERVING MANUAL Controt baton faults ‘SYMPTOM PROBABLE FAULT ACTION REFER TO: (li Walon wilt sat pan | Motor faults Tatar t2 maton manufacturers on ele spent. ‘wiring faut, om prage ruse siown, | Roror to etroutt agra Sections (du) Motor doce not drive Poly Vee belt Brotan. Replace Poly Vee batt, (2) Na calibration utd to Injecsor Fu rae ery Mtn fer blocked Ccalibeation Fats pure faul,oF Replace Miter element (Wd lector ‘ohatters ‘Slow through with comprasced alr. (uD Low Aiet pressures (Rall valven ratnajated. Feiler valve fault worn on damaged seats whare (vit) macortng eytier ‘Section 8 paras. baton or Printed Ciroute Sone ‘Somponere as Receasarye Geantce Pate (60 Drain starts ans Relay (Rit) on ehasate detective, | Canfnen by hoteing button ine cain wl Figure 3.9) immediately stops. rescsminarice fut sop i outon ts Feleazed prior to slat gauge Reeching Boro. Replace rotaye Figure 5.9 (00) Count lt rot start ‘Mater sutout Sutton fault Pokoup faulty an inne of juctmert Replace Button. Replace on adjust plok-up. Clean contacts and an bridge plese. Figure 5.17, (et) Metering ayltnaee “Gauze line Fiter blockess, atering uit filter Bloaked. Inlet stant valve, Printed Strout Board on eatin TL ‘Clean Futter Caney out sts and replace detective Figue 5.17 Sectlon 5 pana. 59 (At _Foonststont or Iscrurate Output Resaino ‘Dial tnstentor Fault. Inteteotenote valve leaks. Re-sut cero adjust screw on have ota (heleator teat 0" = shocker carry ext alagnasts ~ Task ‘A ~ and renew parte ae receasiiy. nd roplace valve I Fall. Section § para. Section S pare. oe 2 co (eit Stamping tone ‘Air prescure regutelor out oF ‘Aas ctor hea teak. ‘check pipe connections. Renew platon seule No olt tn nydrautic chamber Rect chamber. Seotion 2 para, 82 Low slp line supe pressure. Fecitly at source, ction t pars. 212| Ar ine Fitter Blocked. (clean or renews Seetion 5 pares AG lamplng vatve Fate Replace air valves Section 8 pare. C8 [civ Clamping Yaad fate | Locking valve Faulk ‘Ranulte'valve with naw parts axnecoasary. | Section S pare. C3 Section § pan oe9 Soetoro re eter not runnlnse (clean valve, chock wator supply for eleantinaes | Saotion 5 pans (carry out continuity check and reptecs vale Seaton § pars. ce Jon. estan permanertiy Jory 82 indicted by ware inrip glowing continuausty.| Bnd make vioualtnepection of Tian FRoplace dareotiva compenerts as receesiry. eo i Hemar perme eater Fale, Replace plug Replace detective components carry out continuity cack betwean tormtnals “Gia” anc "006" ane repiace Hester Wh reoesssey. Section 9 para. endHartridge rsa avec. OSERATING & SERVIGNE MANUAL2 Hartridge cesa ove Ba. TESTING FOR FAILURES OF ELECTRONIC COMPONENTS i Picks 5. Ensure that tn toot stand le aotate electrically then seect the rebistence range ona muikimater (e.g. an Avoreton 8) ere Greckihe neelatance of the sol in tne mognetle pikeup (1) whieh, Ie'just behind the camoox pulley Pull the piu (@) atthe end of he pickup tead feom tte loeatlon in the pried sincutt Board a Shown. Now sonmoct te probes of the uititnetar tothe BINS Gero tae tis Blan, aramical racing of sc ore shove Fino. Renew the magnetle ple ile to faulty, ming Sune thot W te sclustew ve dareribes below Iv the electrical eat are anilatactory, obeck that tne magneste panel [if atted. Slacker the lockent{a) and aslust te plaka ution i te braciet wt & tenance of 2.685 (0. 126rm, at Fiskcup sod the peg (2) tn pullay. salen check at hare = ‘Dood cantare 8 nlp (2). 1 the metering ince does nat dain item wit of the Fut boingnosts Chard, and iets not apparent ube eomperent Getective, carry out the follow rest, fof wa orange enaten cute tution; nnest 2 valemetan hetamean teminal ‘986! ane! 000", ese and hole tix Baton doar ‘ending of 28 vol should be racardse, Release the Button, where pon nit woite snouts be necarces, Printed Circule Goad and the outut amiteh are funstioning 2orrsety, So the fault i in ene drain solenoia (So-2, Beaty. the Feadinga recorded are not coerect, measure the voitage Cetwoon faut te inthe button, Urn, the fault fe hy the Printed Ctrsult Fig, 8.8 CONDUCTING RESISTANCE TESTS AND SETTING THE MAGNETIC PISK-UP OPERATING & SERVICING MANUAL Female sod Fig. 8.8 SOMEMATIC VIEW OF THE ELECTRICAL CHASSIS Inlet Solenoid, Hestsbik or Srinted Cireutt Boars Ifthe metering cylinder drains, tut will not fl, and te “chasis in (erin ¥ anid ofthe PauleDiagnoels Chert Fat usta the ounce raul, canny out the following Sant ‘by wires marked ‘695! on the Terminal Board (7.8.1) ‘esorded during ne metering programms. IF {iby the ‘metering Slvocit of te Prieta Cincult Board, tre Hastnirke ae the Migrate piei-ep arm all Rnotioning correct’, 20 the faults inthe inet fear) solensie valve (Se. ty see cireute Disarem 1 the correct vollage fo not rasordad in the above testy and Sacra, the fat Wow mh other tne Printed Crete the Hastert rectiy by syotmatte sutarinaion, Note ta i the Somoonent first swsetitted fais to reobity the faut, ram Be origina corroonent bafors procoagina. 1 the rater dows rot Function correctly, anc he chock (6 ‘terns vt on vito the Paull Diagroste Ghar fail to eetaaiten| fhe heatsink om Printed Cireult Board is defective, Make a visual If bene mas been @ sudden rise in calibration fluid trrporatine, fs wate y rear tertperatae age a he a= the narrstctor fn the ful sar nthe haaestnc on the alaska retan (2-01 an Avornster 8) ana chock tho resistance of te UNere= {enor th toe tact tory PLit the large Black ples ie atthe sable Ue tie raasing te nok obtained, she thermistor (zee S.L 4) has Batiofactory, the Trise on ts heat sirk has probsbly short acini with 409 watt hantarss stan machina (from Md. St "Ciyane hited with maine voltage 450 wate haators, are 2 safety High inthe event oF Ue zontrel ayetorn develoning a faults IF MS bappsns tha veater wt be awitohad ey aba tampersturs SpprO~ imntaly 15°C (27°F) above tne rons! operative tenperatans ‘Tho tomporature wareing lamp wit become extinguiened ara th rnin metor cannot be started. Conduct ine teste ae ove 2 entry the ute.Hartridge oesa. ovsen OPERATING & SERVICNG MANUA Fig. 8:19. FOLY-VEE GEL REPLACEMENT C.REPAIR AND ADJUSTMENT C1, CHANGING THE FOLY-VEE BELT (Fig. 5.10) panel (Section Saarasat) te 62, SERVICING THE COOLER SOLENOID VALVE (Fig, 6.11) Figs S.tts DISMANTLING THE COOLER SOLENOID Fig.S.12, THE AIR ANO Ol. VALVES 63, AM AND OIL VALVES ~ SERVICING ‘Aun mive (taming valu ig. 8.92) “The aie sive car anly be serviced by replacement. Provasd the apen pacition (left) than remove Dy ts Sp plage 3), aie {retained by 8 ane soring Pu out the tec wire (10) retease the tp ring (11) ane 2) are wits te 18) and tae oat pg 04 je or cameges in ary soy te valve anny Fig.5:10, A SECTIONAL VIEW OF THE OIL VALVEHartridge cesa. oveo OPERATING S SERVICING MANUAL D C4. CLAMPING HEAD ~ SERVICING (Fip.8.18) Ir the champing peas rails to matain ce correct toad (S00 Cty Took ry seat an the Internat weal ay 2) Check tat the afr valve suitch andthe Locking leva have > Disconnect the nigh pressure alpe to ene earroing mead (19, ©} Remove the to bolts (2) securing the claepingyhead £ Sand off tne clamping nead aaaably ) Reaves bolt ) tu releasing te caver (8) 295ing 6) {Use (7) and washers (0), then witedraw tha praton seeomy (8) from the oplindor (10) nd remoce the aaa! (17) e) Retaase fp roraning waren (12) 8) namoviag whe tyres ° Securing serews and eamave the uaper seal (19) from the =, packing the cavity ofthe wpper one with arcten and erally ening ath SAE 20 orgie blaes the hyro-poeurmatic system ae descriaed Below. ILEEDING THE HYDRO-PWEUMATIC SYSTEM (Figi5. 14) i te Locking lever to the “open” position aft and opsrate the air valve to dtoplace tha ol {nthe ydrsutve system (Section parse. As EAS refer), Bey, sth these centro'e sr ithe otto deter tonaen ch npr ton (1) thw ean Fetighton the union and switch ff the air valve, "var oil, Face af at~ Buboleay mun out Fromm the pane “Top um the hydraulic chamber az nacescary a described in 8. OVERHAULING CAMEO Dismantling Fig. 8.46) [Al maton components of the carbon Nkly to requine r= |5) teolnte the machine fram the maine svpply and remove b) Remove the oaphata screw (2m) and pine out the sam Sstbotor lover (30). Now remove the circa (31) fram tha com eetector shat (20) ©) Turntermacine by hd nl ht app (0) 9 at 4) Te enable the slamping nese w be removed as an \ipper benjo cerisction 1) fram the Rseptecey then USntach tne age lever link from the slide by removing tha allan sorew (2), Otacornact the preseura pga hom the stamping hand at tre union (2) 12) Rerrave the foun ean head serena (28) and WL off tye hese. Rernove the cam selector bar (20) 6) Datsch ths tapout lamp and release the Lppet assembly Sind spring. enew tapiae aaseraly fer, hy Remove itams 5, 8. 7 and 6 from the sett, The retain leg not (©) te eat bya grubacrew which must be Ieosened before Wear be unone, itmay be necessary tease an entracta” ts relaase te Ply Vos pulley @, 1) Foren tye four soraens (41) and detach to Front howeing (Gi taking care not ts aarrage the ol nea (12). raw tno carmahate sasembiy, complote withthe Baltrace (ayand rotten cage (29), out of tre cammoon 1) Lodsen ae grubecrens Iocng the hexagon ruts (9 ana faa). Unscrtn thast ruta ard draw the bearings (19 ar 25) "the share using 2 mate extractors FRemave the cicline (1? and 22) Grom tne camshaft nd lide the caen clewve (12) ff tha that, racking Wt for 1) Separate the purne trom te eunting pedestal by removing {he bolts (82) then otach te pesos from the Dak ot the camo by sntracting te Four courlarna sorts oy ©) ara he ot tk Ft oer baring (FrmHartridge oes oven. OPERATING G SERVING MANUAL. Fg. 8.18, THE CAMBOX AND CALIRRATION FLUID PUMP ASSEMBLIES (©7. CALIBRATION FLUID FUMP REPLACEMENTHartridge cess. avec. OPERATING & SERVICING MaANLIAL C8. OVERHALLING METERING UNIT (FUSL RECORDER) Hany of the tests in the Patt Finding Section 69. \iton valve faces ( arrowed ) for ponalbia vetestey Fig. 8.17. REMCVING AND DISMANTLING THE METERING UNIT. Detail A" gopieta the Init selenoid valve, ac "3! the MasteringHartridge seca oscOPERATING & SERVIDING MANUAL @ Hartridge ese oveon.Hartridge ceca. ovecn OPERATING & SERVIONG MANUAL SECTION 6 SPARES LISTS ‘SPARES ORDERING SPARES List 4 SPARES LIST & CONTENTS: GENERAL ASSEMBLY AND IDENTIFICATION MASTER INJECTORSOPERATING & SERVING MANUAL £8 Hartridge cece ovsonHartridge ese ovecn SeABES LIST 1 con et. o OPERATING & SERVICING MANUAL THis 1 8 yo to Tank ine” 1 Tamara 3 Bites Ae’ Tas ee BN nm ite Ec ar, i elie ote eee, Era a saat ee ae Bio eee Bes pee ene es le kt teeta tact ee Pata rae Para aaa cent eve ae nt ae seen Se ae Beare eciie Sets ce oi a Pham itutitis vail aay can Shon come eee Fhe ene att tee eau eaa ett aac faiee tne ft SSL swe eet cuenta roozcmenaves —_@ an fatten Oise _@ ered ain & toad oe aaa Sahn es Seat cette cata Beers 8 Fig.0.8 CALIB2ATION FLUIO METERING UNIT SEANES LIST. 3x METERING UNIT (Apsenbly Port Noe FROL« Description Ne, aus {olncld Valve ~ Exnaus, coe & goer) ey 28 cg es - sovars Sra eo, Bn Ee |Hartridge cece. avec OPERATING & SERVING MANUAL 13," the pare nay ate A aa0/60/ 90, Bef Mo, Dasstlation Pait.Noe Qs 1 overinga 1 20 1.88, Enpisieyec 1 eaten Essre/e/ae | 2 Contactor BY s0/oue ‘Teaast + 5 Transformer Mod, st A & 9 Troe Tranefarmar Mod: St@ © on these | Fuse toa'nito. 5 8 Neon (RUTH) ats-asoy t 2oweeay : 1 Baton tsotation (RED) (Sit) 1 Pek Button Sv (GREER) (oie) Teargyia t & Binh Sutton Sw (RED) a Spindle = Vaive Thloel2rs 2 Ping, 1 O.b x 1/180 Section Beatetie gsso1so 2 over = valve Teroerers + a erm, Nylon: at pan GBA x 2/8iq lp Sz be ome Nut 3/6 Ua Seaaasi 1 be Sorow, Mociieg (Rell Vaiva) ——Thtbg2re n Wasnet,Bewty tan Sesto 2 a oor Wits 3/40 UNF" pecorna Ey Stig Coupling, PUSC & 859, feearns/iah pastas 2 a0 Spring {tow resaurs} auaralo n foot ricer) 8, 2 Gannastor, spect rear st % itor Assay Senin9 Hartridge seca oucow CRERATING & SERVING MANUAL SPARES LIST 8, cANBOX AND PUMP ft Nos Descriaton fart No, Our. Be Noy Dasaription Pat noe Otte 1 sari t Fuel pune w/aay Besouers + : iaost | 2 Tali goat type (Wed, ud. 0% an) Some 4 ker Gwiorts 7 sen | sehen pec Ueland 5 Bile Ascensty Guanes aes Pn & Spacer Stott 2 Bing soliow spies 1/3 in Sion 8 Rate toast amos 4 a Suasrs 8 Grubearew' 28 x sin See 1 Sa rub 254 x yin Stossst | 8 Banyan vin astioss | = Suiorze | 2 et i i 8 Mop a/a ase nos 2 Mate Shao 1 x atts can 3x 8/0 aes 1 Ubodtut now 12 Thesis} = degion etasyeo/o 2 18 Front Hosting cus 3 288 5 900 oor 1 Sree tt Zn, 208 x ain Stasaot 3 « tor tor 978 SP Stee I % i Sites ‘Nu to an hms wrany ainor2r0/21 Bien Teen saat i Swus/s0 8 “4 Suasress | ie Gtbboorew, okty kop, 204 x 9/%6im aaaeset & Cap 264 x 1.268 Serena an ans Serio, 2 S Gass a Beacines fae a AO inf Sahel 4 B Shag Stora + ae seme ss Fu Sieer 4 B San on Tsianle t 6 Bug eiste Ta se omens Be on Seat Sutere Bamana aonfave | = Setow sit, cap hd, 208 x a/iem eam! & Tesora + a key oust 3 Guo | e Fler searing itsier 2 Sirs | = Finehetonr doit, v0 x vine deroe 2 : Ring Gosoe some worse 2 3 Spring rng Tessa a Sooseos 3 Ghee Satine amore & beesiss 2 a py Eta Suoiss 2 Secony Pay Pan 284 x din Suse 5 iene Lever vhbotrarere + 36 Soron,“Set, Cap A UNC x t.sin tg "ota Roe rin} one easels} Ccenbox Aveanbly (molucing pullay & ceo) Toa Krai Type Sa, rey, 0 4 Siar Fig.0.8 CANBOx AND PUMP© Hartridge oesa. avec SPARES LIST T NOSE PIECE 89% Ly Nite swale al Mo, Bascripion PartNo: aye + rite 0.0115 (3 ete) NTAIOS/13 Bio4gin” Gots) Nratosyia + Grazia (det Nratossis Stcatin (dete) rata’ 2 Seat Geom: 2 Bite piace Attombly = for Cunmion — NEAIOB/12 3 O'mng''x Xe 1/8in Section po0Bs210 Bse0"00. | 4 Rowe Piece Nrrasogy tt 2 Watters Soppae wa sat torn Sear 8 Grits tatoo 12/24 Ba Staes 17810 cian Savage & Seino NTAtSr2¢3 1 8 Dang fa x 14 x w/0in estion TIES 0 Yayo Step Nratosria/s + Th Ring 8b x 7/16 x 9fsain Section Pooashit sscss9 1 12 Sera, Hox Ha Nratooriars'1 LonD CELL KIT (HH209) suooteg Figs ht3e b Tes stand. Comores the fod coll NTA 17 stow In DPERATING & SERVICING MaANLAL Fig.8.7 NOSE PIECE ASY (UTA 108/12) SPARES LIST 8 NOSE PIECE ASSEMDLY NTA 100/11 at No, Desorption Noge Ploge Aszamly (for Oot tn 1 Bigg EX avte x s/szi0 Secon Pooadd 5 "ie x 1116 » 3/32in Section ssoesr | Rratooriva' SPARES (ISE_9. TWO-YEARS SPARES KIT (48 109) FigiRet pescription Pareto Oty. 6.9/80 Tappet Assonbly nnoyers 1 SAS Alter Elonont aia” 8 Gif Belt ‘auesio Een Osea isis Ysueya Weare 4 Fis wane Uaabery Nylon (Sanyo Connection) ALPAG/2. Miaaher’ Bouty 2/tain 6 Ball Looking, Nylon osinass fuss 39,010 Fra omin rongeaoe sion = 4y012 0/0 x s/i8in Section POOBSOND — assOHSE 4 lin O/d x Vale Section Pageueto, —besoro Vin bfo's'aisain Sesion Poosiia—BEStES? 15/%6in 0/0 x 9/9210 Section PeCBENIE assoss9 2 san aa\sia 1.28 x 0,280 suse 2 Sarle Tal ofa tees u28 Suese 2 Se BA Tubaae Seems Bias fos" Tubular sseeos 3 @ \ Fig.0.8 NOSE PIEDE ASY (NTA 100/11 SPARES LIST 10. MASTER IWECTORS 21D Inpstors teria PTD Ik Type Injectors tsrieee ‘Top Stop Imectore TereiS DIESEL DIVISION BUCKINGHAM: MK18 1EF-ENGLAND Tol: (0280) 813661: Tolex:83309 525 VIKING DRIVE. VIRGINIABEACH-Vaea452-UBA Tel:804-340 7535: 822452