tm 9-4910-622-14&p distributor tester, engine model pdt-5d
Contents
1. 9 4910 622 14 amp P TECHNICAL MANUAL OPERATOR S ORGANIZATIONAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS LIST FOR DISTRIBUTOR TESTER ENGINE MODEL PDT 5D SUN ELECTRIC CORPORATION NSN 4910 00 392 2939 HEADQUARTERS DEPARTMENT OF THE ARMY DECEMBER 1980 9 4910 622 14 amp P WARNING This equipment detrimental to communications do not operate within 100 feet of operating communications electronic equipment 9 4910 622 14 amp P Technical Manual HEADQUARTERS DEPARTMENT OF THE ARMY 9 4910 622 14 amp P Washington DC 29 December 1980 Operator s Organizational Direct Support and General Support Maintenance Manual Including Repair Parts List For DISTRIBUTOR TESTER ENGINE MODEL PDT 5D SUN ELECTRIC CORPORATION NSN 4910 00 392 2939 REPORTING OF ERRORS You can help improve the 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 US Army Armament Materiel Readiness Command ATTN DRSAR MAS Rock Island IL 61299 A reply will be furnished to you NOTE This manual is published for the purpose of identifying an authorized commercial manual for the use of the personnel to whom the tester is issued Manufactured by Sun Electric Corporation2. this instruction book Is written to completely test a distributor in logical sequence The settings of controls are not re stated in the following test if they are unchanged for that test For test specifications for a particular distrib utor see the applicable manufacturer s test data ADAPTER FOR TESTING 24 VOLT WATER PROOFED DISTRIBUTORS Se Figure P An adapter tachometer connector is supplied with the distributor tester for making overall distributor tests on 24 volt waterproofed distributors without re DOTTED LINES INDICATE THE 60 BETWEEN CAM LOBES ALLOTED TO THE FIRING OF EACH CYLINDER OF A 6 CYLINDER ENGINE Figure 2 Dwell Angle for 6 Lobe Cam REMOVE PLUG AND INSTALL TACHOMETER CONNECTOR Figure 3 Waterproof Distributor with Tachometer Connector Installed moving the distributor cover waterproof seal under the cover of a good distributor need not be broken for testine the condition of the distributor Seel Figure 11 for adapter DISTRIBUTOR VISUAL INSPECTION The distributor should be inspected visually be fore 1t 1s installed in the distributor tester Ex amine and note the condition of the following a Distributor shaft side clearance and end play b Distributor shaft bearings and bushings for wear and smoothness of operation Flexible couplings for wear d Breaker plate bearings or bushing for wear smoothness of operation and lubri cation 6 Cam wick for prope
3. WHAT SHOULD BE DONE ABOUT GRAPH NO NO ALONG PERFORATED LINE lt ar aras eee Ge Cee PRINTED NAME GRADE OR TITLE AND TELEPHONE MUMBER DA FORM 2028 2 PREVIOUS EDITIONS 5 YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 1 JUL 79 UCU 4 OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE TO YOUR HEADQUARTERS maaa ma w X uu Q ss ush Qa asw jaa a a TRAN REVERSE DA FORM 2029 2 FILL IN YOUR UNIT S ADDRESS FOLO BACK DEPARTMENT OF THE ARMY POSTAGE AND FEES PAID DEPARTMENT OF THE ARMY DOD 314 OFFICIAL BUSINESS PENALTY FOR PRIVATE USE 300 Conmander US Army Armament Materiel Readiness Command ATTN DRSAR MAS Rock Island IL 61299 arn 00077 urit P sEECTAT FCURTE CLASS KATE ELLEKE i LSA SEI Fily AITN LRIMNL Hr LEXINCILA KY 465211 d DUCI PU t H a Hes ere mau ps E 1 S it H 1 Y UJ c bes 49 m o l A m lt e lt e e m pe g e bes e 0861 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD
4. 3011 East Route 176 Crystal Lake IL 60014 Procured under Contract DAAAQ09 76 C 6149 This technical manual is an authentication of the manufacturer s 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 9 4910 622 14 amp 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 by the supply officer 1 Manufacturer s Federal Supply Code Number 40067 2 Manufacturer s Part Number exactly as listed herein 3 Nomenclature exactly as listed herein including dimensions if necessary 4 Manufacturer s Model Number PDT 5D 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 15 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 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 00 392 2939 Manufacturer Sun Elect
5. CAREFULLY TEAR IT Your mailing address UT FOLD IT AND DROP IT IN THE INE MAIL DATE SENT Date you filled out form PUBLICATION DATE PUBLICATION TITLE PUBLICATION NUMBER TM 9 XXXX XXX XX Date of TM Title of AND WHAT SHOULD BE DONE ABOUT 400 183 Change illustration Reason Tube end shown assembled on wrong side of lever cam 512 191 Figure 191 item 3 has the wrong NSN Supply rejects orders for this item The NSN showm here is not listed the AMDF or the MCRL Please give us the correct NSN and P N gt PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER John Smith S SGT 793 XXXX 2028 2 PREVIOUS EDITIONS 8 YOUR OUTFIT WANTS TO KNOW ABOUT YOUR D A 1 JUL T ARE OBSOLETE COMMENDATION MAKE A CARBON COPY OF THIS lt str 11 ne Qum a qa m TEAR ALONG PERFORATPD LINE www O APO CUA qupun Qamman do See sas a Wa FILL IN YOUR UNIT S ADDRESS DEPARTMENT OF THE ARMY OFFICIAL BUSINESS PENALTY FOR PRIVATE USE 300 FOLO BACK POSTAGE AND FEES PAID DEPARTMENT OF THE ARMY DOD 114 U S MAIL Commander US Army Armament Materiel Readiness Command ATTN DRSAR MAS Rock Island IL 61299 us ae A oe j qh Q mm s om me mm n 1 EV31 RECOMMENDED CHANGES
6. Spring tension scale reads in either direction from zero and maybe used to push the point lever arm when necessary Slowly pull spring tension tester at right angles to point lever arm and gradually increase the pull exerted d Watch dwell meter for indication of con tact separation by the reading falling to Zero e Note reading on tension scale under the rding pointer Compare reading with distributor test specifications f Hold points open to approximately the rec ommended gap with the spring tension scale and slowly let them close If scale reading decreases noticeably from pre vious reading before the points close it 1s probable the pivot requires lubrication NOTE On distributors equipped with two sets of breaker points one set must be held open while testing the other set thick piece of clean fiber may be placed between the contacts to hold them open BREAKER POINT ALIGNMENT DWELL DWELL VARIATION AND CAM LOBE AC CURACY The breaker point alignment is checked as follows a With test leads connected to the distrib utor as in the Distributor Resistance Test turn tach dwell switch to position which corresponds to type of distributor being tested 4 8 or 6 cylinder b Place RPM toggle switch in the 2500 rpm position c Adjust distributor speed to 1000 rpm d Observe the slight arc appearing between the breaker points If the points are prop erly aligned the arcing will appear in the
7. EE HN EE ELTERN i bs eat mt n 13 E quii KK H seit RE E Figure 1 Engine Distributor Tester Model PDT 5D PARTS LIST FIGURE 1 ENGINE DISTRIBUTOR TESTER MODEL PDT 5D FIG AND PART INDEX NO NUMBER DESCRIPTION E 848 007 WORK LIGHT I 910 027 LIGHT BULB 60 WATT 3 1185 KNOB 4 6002 34 LEAD ASSY DISTRIBUTOR GROUND 5 942 2 KNOB FOR DEGREE RING 6 1493 3 KNOB BAKELITE 13 16 DIA VACUUM REGULATOR 7 6006 2 VACUUM 55 8 5675 1 INDICATOR 8 1938 1 GLOW 51 9 689 48 SWITCH TOGGLE 3 P3T MOTOR SWITCH 10 689 12 SWITCH TOGGLE SPST RPM 1492 6 KNOB 1 1 8 DIA 12 337 001 GAGE VACUUM 0 21 13 767 0118 METER DWELL 0 502 14 767 0117 METER 0 500 0 2500 15 6002 33 LEAD ASSY DISTRIBUTOR TERMINAL 16 1243 504 NAMEPLATE WARNING e 1493 3 KNOB BAKELITE 13 16 DIA DWELL METER 18 942 2 KNOB FOR SPEED CONTROL HAND WHEEL VI SYMBOL SW3 SW2 M3 M2 M1 QUANTITY PER TESTER B P L gt F Ep INTRODUCTION This Instruction book contains operation and maintenance instructions and a parts list for the Engine Distributor Tester Model PDT 5D The Engine Distributor Test
8. EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH THIS PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT ON THIS FORM CAREFULLY TEAR IT Be a o nor OUT FOLD IT AND DROP IT IN THE DATE SENT PUBLICATION NUMBER PUBLICATION DATE PUBLICATION TITLE Distributor Tester TM 9 4910 622 14 amp P 29 Dec 80 Engine Model PDT 5D PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER SIGN HERE D A FORM 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 1 JUL 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AS lt mana er wx wara s emeng qam w s TEAR ALONG PERFORATFD UNE am cee e E eee A Sees Gee AU Quam qaw q GIVE IT TO YOUR HEADQUARTERS FILL IN YOUR UNIT S AODRESS FOLD BACK DEPARTMENT OF THE ARMY POSTAGE AND FEES PAID DEPARTMENT OF THE ARMY DOD 314 OFFICIAL BUSINESS PENALTY FOR PRIVATE USE 300 Commander US Army Armament Materiel Readiness Command ATTN DRSAR MAS te 4 _ 3 e MA Rock Island IL 6129 NO WR m Q w RECOMMENDED CHANGES EQUIPMENT TECHNICAL PUBLICATIONS SOME VING WRONG wm Tuis PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT QUT FOLD AND DROP IT IN THE MAIL PUBLICA
9. ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines lt A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
10. center of the contacts when viewed from above or from the side e Reduce distributor speed to 200 rpm BREAKER POINT DWELL Adjust the breaker point dwell as follows Observe the dwell meter and if necessary adjust the point spacing until the dwell meter indicates the specific degrees of dwell 1 On distributors equipped with dual points it will be necessary to adjust the dwell on each set individually To isolate each set for adjustment the other set may be blocked open by serting a clean piece of fiber between the contacts 2 See CONTACT POINT GAP AND DWELL paragraph for additional in formation on point dwell and point gap adjustment BREAKER POINT DWELL VARIATION The breaker point dwell variation is checked as follows a While watching dwell meter vary the dis tributor speed from 200 to 1750 rpm A dwell variation in excess of 2 degrees in dicates worn distributor shaft or bushings O 2 2 5 2262 DIRECTION 2 a de SHAFT 5 2 S 2 ROTATION A S 2 lt gt a O Y e 09 Dy ARROWS ADVANCE gt OKO Y D M gt lt Q d L I y Tr Y 468 gt DIRECTION OF SHAF T ROTATION ARROWS ADVANCE gl nm me 488 Y STARTING POSITION W READING POSITION Figure 6 Stroboscopic Arrows Showing Advance b Reduce tester speed to 200 rpm C If testing LOADOMATIC type of distrib
11. plate movement must be smooth and even as it rotates or the breaker plate will twist thereby changing the relationship between the cam and rubbing block and causing the dwell angle to change Any change in dwell angle af fects the ignition spark both in quality and timing a Adjust speed control to 1000 rpm b Using the vacuum control knob adjust the vacuum reading to zero Then increase vacuum to 20 inches while watching the dwell meter pointer for variations If dwell reading varies more than 2 degrees see NOTE below from O to 20 inches of vacuum it indicates worn breaker plate bushings and bearings or intermittent dis tributor resistance Note condition of the distributor wiring The strands of wire may be broken within the insulation due to flexing d Adjust vacuum control to zero vacuum NOTE This specification applies only to distributors which have centrally lo cated breaker plate bearings On Auto Lite distributors Models IAT IBP and IBR which have side pivoted breaker plates the dwell will normally vary by more than 2 degrees when the vacuum unit is operated No definite specifications are given by the manufacturer for the dwell variation of these distributors since the amount of dwell variation varies with the individ ual distributor depending upon the amount of maximum vacuum advance VACUUM SPARK ADVANCE TEST The vacuum spark advance adjusts the spark timing according to the load on the en
12. the SET LINE 6 CYL Place in this position for 6 lobe distributor 8 CYL Place in this position for an 8 lobe distributor 4 CYL Place this position for a 4 lobe distributor Figure MN 1 1 7 8 1 15 1 1 Common Marking Dwell Meter Adjust ment DWELL CALI BRATOR Rpm Switch RPM 500 2500 Vacuum Control VACUUM REGULATOR Master Switch MOTOR SWITCH LEFT HAND DRIVE RIGHT HAND DRIVE Speed Control Hand Wheel HIGH LOW Elevation Hand Wheel UP DOWN Vacuum Line Distributor Wires Bench Light TABLE 1 cont Description and Function Black bakelite control knob Turn control to set DWELL METER pointer on SET LINE when Tach Dwell switch is in CAL position Two position toggle switch changes the full scale reading of the DISTRIBUTOR RPM meter to 500 or 2500 rpm Black bakelite control knob multi turn Controls the amount of vacuum which is applied to the vacuum advance mechanism on the distributor Toggle switch with three positions OFF Motor is turned off LEFT HAND DRIVE Motor turns the drive chuck in a counterclockwise direction RIGHT HAND DRIVE Motor turns the drive chuck in a clockwise direction Solid wheel with knob in front of panel increases the speed of the distributor shaft when turned counter clockwise decreases speed when turned clockwise Metal ring calibrated in degrees in both directions which is adjustable
13. utor turn to the single or dual loadomat distributors paragraphs for remaining tests LOBE ACCURACY Seb Figure b Determine the cam lobe accuracy as follows a Adjust distributor speed to 1000 rpm b Rotate the degree indicator ring on the panel until the zero the degree ring 15 aligned with one of the arrow flashes c Observe relative position of all arrow flashes The arrow flashes should be evenly spaced around the degree ring within 1 degree d The spacing in degrees depends on the number of lobes on the cam MECHANICAL ADVANCE TEST This test is made to determine if the ignition timing conforms to the manufacturer s spec ified advance curve throughout all speeds of en gine operation defective mechanical advance unit will result in the engine being out of time at certain speeds This will always result in loss of performance of the engine and may also cause spark knock and overheating Figure 6A shows direction of advance f or shaft counter clockwise rotation 6B for clockwise rotation The procedure for the mechanical advance test is as follows a Set zero of the degree indicator ring in line with the arrow flash nearest the op erator b Increase distributor speed pausing at each specified speed to note if the amount of ad vance occuring is within 1 of the spec ified figure The manufacturer may allow more tolerance Momentarily exceed the highest speci
14. 8 VACUUM CHAMBER DIAPHRAGM TEST a Insert the proper adapter In the primary vacuum chamber tighten to Insure a good seal Leave test leads connected and the lobe selector switch In the proper position as before Attach hose to vacuum unit and seal hose with metal clamp Adjust vacuum control until gage reads 7 inches for 1953 models or 20 inches for later models Release hose clamp and observe gage Gage will momentarily fall to a lower reading 1 If gage reading returns to original reading within a few seconds vacu um chamber is air tight 2 If gage reading fails to return to orig inal reading chamber is leaky BREAKER PLATE TEST 12 a Adjust speed to 1000 rpm b With the vacuum control increase vacu urn from 0 to 7 inches while watching dwell meter If the dwell meter reading varies more than 2 degrees wear in the breaker plate bushing is indicated DISTRIBUTOR CENTRIFUGAL VALVE Figure 9 ADVANCE TEST a Adjust vacuum control until gage reads b zero then disconnect hose With distributor operating at minimum rpm place degree ring zero in line with one of the arrow flashes Adjust vacuum and distributor speed for each specified check point in turn and note the amount of advance obtained Reduce vacuum and distributor speed and again note advance obtained at each spec ified check point Consult service manual for specific adjusting pro ce
15. Black bakelite knob on clamping arms Tightens and loosens clamping arms on distributor Solid wheel with knob above clamping arms raises and lowers the clamping arms Turn clock wise to raise and counterclockwise to lower Indicator Light Indicates when tester is turned on Rubber hose with rubber connector shut off clamp vacuum connection for vacuum advance Red clip is positive black clip is negative Wires provide electrical power 6 volts approx for distributor test Adjustable bench light illuminates the working area DISTRIBUTOR POINT DWELL Figure 2 Dwell or dwell angle is the number of degrees the distributor shaft rotates measured from the point where the ignition contacts close to the point where the y open again Dwell angle is in versely proportional to point gap that 15 In creasing the gap decreases the dwell and vice versa Insufficient dwell may cause ignition failure at high speed while too much dwell increases the total average current which the points must han dle particularly at low speed This usually leads to very short point life After a distributor is initially timed for a given engine any change indwell will result in a change in timing requiring re timing of the distributor since the rubbing block of the moving arm will contact the cam in a different place When a dwell specification is given with a high and low limit set the point dwell to the lower limit
16. Dual Vacuum Chamber Loadomatic Distributors Vacuum Chamber Diaphragm Test Breaker Plate Tee Advance Test gt 0 i Transmission Over Drive Governor Test Governor Test Holley Governor Page Es al e El kl E l Figure E El el E El El m A A LA 1 LIST ILLUSTRATIONS Title of Illustration Engine Distributor Tester Model PDT 5D Dwell Angle for 6 Lobe Cam Waterproof Distributor with Tachometer Connector Installed Dwell Meter Resistance Readings Measuring Breaker Arm Spring Tension Stroboscopic Arrows Showing Advance Loadomatic Distributor Loadomatic Distributor Delco Remy Governor Cross Section Holley Governor Cross Section Engine Distributor Tester Model PDT 5D and Accessories Interior Components Interior Components Flash Tube Assembly Electrical Wiring Diagram PARTS LISTS Page Figure 11 Be Figure 111 14 Figure 12 Lid Figure 13 OR Figure 14 20 Page La kl GN RE EIE GH
17. N POWER SUPPLY CHASSIS CAPACITOR FIXED ELECTROLYTIC 6000 UF 15 VDC CONNECTOR PLUG ELECTRICAL 2 PRONG M CABLE FOR XFMR2 TRANFORMER POWER SEMICONDUCTOR DEVICE DIODE RESISTOR VARIABLE 0 1000 OHMS CAPACITOR FIXED ELECTROLYTIC 640 UF 6 4 VDC CAPACITOR FIXED ELECTROLYTIC 50 UF 50 VDC REACTOR 12 MILLIHENRIES RESISTOR ASSEMBLY 0 600 OHMS RESISTOR ASSEMBLY 0 3000 OHMS CONNECTOR PLUG ELECTRICAL 2 CONTACT F INCLUDES SHELL 1 2W R10 RLS MOTOR AC 1 4 HP 1725 RPM 115 VAC BELT v CONNECTOR RECEPTACLE ELECTRI CAL 8 ON POWER SUPPLY CHASSIS SEMICONDUCTOR DEVICE DIODE HV RESISTOR FIXED WIRE WOUND 2500 5W RESISTOR FIXED WIRE WOUND 5 5W IRANSFORMER POWER 17 OHMS REF SYMBOL Li CR1 CR2 P3 1 P2 XFMR2 CR3 CR4 CR7 CR8 R9 211 5112 C9 CLO 1253 13 R10 R15 Jii MOT 74 CR11 R2 R3 XFMR1 QUANTITY PER IESTER Fig 13 1 20 3 4 5 6 7 18 Part Number 859 4 763 4 680 95 679 79 763 1 778 129 825 15 Figure 13 Interior Components PARTS LIST Description ELECTRON TUBE 5U4 GB SOCKET ELECTRON TUBE octal RESISTOR FIXED COMPOSITION 47 ohms 1 2W 10 CAPACITOR FIXED ELECTROLYTIC 10 UF 600 VDC SOCKET 5 contact wafer F on power supply chassis TRANSFORMER PULSE CONNECTOR RECEPTACLE ELECTRI CAL 2 co
18. TED SWITCH CONTACT AND CAPACITOR ASSY FIXED PAPER DIELECTRIC 0 25 600 VDC CONNECTOR FASTON CONNECTOR PLUG ELECTRICAL RED 1 MALE PIN JACK IDLER FORK AND SWITCH ASSY WITH CONTACT ARM FOR SW4 CONNECTOR RECEPTACLE ELECTRI CAL RED 1 CONTACT FEMALE PIN JACK 19 REF SYMBOL R5 R11 R7 CR10 CR9 R6 R14 R18 R12 R19 R4 CR5 CR6 R8 R13 SW1 D4 SW2 REL1 Che SW4 J5 P6 J6 QUANTITY PER TESTER AS REQ Fig Index No 14 1 3 20 Part Number 1045 4 1045 0501 679 177 Figure 14 Flash Tube Assembly PARTS LIST Figure 14 Flash Tube Assembly Description FLASHTUBE FLASHTUBE AND CONTACT ASSY on bakelite base CAPACITOR FIXED PAPER DIELECTRIC 0 25 UF 600 VDC Quantity Ref Per Symbol Tester l l Ic SW3 J PILOT LIGHT TO WORK LIGHT Figure 15 Electrical Wiring Diagram For PDT 5D GRO LEAD DIST LEAD Order of the Secretary of the Army E C MEYER General United States Army Official Chief of Staff J C PENNINGTON Major General United States Army The Adjutant General U S GOVERNMENT PRINTING OFFICE 1983 381 302 2485 Region 4 RECOMMENDED CHANGES EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG with ms PUBLICATION Y 2 FROM PRINT YOUR UNIT S COMPLETE ADDRESS 2 JOT DOWN THE y DOPE ABOUT IT ON THIS Fa FORM
19. TION NUMBER PUBLICATION DATE PUBLICATION TITLE Distributor Tester TM 9 4910 622 14 amp P 29 Dec 80 Engine Model PDT 5D BE EXACT PIN POINT WHERE 7 IS J IN THIS SPACE TELL WHAT 18 WRONG AND WHAT SHOULD BE DONE ABOUT IT NO NO PRINTED MAME GRADE OR TITLE ANO TELEPHONE NUMBER 2028 2 PREVIOUS EDITIONS 5 YOUR OUTFIT WANTS TO KNOW ABOUT YOUR A 129 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE TO YOUR HEADQUARTERS mama ram a qr qawas qa xw geen qaa x TUAN ALONG PERFORATED UNE eee lt a wamra w a vs cw a qr quam REVERSE DA FORM 2028 2 FILL IN YOUR UNIT S ADDRESS FOLD BACK DEPARTMENT OF THE ARMY POSTAGE AND FEES PAID DEPARTMENT OF THE ARMY DOD 314 OFFICIAL BUSINESS PENALTY FOR PRIVATE USE 300 Commander US Army Armament Materiel Readiness Command ATTN DRSAR MAS Rock Island IL 61299 a Seil RECOMMENDED CHANGES EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG wm mis PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT E OUT FOLD IT AND DROP IT i THE PUBLICATION NUMBER PUBLICATION DAT PUBLICATIONTITLE Distributor Tester TM 9 4910 622 14 amp P Engine Model PDT 5D BE EXACT PIN POINT WHERE T IS a T LL a 4 pe PAGE Pana FIGUAE TABLE
20. der the influence of the vacuum spark control unit Ex cessive plate tension may cause sluggish action of the advance mechanism causing erratic tim ing under changing loads a Remove the vacuum spark control unit from the distributor Finger tighten the small screw in the plate to provide an attaching point for the spring tension scale b With the plate adjusted to full retard po sition full travel in the direction of cam rotation hook the spring tension scale on the screw securely and pull noting the amount of pull necessary to start move ment of the breaker plate 1 This specification is not over 20 ounces for the type plate shown and not over 15 ounces for the type plate 2 Tension may be adjusted on type by adding or removing shim washers to the tension spring on the underside of the plate and on the type by stretching or replacing the helical plate tension spring SINGLE VACUUM CHAMBER LOADOMATIC DISTRIBUTORS With the exception of the advance mechanisms loadomatic distributors are tested in the same manner as described in the preceding pages VACUUM CHAMBER DIAPHRAGM TEST Insert the proper adapter the vacuum chamber tighten to Insure a good seal b Connect the test leads and place the lobe selector switch in the proper position c Attach hose to vacuum untt and seal hose with metal clamp d Adjust vacuum control until gage reads 5 Inches e R
21. dures TRANSMISSION AND OVER DRIVE GOVERNOR TEST Test the transmission and overdrive governor as follows a b C Place governor drive adapter the dis tributor tester drive chuck tighten Place governor in clamp and tighten se curely Adjust the elevating control so governor shaft fits into slot in drive adapter Connect distributor lead to contact ter minal on governor and ground lead to gov ernor body Delco Remy Governor Cross section e f g Turn motor drive switch to right or left hand rotation as indicated by the spec ifications for the governor being tested Turn selector switch to 8 cylinder position Use dwell meter to indicate make and break on acceleration and deceleration against the manufacturer s specifications for the governor being tested DELCO REMY AND HOLLEY GOVERNOR TESTS DELCO REMY GOVERNOR TEST Figure 9 a With distributor mounted in tester insert proper vacuum adapter in lower fitting on distributor housing and tighten with wrench to insure a good seal Set MOTOR SWITCH to proper direction of rotation and adjust speed to zero rpm Attach hose to vacuum adapter and seal hose with metal clamp Adjust vacuum control until gage reads 5 inches Release hose clamp increase distributor speed until vacuum gage reading reaches a maximum value This maximum value will vary depending on the type of centri fugal valve parts used After this maximum
22. ection Vi amni Figure 11 Engine Distributor Tester Model PDT 5D Accessories LIST OF ACCESSORIES POR PDT 5D INDEX NO Ho OF C0 ES 10 12 OTY PART NUMBER 6 1 712 334 101 1700 2546 003 3127 2 1336 669 519 7009 044 15 COMPONENTS amp SUB ASSEMBLIES VACUUM FITTINGS 115 1 1 VAC FTG 1 8 N P T 115 2 1 FTG 7 16 24 115 3 1 VAC FTG 3 8 24 115 4 1 VAC FTG 5 16 24 823 1 1 ADAPTER BUSHING 1 4 1 8 N P T SPRING TENSION GAUGE COLLET CHEVROLET 675 57 1 SCREW 1700 1 COLLET 1701 1 BRACKET 400 20 1 WASHER 409 18 1 NUT ADAPTER PRIMARY CIRCUIT ADAPTER STUDEBAKER amp CADILLAC 51 amp 52 INTERNATIONAL amp CORVAIR amp RENAULTS CHUCK WRENCH TUBING INSUL FOR CHUCK JAWS COVER 20 19 18 16 Figure 12 Interior Components 12 PARTS LIST FIGURE 12 FIG AND INDEX NO deck 2 2 4 8 9 1 1 12 14 15 16 e 18 19 20 118 8 114 203 1020 5 825 3 679 161 825 3 7718 193 771 215 685 108 679 462 679 212 484 2 685 111 685 111 825 4 502 032 658 2 763 4 774 115 684 226 684 87 778 128 INTERIOR COMPONENTS DESCRIPTION REACTOR 10H 500 OHMS DC RESISTANCE RECTIFIER ASSY METALLIC CONNECTOR PLUG ELECTRICAL 5 CONTACT M CONNECTOR RECEPTACLE ELECTRI CAL 2 CONTACT M O
23. elease hose clamp and observe gage Gage will momentarily fall to a lower reading 1 If gage reading returns to 3 inches within a few seconds vacuum chamber 15 air tight 2 If gage reading fails to return to 5 inches vacuum chamber 15 leaky BREAKER PLATE TEST a Adjust speed to 1000 rpm b With the vacuum control increase vacu um from 0 to 5 inches while watching the dwell meter If the dwell reading OMEN PRIMARY CHAMBER v REMOVE CONTROL CABLE BEFORE MAKING ADVANCE TESTS VACUUM CHAMBER DIAPHRAGM TEST Figure 7 varies more than 2 degrees wear in the breaker plate bushing is indicated c Adjust vacuum and distributor speed for each specified check point in turn and note the amount of advance obtained d Reduce vacuum and distributor speed and again note advance obtained at each spec ified check point Consult service manual for specific adjusting pro cedures DUAL VACUUM CHAMBER LOADOMATIC DIS TRIBUTORS There are two types of dual vacuum chamber LOADOMATIC distributors an early type used only on Lincoln in 1953 eu pct and a later type used more recently on Ford Lincoln and Mercury products see figure 8 With the exception of the advance mechanisms LOAD OMATIC distributors are tested in the same manner as described in the preceding pages If a 1953 Lincoln distributor is being tested the control cable on the distributor should be re moved PRIMARY CHAMBER Figure
24. er Model PDT 5D which will be referred to as the distributor tester in this instruction book 1s capable of making complete tests on automo bile and truck ignition distributors The condi tion of 24 12 and 6 volt ignition distributors can be determined DESCRIPTION Sed Figure 1 The distributor tester consists of a metal cab inet with a sloping panel containing the distrib utor mounting clamps driving mechanism stroboscopic indicator ring and associated in struments and controls The metal cover has two handles and slides over the distributor tester gripping the base with four fasteners The base of the tester rests on four rubber feet An accessory box with a lead hanger on each end is mounted at the top of the cabinet and the in struction books are in back of the cabinet The Engine Distributor Tester Model PDT 5D is detrimental to communications DO NOT operate within 100 feet of communications electronic equipment OPERATION The electric motor that turns the distributor shaft and the electrical circuits for the indi cating instruments operate on 115 volts 60 cy cle power The drive motor turns the chuck and stroboscopic light assembly through a variable speed drive Speed vacuum and dwell are indi cated on meters and the advance is indicated on the indicator ring which is graduated in de grees and is adjustable The stroboscopic light flashing on the arrow on the moving disc indi cates the amoun
25. fied speed given as a check speed Then while returning the distributor speed to zero re check at each test speed to see that the amount of advance at that speed Is the same as it was step b and as specified Any inconsistency in readings requires correction for best engine per formance 1 If advance is excessive on both steps b and c the governor weight springs are weak or the wrong springs are in Stalled 2 If advance is slow in step b and ex cessive in step c the governor weights are sticking and should be freed up 3 If advance is insufficient both on accel eration and deceleration the governor spring tension is excessive 4 Refer to the specifications for proper service procedure VACUUM CHAMBER DIAPHRAGM TEST The following procedure is for the usual type of distributor For LOADOMATIC type distrib utors see loadomatic distributors paragraphs a Insert proper adapter in the vacuum ad vance unit and tighten with wrench to in sure a good seal b Attach hose to adapter and pinch hose with metal clamp c Adjust vacuum control until the vacuum gage reads 15 inches d Release hose clamp and observe gage Gage reading will momentarily fall to a lower reading 1 If gage reading returns to 15 inches within a few seconds the vacuum chamb er is air tight 2 If gage reading fails to return to 15 inches the vacuum chamber is leaky VACUUM CONTROLLED BREAKER PLATE TEST breaker
26. for new points to allow for rubbing block wear The percent of dwell is the percentage of the actual dwell angle of the points as compared to the maximum dwell angle possible 100 percent dwell The 100 percent dwell for 4 6 and 8 cylinder engines and some examples of percent of dwell are listed in Table 2 TABLE 2 Comparison of percent of dwell and dwell angle Maximum dwell angle 100 dwell No of cylinders CONTACT POINT GAP AND DWELL Cam Angle Relationship If a distributor cannot be adjusted so that gap and dwell are within specifications at the same time inspect the distributor for the following possibil ities a Improper spring tension or sticky pivot b Wrong point set installed c Bent shaft causing point opening to vary on each cam lobe d Worn cam lobes or defective cam as above Compare gap at each cam lobe if in doubt e Points floating or not following the cam at high speeds f Excessive resistance causing false dwell reading In practically every case the remedy will be self evident Percent of dwell Calculation Corresponding dwell angle 60 90 60 60 60 45 MAINTENANCE OF DISTRIBUTORS It is highly recommended that all the functions of a distributor be tested before repair to deter mine the amount of repair work required and again after repair to make sure that the distrib utor Is in serviceable condition The test pro cedure
27. from the primary ter minal to the ground return Where the resistance reading on the dwell meter changes considerably from one point to another correct the high resistance condition DEGREES DEGREES OF OF OWELL SETLINE OWELL SETLINE Figure 4 Dwell Meter Resistance Readings Figure 5 Measuring Breaker Arm Spring Tension distributors where two sets of breaker points used test the re sistance of each set of points sepa rately by holding or blocking one set open while testing the other set BREAKER POINT SPRING TENSION TEST Proper tension of the breaker point spring 15 important factor in obtaining normal breaker as sembly life and maintaining full ignition system efficiency throughout the speed range of the en gine Excessive spring tension can cause rapid rubbing block cam and contact wear while in sufficient spring tension may allow the points to bounce at high speeds which generally results in arcing and burning of the points and causes the engine to misfire Sed Figure 3 Procedure a Turn small knob in center of spring ten sion scale until the adjustable riding pointer engages the pointer of the ten sion scale and moves it to the zero mark b With dwell meter calibrated and distrib utor test leads connected to distributor as for distributor resistance test place hook of tension scale over movable lever near the contact point Sed Figure 5 NOTE
28. gine to provide peak fuel economy at moderate loads and full power without detonation at heavier loads In the course of the test look for improper cal ibration sticky or erratic breaker plate action tilting of the breaker plate or interference of the condenser with action of the plate Refer Adjust speed control to 1000 rpm b With no vacuum applied to the untt hose pinched set the zero of the degree indi cator ring in line with one of the arrows c Open hose clip and adjust vacuum control to apply proper amount of vacuum for each specified check point in turn and note the amount of advance obtained Compare with manufacturer s specifications d Momentarily exceed highest vacuum value specified then reduce vacuum and again note advance obtained at each specified check point 1 If advance Is excessive during steps and d a weak vacuum advance spring is indicated 2 If advance is insufficient during steps and d an excessively strong advance spring 15 indicated 3 H advance Is insufficient in step and excessive in step d Is erratic in both steps c and d distributor plate Is sticking or binding Refer to manual for proper service procedure NOTE For Delco Remy breaker plate spring tension test see next para graph BREAKER PLATE SPRING TENSION TEST FOR DELCO REMY CENTER BEARING BREAKER PLATE This test is made to determine if the breaker plate is free to rotate as it should un
29. ntact F on power supply chassis Ref Symbol RI C5 J3 XFMR3 Quantity Per Tester PARTS LIST FIGURE 13 FIG APART INDEX NUMBER 8 9 10 EL 12 xt 14 15 16 17 18 19 20 21 22 23 24 25 26 2 1 28 29 30 51 680 3 680 6 774 103 771 215 680 106 680 142 680 65 680 9 680 113 680 67 112 104 685 104 685 59 62 58 1028 1 689 12 120 135 1340 3 2 2025 676 71 1040 2 106 503 1041 2 DESCRIPTION RESISTOR FIXED COMPOSITION 150 OHMS 1 2W 10 RESISTOR FIXED COMPOSITION 100 OHMS 1 2W 10 SEMICONDUCTOR DEVICE DIODE SEMICONDUCTOR DEVICE DIODE RESISTOR FIXED COMPOSITION 330 OHMS 1 2W 10 RESISTOR FIXED COMPOSITION 560 OHMS 1 2W 10 RESISTOR FIXED COMPOSITION 3 9K 1 2W 5 RESISTOR FIXED COMPOSITION 300 OHMS 1 20 5 RESISTOR FIXED COMPOSITION 3 3K OHMS 1 2W 10 RESISTOR FIXED COMPOSITION 680 OHMS 1 2W 5 SEMICONDUCTOR DEVICE DIODE ZENER DIODE RESISTOR VARIABLE 0 600 OHMS 1 2W CAPACITOR FIXED PAPER DIELECTRIC 200 VDC PADDING FOR C7 AND C8 CAPACITY AS REQ D RESISTOR VARIABLE 0 300 OHMS 1W DWELL CALIBRATION SWITCH ROTARY 3 SECTION W AC SWITCH TACH DWELL SWITCH CONNECTOR PLUG ELECTRICAL 8 SWITCH TOGGLE 5 5 RPM REPLACEMENT KIT VACUUM PUMP ASSY RELAY CAM OPERA
30. of rubber hose over each one of the three chuck jaws It is then possible to tighten the chuck without damaging the gear DISTRIBUTOR RESISTANCE TEST This test indicates the electrical resistance of the distributor primary circuit from the primary terminal through the points to the distributor body Excessive resistance in any portion of the distributor primary circuit will prevent the coil from performing at full efficiency Procedure for checking distributor resistance a With MOTOR SWITCH positioned for prop er distributor rotation turn Speed Control for zero rpm no rotation of distributor shaft b Clip the distributor and ground test leads of the tester together c Set tach dwell selector switch to CAL po sition and adjust calibrator until dwell meter pointer reads on the Set Laine See Figure 4 A d Separate the test leads and connect the dis tributor lead red to the distributor pri mary terminal and the ground lead black to the ground stud on the clamping arm e With distributor points closed dwell meter pointer should read within black bar at right end of distributor resistance scale Seel Figure 4 B 1 If the dwell meter pointer reads n the white area to the left of the black bar excessive resistance is present n the distributor primary circuit 2 To locate the cause of the excessive resistance move the clip red step by step through the distributor s elec trical circuit
31. r lubrication f Breaker cam for smoothness and lubri cation Insulators pigtails and flexible internal leads h Contact points for alignment pitting and burning and rubbing block wear 1 Vacuum advance linkage for alignment wear and binding DISTRIBUTOR MOUNTING Procedure for mounting the distributor a Using the elevation crank raise clamp arms high enough to permit shaft of dis tributor being mounted to clear drive chuck b Position distributor in clamp with vacuum chamber pointing to the right Tighten clamp arms securely on machined surface of distributor body If vacuum advance tates entire distributor install proper a dapter Four adapters are included in the accessories sed 11 c Using the elevation crank lower the dis tributor until the drive gear or drive shaft enters the drive chuck For other types of distributor shafts select one of the four adapters supplied with the unit not bottom the distributor shaft in the drive chuck d Tighten the chuck For an ex ternal adjustment type of distributor cen ter the drive gear between its upper and lower limits of end play travel before tight ening the chuck Do not try to raise or lower the distributor after the drive chuck has been tightened NOTE Care should be taken when mounting distributors which use a nylon drive gear To prevent damage to the gear when mounting the shaft into the drive chuck place a small piece
32. reading has been reached slowly decrease the distributor speed until the vacuum gage falls 0 1 inch from its maximum reading speed at which this 0 1 inch vacuum drop occurs will be the no load governed speed NOTE Distributor rpm is one half engine rpm 1f factory recommendations call for 3600 rpm no load governed speed this would be 1800 rpm on the tester and the governor should be adjusted so that valve will close at this speed Repeat test after each adjustment HOLLEY GOVERNOR TEST Figure 10 a ADJUSTING SCREW A PE EA VACUUM ADAPTER Figure 10 With distributor mounted in tester insert proper vacuum adapter in lower fitting on distributor housing and tighten with wrench to insure a good seal set MOTOR SWITCH to proper direction of rotation and adjust speed to zero rpm Attach hose to vacuum adapter and seal hose with metal clamp Adjust vacuum regulator until gage reads 4 5 inches Release hose clamp Vacuum reading should now be approximately 2 inches Adjust distributor speed to a point well above the desired governing rpm At this speed the vacuum gage should again read the pre determined setting of 4 5 inches Slowly decrease the distributor speed while observing the vacuum gage The speed at which the gage reading begins to fall will be the no load governed speed VALVE ORIFICE FS EE A Kg SPRING SHAFT Holley Governor Cross s
33. ric Corporation Model PDT 5D Serial Any other pertinent information such as frame number type dimensions etc TABLE CONTENTS Subject TO ST 0 1 s 7 2 3 BOE Vb danes dC A a Instruments and Controls Distributor Point Dwell Contact Point Gap and Dwell Maintenance of Distributors o oaoa Adapter for Testing 24 Volt Waterproofed Distributor Distributor Visual Distributor Distributor Resistance Breaker Point Spring Tension Breaker Point Alignment Dwell Dwell Variation and Lobe Breaker Point Dwell 32k oe kG ek eRe RS Breaker Point Dwell Lobe Mechanical Advance Vacuum Chamber Diaphragm Test Vacuum Controlled Breaker Plate Vacuum Spark Advance Breaker Plate Spring Tension Test for Delco Remy Center Bearing Breaker Single Vacuum Chamber Loadomatic Distributors Vacuum Chamber Diaphragm Test Breaker Plate Test
34. t of advance of the distributor A ground stud is conveniently located on the rght hand distributary clamp for attaching the ground lead INSTRUMENTS AND CONTROLS Se Figure The names and functions of the instruments and operating controls of the distributor tester are listed in Table 1 TABLE I Figure and Common Name Index No and Marking 1 11 Vacuum Gage INCHES VACUUM 0 21 ZERO ADJUST Dwell Meter DEGREES OF DWELL 0 50 SET LINE DIS TRIBUTOR RESISTANCE RPM Meter DISTRIBUTOR RPM 0 500 0 2500 Tach Dwell Switch OFF CAL 6 CYL 8 CYL 4 CYL Description and Function Bourdon tube type gage with pointer reading inches of vacuum applied to the distributor vac uum advance mechanism Set pointer on zero before using by turning ZERO ADJUSTMENT Pointer type meter with a 0 50 degree scale and a black band indicating electrical circuit resistance in the distributor The dual function meter in dicates breaker point dwell in degrees and nor mal resistance in the distributor when the point er reads in the black band When the pointer reads out of the black band the resistance 15 too high Pointer type meter with two scales reading from zero to 2500 rpm Indicates the speed of the dis tributor shaft in revolutions per minute Black bakelite control knob with 5 positions OFF RPM and DWELL Meters turned off CAL In this position the DWELL METER pointer should be set on
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