Engine Retarder Replacement and Repair

TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance

This task covers: a. Removal b. Disassembly c. Cleaning d. Inspection e. Repair f. Assembly
                  g. Installation h. Adjustment

Tools and Special Equipment:                    Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31               Reference                CondItlon Description
Tool Kit, SC 5180-90-CL-N05
                                                TM 9-2320-363-20         Batteries Disconnected
Materials/Parts:
                                                Page 3-71                Rocker Cover Removed
Ring, Seal                P/N 001081
                                                General Safety Instructions:
Ring, Seal                P/N 001082
Ring, Seal                P/N 001083                             WARNING
Ring, Retaining (2)       P/N 012991                       Parts are under spring
                                                         tension. Release tension
Toweling, Paper           Appendix B, Item 63            slowly to prevent personal
Oil, Lubricating          Appendix B, Item 37            injury.
Towel, Shop               Appendix B, Item 62             To prevent injury when
                                                         blowing oil from bolt holes,
International             Appendix B, Item 29            wear adequate protective
Compound No. 2                                           clothing.
Personnel Required: (2)

TM page 3-130

Illustration from TM 9-2320-363-34-1 (PDF page 206)

CAUTION Grasp connectors when removing wiring harness solenoid connectors from terminal. Do not pull on wires to prevent damage to equipment.

1. DISCONNECT THREE WIRING HARNESS SOLENOID CONNECTORS (1) FROM THREE SOLENOID VALVES (2).

2. REMOVE THREE BOLTS (3) AND THREE WASHERS (4) FROM THREE ENGINE RETARDERS (5).

TM page 3-131

Illustration from TM 9-2320-363-34-1 (PDF page 207)

CAUTION

Tag each engine retarder to aid in installation. Do not mix engine retarders.

3. REMOVE SIX BOLTS (6), SIX WASHERS (7), THREE ENGINE RETARDERS (5), AND TWO SPACER BARS (8) FROM CYLINDER HEAD (9).

Procedure is the same for all three engine retarder housings.

1. PLACE ENGINE RETARDER HOUSING (1) ON BENCH.

CAUTION

Do not disassemble or tamper with solenoid valve. Engine damage could result.

2. UNSCREW SOLENOID VALVE (2) WITH 12-POINT SOCKET.

3. REMOVE AND DISCARD THREE SEAL RINGS (3, 4, AND 5). IF SEAL RING (5) STAYS IN BOTTOM OF ENGINE RETARDER HOUSING (l), REMOVE SEAL RING (5) WITH WIRE.

WARNING

Parts are under spring tension. Release tension slowly to prevent personal injury.

4. PRESS DOWN ON WASHER (6) AND REMOVE RETAINING RING (7). DISCARD RETAINING RING.

5. REMOVE WASHER (6) AND SPRING (8).

6. USING MAGNET, REMOVE ACCUMULATOR PISTON (9) FROM ENGINE RETARDER HOUSING (1).

TM page 3-132

Illustration from TM 9-2320-363-34-1 (PDF page 208)

NOTE

Steps 7 thru 15 are for right side of engine retarder housing. Repeat steps 7 thru 15 for left side.

7. PRESS DOWN ON WASHER (1 0) AND REMOVE RETAINING RING (11). DISCARD RETAINING RING.

8. REMOVE WASHER (10), SPRING (12), SPRING (13), AND COLLAR (14).

9. REMOVE CONTROL VALVE (15) FROM ENGINE RETARDER HOUSING (1).

10. LOOSEN LOCK NUT (16) AND REMOVE ADJUSTING SCREW (17) FROM ENGINE RETARDER HOUSING (1).

TM page 3-133

Illustration from TM 9-2320-363-34-1 (PDF page 209)

11. TURN ENGINE RETARDER HOUSING (1) OVER.

12. REMOVE CAPSCREW (18), WASHER (19), AND FLAT SPRING (20) FROM ENGINE RETARDER HOUSING (1).

13. REMOVE MASTER PISTON (21) FROM ENGINE RETARDER HOUSING (1).

14. REMOVE SCREW (22), TORSION SPRING (23), SLAVE PISTON BRIDGE (24), AND SLAVE PISTON (25).

15. LOOSEN LOCK NUT (26) AND REMOVE ADJUSTING SCREW (27) FROM SLAVE PISTON BRIDGE (24).

CAUTION Do not use rags that may leave lint and residue which can plug oil passageways.

1. USE GENERAL CLEANING METHODS TO CLEAN ALL PARTS (PAGE 2-30).

2. USING CLEAN PAPER TOWELING, CLEAN ENGINE RETARDER HOUSING BORES. DIP CONTROL VALVES AND PISTONS IN CLEAN ENGINE LUBRICATING OIL.

TM page 3-134

Illustration from TM 9-2320-363-34-1 (PDF page 210)

1. VERIFY BALL (1) MOVES FREELY BY PUSHING WIRE THRU HOLE (2) IN BASE OF CONTROL VALVE (3). LIGHT PRESSURE ON WIRE SHOULD MOVE BALL (1). BALL SHOULD RETURN WHEN PRESSURE IS RELEASED.

2. MAKE SURE PLUNGER (4) PROTRUDES FROM BOTTOM OF ADJUSTING SCREW (5).

3. MAKE SURE PLUNGER (4) HAS LIGHT SPRING PRESSURE WHEN PRESSED AND MOVES FREELY.

4. INSPECT ALL PARTS FOR WEAR OR DAMAGE.

1. IF DEFECTIVE, REPLACE ENTIRE ADJUSTING SCREW AND LOCK NUT.

2. USE GENERAL REPAIR METHODS TO REPAIR DAMAGED PARTS (PAGE 2-33).

TM page 3-135

Illustration from TM 9-2320-363-34-1 (PDF page 211)

NOTE

Procedure is the same for all three engine retarder housings. Steps 1 thru 12 are for right side of engine retarder housing. Repeat steps 1 thru 12 for left side.

1. INSTALL ADJUSTING SCREW (1) AND LOCK NUT (2) IN SLAVE PISTON BRIDGE (3).

2. INSTALL SLAVE PISTON (4) IN ENGINE RETARDER HOUSING (5).

NOTE

Locate part number on slave piston bridge away from engine retarder housing.

3. INSTALL SLAVE PISTON BRIDGE (3) WITH ADJUSTING SCREW (1) TOWARD CENTER OF ENGINE RETARDER HOUSING (5).

4. INSTALL TORSION SPRING (6) WITH ENDS OVER SLAVE PISTON BRIDGE (3).

5. INSTALL SCREW (7) OVER CENTER PART OF TORSION SPRING (6) ON ENGINE RETARDER HOUSING (5). TIGHTEN SCREW TO 180 LB-IN. (20 N.m).

NOTE Make sure flat spring legs are centered around master piston boss.

6. INSTALL MASTER PISTON (8), FLAT SPRING (9), WASHER (10), AND CAPSCREW (11) IN ENGINE RETARDER HOUSING (5). TIGHTEN CAPSCREW TO 100 LB-IN. (10 N.m).

TM page 3-136

Illustration from TM 9-2320-363-34-1 (PDF page 212)

7. TURN ENGINE RETARDER HOUSING (5) OVER.

8. INSTALL ADJUSTING SCREW (12) AND LOCK NUT (13) IN ENGINE RETARDER HOUSING (5)

9. HOLD CONTROL VALVE (14) BY STEM AND DROP VALVE (14) INTO ENGINE RETARDER HOUSING (5). IF BINDING OCCURS OR IF BALL IS STUCK IN CONTROL VALVE (14), REPLACE CONTROL VALVE.

10. INSTALL COLLAR (15) IN ENGINE RETARDER HOUSING (5) WITH LONG SLEEVE AREA UP.

11. INSTALL SPRING (16) IN CENTER OF COLLAR (15) AND INSTALL SPRING (17) OVER TOP OF COLLAR (15).

12. PRESS WASHER (18) TO COMPRESS SPRINGS (16 AND 17). INSTALL NEW RETAINING RING (19). ROTATE RETAINING RING (19) 90 DEGREES TO ENSURE PROPER SEATING IN GROOVE.

TM page 3-137

Illustration from TM 9-2320-363-34-1 (PDF page 213)

13. INSTALL ACCUMULATOR PISTON (20), SPRING (21), AND WASHER (22) IN ENGINE RETARDER HOUSING (5).

14. PRESS WASHER (22) TO COMPRESS SPRING (21) AND INSTALL NEW RETAINING RING (23). ROTATE RETAINING RING (23) 90 DEGREES TO ENSURE PROPER SEATING IN GROOVE.

CAUTION

Be careful not to twist seal rings while installing to prevent damage to equipment.

15. COAT THREE NEW SEAL RINGS (24, 25, AND 26) WITH CLEAN ENGINE LUBRICATING OIL. INSTALL SEAL RINGS (26 AND 25) ON SOLENOID VALVE (27).

16. INSTALL SEAL RING (24) IN BOTTOM ENGINE RETARDER HOUSING (5).

17. THREAD SOLENOID VALVE (27) INTO ENGINE RETARDER HOUSING (5). TIGHTEN SOLENOID VALVE TO 60 LB-IN. (7 N.m).

TM page 3-138

Illustration from TM 9-2320-363-34-1 (PDF page 214)

WARNING To prevent injury when blowing oil from bolt holes, wear adequate protective clothing. **CAUTION** Make sure oil is removed from bolt holes to prevent engine block from cracking when tightening bolts.

1. COVER BOLT HOLES WITH SHOP TOWELSTO MINIMIZE OIL SPRAY.

2. ATTACH TUBING TO BLOW GUN NOZZLE AND BLOW OIL OUT OF BOLT HOLES.

NOTE Position word OUT, stamped on each spacer bar, toward mid-engine, facing outside of engine.

3. POSITION TWO SPACER BARS (1) ON EXHAUST MANIFOLD SIDE OF CYLINDER HEAD (2), ALINE BOLT HOLES IN SPACER BARS (1) WITH ENGINE RETARDER BOLT HOLES IN CYLINDER HEAD (2).

TM page 3-139

Illustration from TM 9-2320-363-34-1 (PDF page 215)

CAUTION

Make sure engine retarder housings do not interfere with wiring harness to prevent damage to equipment.

4. INSTALL THREE ENGINE RETARDER HOUSINGS (3) OVER ROCKER SHAFTS (4).

5. APPLY INTERNATIONAL COMPOUND NO. 2 TO THREADS AND UNDERSIDES OF HEADS OF NINE BOLTS (5).

CAUTION

Make sure wires are away from moving parts to prevent possible movement and contact with valve springs.

6. INSTALL NINE BOLTS (5) AND NINE WASHERS (6) IN ENGINE RETARDER HOUSING (3). TIGHTEN BOLTS TO 40 LB-FT (55 N.m).

7. REPEAT TIGHTENING OF NINE BOLTS (5) TO ENSURE ALL BOLTS ARE TIGHTENED TO TORQUE VALUE OF 80 LB-FT (110 N.m.).

8. CONNECT THREE WIRING HARNESS SOLENOID CONNECTORS (7) TO THREE SOLENOID VALVES (8).

TM page 3-140

Illustration from TM 9-2320-363-34-1 (PDF page 216)

CAUTION Failure to use slave piston adjustment procedure will cause poor engine brake performance and/or serious engine damage. It is necessary to rotate engine to put exhaust valves in closed position for each cylinder being adjusted. Make sure proper engine valve lash has been obtained to prevent damage to equipment.

1. BACK OUT ADJUSTING SCREW (1) IN SLAVE PISTON BRIDGE (2) UNTIL END OF ADJUSTING SCREW (1) IS FLUSH WITH BOTTOM SURFACE OF SLAVE PISTON BRIDGE (2).

2. PLACE 0.02 IN. (0.5 mm) FEELER GAGE BETWEEN SOLID SIDE OF SLAVE PISTON BRIDGE (2) AND EXHAUST ROCKER ARM ADJUSTING SCREW (3).

3. TURN ADJUSTING SCREW (4) CLOCKWISE UNTIL LIGHT DRAG IS FELT ON FEELER GAGE.

4. HOLD ADJUSTING SCREW (4) IN POSITION AND REMOVE FEELER GAGE.

5. TIGHTEN LOCK NUT (5) TO 26 LB-FT (35 N.m).

6. USING FEELER GAGE, SET 0.02 IN. (0.5 mm) CLEARANCE BETWEEN ADJUSTING SCREW (1) AND ROCKER ARM ADJUSTING SCREW (6).

7. TURN ADJUSTING SCREW (1) CLOCKWISE UNTIL LIGHT DRAG IS FELT ON FEELER GAGE.

8. HOLD ADJUSTING SCREW (1) IN POSITION AND REMOVE FEELER GAGE.

9. TIGHTEN LOCK NUT (7) TO 26 LB-FT (35 N.m).

10. REPEAT STEPS 1 THRU 9 FOR REMAINING CYLINDERS.

NOTE Follow-on Maintenance: Install rocker cover (page 3-71). Connect batteries (TM 9-2320-363-20).

TM page 3-141

Illustration from TM 9-2320-363-34-1 (PDF page 217)