Engine Retarder Solenoid Test and Replacement

TM 9-2320-363-34-1 · Chapter 4 — Electrical System Maintenance

This task covers: a. Test b. Removal c. Cleaning d. Installation

Tools and Special Equipment:              Materials/Parts (Cont):
Shop Equipment, SC 4910-95-CL-A31         Toweling, Paper           Appendix B, Item 63
Tool Kit, SC 5180-90-CL-N05
                                          Oil, Lubricating          Appendix B, Item 37
Materials/Parts:
                                           Equipment Condition:
Solenoid                P/N 016440
                                           Reference                Condition Description
Ring, Seal              P/N 001081
                                           Page 3-71                Rocker Cover Removed
Ring, Seal              P/N 001082
Ring, Seal              P/N 001083

1. MAKE SURE THREE WIRING HARNESS SOLENOID CONNECTORS AND TERMINALS (1) ARE FULLY ENGAGED AND TIGHT.

Grasp only connectors when disconnecting harnesses. Do not pull on wires to prevent damage to equipment.

2. DISCONNECT ENGINE RETARDER WIRING HARNESS CONNECTOR (2) FROM VEHICLE ELECTRICAL HARNESS (3).

3. CONNECT JUMPER LEAD (4) TO NEGATIVE (-) TERMINAL ON 12 VOLT DC POWER SOURCE (5) AND TO GROUND (6) ON CYLINDER HEAD (7).

4. CONNECT JUMPER LEAD (8) TO POWER SOURCE POSITIVE (+) TERMINAL (9) AND INSERT JUMPER LEAD PROBE (10) INTO BLUE WIRE TERMINAL CAVITY (11) OF ENGINE RETARDER WIRING HARNESS CONNECTOR (2).

When power is applied, solenoid of center engine retarder assembly should be activated. Activation can be heard and noted by movement of solenoid cap.

5. APPLY POWER.

6. REPEAT APPLYING AND REMOVING POWER 2 OR 3 TIMES TO ENSURE CENTER SOLENOID (12) IS OPERATING PROPERLY.

When power is applied, solenoid of center engine retarder assembly should be activated. Activation can be heard and noted by movement of solenoid cap.

7. IF SOLENOID CAP (12) DOES NOT MOVE, REMOVE BLUE WIRE (13) FROM SOLENOID TERMINAL (1) AND CONNECT POWER SOURCE POSITIVE JUMPER LEAD (8) TO SOLENOID TERMINAL (1). APPLY POWER.

8. IF SOLENOID OPERATES, REPAIR OR REPLACE BLUE WIRE OR CHECK CONNECTOR FOR BREAKS. IF SOLENOID FAlLSTO OPERATE, REMOVE AND DISCARD SOLENOID.

9. CONNECT JUMPER LEAD (8) TO POWER SOURCE POSITIVE (+) TERMINAL (9) AND INSERT JUMPER LEAD PROBE (10) INTO RED WIRE TERMINAL CAVITY (14) OF ENGINE RETARDER WIRING HARNESS CONNECTOR (2).

When power is applied, solenoids of front and rear engine retarder assemblies should be activated. Activation can be heard and noted by movement of solenoid cap.

10. APPLY POWER.

11. REPEAT APPLYING AND REMOVING POWER 2 OR 3 TIMES TO ENSURE FRONT AND REAR SOLENOIDS (15 AND 16) ARE OPERATING PROPERLY.

When power is applied, solenoids of front and rear engine retarder assemblies should be activated. Activation can be heard and noted by movement of solenoid cap.

12. IF SOLENOID CAP (15 OR 16) DOES NOT MOVE, REMOVE RED WIRE (17) FROM SOLENOID TERMINAL (1) AND CONNECT POWER SOURCE POSITIVE JUMPER LEAD (8) TO SOLENOID TERMINAL (15 OR 16). APPLY POWER.

13. IF SOLENOID OPERATES, REPAIR OR REPLACE BLUE WIRE OR CHECK CONNECTOR FOR BREAKS. IF SOLENOID FAILS TO OPERATE, REMOVE AND DISCARD SOLENOID.

1. DISCONNECT WIRING HARNESS SOLENOID CONNECTOR (1) FROM SOLENOID TERMINAL (2).

2. REMOVE SOLENOID (3) FROM ENGINE RETARDER ASSEMBLY HOUSING (4).

Three seal rings should come out with solenoid. If lower seal ring remains at bottom of engine retarder solenoid housing bore, remove seal with piece of wire and discard seal.

3. DISCARD SOLENOID (3) AND THREE SEAL RINGS (5, 6, AND 7).

CLEAN RETARDER SOLENOID HOUSING BORE (8) IN ENGINE RETARDER ASSEMBLY HOUSING (4) WITH CLEAN PAPER TOWELING.

1. COAT NEW UPPER SEAL RING (5) AND NEW CENTER SEAL RING (6) WITH CLEAN ENGINE LUBRICATING OIL AND INSTALL ON NEW SOLENOID (3).

2. INSTALL NEW LOWER SEAL RING (7) IN BOTTOM OF RETARDER SOLENOID HOUSING BORE (8).

Make sure seal rings are properly seated on solenoid. Take care not to twist seal rings when installing solenoid to prevent damage to equipment.

3. THREAD SOLENOID (3) INTO ENGINE RETARDER ASSEMBLY HOUSING (4) AND TIGHTEN TO 4-6 LB-FT (6-8 N.m).

4. CONNECT WIRING HARNESS SOLENOID CONNECTOR (1) TO SOLENOID TERMINAL (2).

Install rocker cover (page 3-71).

4-55/(4-56 Blank)

This chapter illustrates and describes procedures for maintenance of the front axle and related parts. A list of tasks contained in this chapter is shown below.

Page

Front Axle Replacement (All Except M915A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Front Axle Shaft Replacement and Repair (All Except M915A2) . . . . . . . . . . . . . . 5-7 Front Ball Socket Replacement (All Except M915A2) . . . . . . . . . . . . . . . . . . . . . . 5-15 Front Ball, Bushing, and Oil Seal Replacement (All Except M915A2) . . . . . . . . . . 5-30 Front Differential Carrier Replacement (All Except M915A2) . . . . . . . . . . . . . . . . . 5-34 Front Yoke and Oil Seal Replacement (All Except M915A2) . . . . . . . . . . . . . . . . . 5-38 Front Axle Assembly Replacement (M915A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

Front Steering Knuckle Replacement and Repair (M915A2) . . . . . . . . . . . . . . . . . 5-44 Tie Rod Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

Front Steering Arm Replacement (M915A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

Front Cross Tube Arm Replacement                 ..................................                        5-58

Front Axle Caster Adjustment (M915A2)                 ...............................                      5-60