Service engine brake flap connection

AR14.15-D-5810AD

Service engine brake flap connection

9.3.10



Disassemble

1

Remove engine brake flap connection

AR14.15-D-6302AD

2

Remove engine brake cylinder (13)

 Release ball socket (11).

3

Take off adjustment lever (9)

4

Detach bracket (6)

5

Remove engine brake flap (4)

 Close engine brake flap (4) for this step.

6

Knock out engine brake shaft (3) and both bearing bushings (2) from the housing

 Use a suitable drift.



Assembly

7

Drive bearing bushing (2) into housing (1) on side of bracket (6)

 Flush with the inside contact surface.

Use a suitable drift.

Coat bearing point with hot lubricating paste.

*BR00.45-Z-1005-06A

8

Insert engine brake shaft (3) into housing (1) and push through

 Coat bearing point with hot lubricating paste.

*BR00.45-Z-1005-06A

9

Knock second bearing bushing (2) into the housing (1)

 Use a suitable drift.

10

Set axial play (A) of engine brake shaft (3)

 Using a suitable drift, drive in bearing bushings (2) on both sides and evenly until axial play (A) is reached. The overlap of bearing bushings (2) to the inside contact surface in housing (1) must be of an equal size.

*BE14.15-N-1004-01B

Feeler gauge

11

Insert engine brake flap (4), balance and screw tight

 The bolt heads (5) must point towards the turbocharger when the engine brake flap (4) is closed.

12

Close the engine brake flap (4) and check the annular gap

 In a closed position the engine brake flap (4) must not lie radially adjacent to housing (1); realign engine brake flap (4) if necessary,.

13

Attach bracket (6)

14

Check ball socket (11) and ball stud at adjustment lever (9) for wear

 If worn:



Replace ball socket (11) or ball stud.

15

Install adjustment lever (9) onto the splined teeth of the engine brake shaft (3)

 Install adjustment lever (9) so that engine brake flap (4) is fully open in drive mode (B) and the stop of adjustment lever (9) is adjacent to bracket (6).

16

Check setting of adjustment lever (9) and position of engine brake flap (4)

 In brake position (C), the stop of adjustment lever (9) must lie adjacent to the bracket (6).

17

Attach engine brake cylinder (13) to bolt (16)

 Replace nut (14).

18

Adjust pretension of engine brake cylinder (13)

Open engine brake flap (4); the dead stop of adjusting lever (9) must touch holder (6) in drive mode (B). Align ball socket (11) centrally to ball stud, then turn ball socket (11) (approx. 2 revolutions) until specified engine brake cylinder tension is obtained.

*BE14.15-N-1002-01B

19

Tighten the nut (12), attach ball socket (11) to ball stud and secure with retainer (18)

 Coat ball stud with hot lubricating paste.

*BR00.45-Z-1005-06A

 Danger!

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases even sever extremities.

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0009-01A

20

Check the brake position (C) of the engine brake flap (4) and perform a function check at engine brake cylinder (13)

 For this step, pressurize fittings of engine brake cylinder (13) with compressed air from the workshop supply system. The piston rod of engine brake cylinder (13) is extended and engine brake flap (4) closes.

21

Install engine brake flap connection

AR14.15-D-6302AD

22

Test drive vehicle and perform a function test on engine brake

Number

Designation

Engine
900.9,

Engine
902.9
without code MS8

BE14.15-N-1002-01B

Engine brake cylinder - preload

mm

1.0 to 2.0

BE14.15-N-1004-01B

Engine brake shafts - axial play between bushes

mm

0.3 to 0.5

Number

Designation

Order number

BR00.45-Z-1005-06A

Paste, hot lubrication 1 kg, DB supply specification 6879.20

A 000 989 76 51