Service engine brake flap connection

AR14.15-W-5810A

Service engine brake flap connection

9.3.10

14.3.05

Perform function test for engine brake flap and engine brake cylinder, added

Step 20



Disassemble

1

Remove engine brake flap connection

Model 374, 375, 673, 674, 676, 958, 970, 972, 975, 976

AR14.15-W-6302A

Model 668, 670

AR14.15-D-6302D

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) to remove bolts (5).

6

Knock out engine brake shaft (3) and both bearing bushings (2) from housing (1)

 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 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 the bearing bushings (2) to the inside contact surface in the housing (1) must be of an equal size.

*BE14.15-N-1004-01B

11

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

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

12

Close engine brake flap (4) and check annular gap

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

13

Attach bracket (6)

14

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

 In case of wear replace ball socket (11) or ball stud.

15

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

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

16

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

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

17

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

 Replace nut (14).

18

Adjust pretension of engine brake cylinder (13)

 Open engine brake flap (4). In drive position (B), the stop on the adjustment lever (9) must lie adjacent to bracket (6). Align ball socket (11) centrally to ball stud, then turn ball socket (11) (approx. 2 revolutions) until the specified engine brake cylinder tension is obtained.

*BE14.15-N-1002-01B

19

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

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

21

Install engine brake flap connection

Model 374, 375, 673, 674, 676, 958, 970, 972, 975, 976

AR14.15-W-6302A

Model 668, 670

AR14.15-D-6302D

22

Carry out a function test on the engine brake

Number

Designation

Engine
904.9,

Engine
906.9 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