eR Installation Manual for Engine Brake — Model 425A ‘The Model 425A Jake Brake* is designed and approved for use on ‘Cummins pre-00/09 Small Cam and Big Cam NHINT engines. ‘Model 425A replaces Models 420 and 425. installation and ‘maintenance information for all three models is contained in this. manual For specitic application and slave piston adjustment information, refer to Jacobs Service Letter No. 342, Rev. A. ‘S00 Jacobs Driver's Manvel Tor proper engine brake Giver techniques “The Joke Brae Raarder na vehicio iow- 4 ioe. a ala red Labatt temas tJ Veto Eauzmor Company ihote ease Pop eos system. The vehi’ service brakes must beused to bring the vehice lo. complete sop. boston nara the mara was aren th tn ol pig si eet ‘Senge want ote era. Sacobs: verse ‘Equipment Company | TAKE! Ta Bloomiield, CT 06002 ABIBRAKE e245 481 | ass ©1801 suet Vie Event Company Pied HUSA ot‘TABLE OF CONTENTS: SECTION 1 INTRODUCTION so a Engina Brake Karticaion 3 ‘SECTION 2 ENGINE PREPARATION . 4-9 Injector and Valve Set Postion 45 CCrosshoad Screw Agjustmant, : 56 Injector Adjusting Scrows/Ol Supply Scrows 87 ‘Sud Lacatons/Torque Sequence. 7 Valve and Injector Adjustment 39 SECTION 3 BRAKE HOUSING INSTALLATION ..... 9-13 Slave Piston Adjustment vovnnnnndO AT Slave Piston Clearance Char. STC en = SECTION & ELECTRICAL SYSTEM INSTALLATION 19-15, Cuich Switch 13 Dash Switch. oa Fuel Pump Sin ary Wing Diagram . _ inna ‘Optional Conta Syetoms 15 ‘SECTIONS ENGINE BRAKE OPERATIONAL CHECK, 16 ‘SECTION 6 ENGINE BRAKE MAINTENANCE, 17-20 Control Vale . : 17 Slave Psion 17,18 Master Piston cnn Slave Psion Adusing Screw 19 Solanald Valo 19 Exhaust Rocker Arm Modifiaton (early engines) 20 ‘SAFETY PRECAUTIONS “The following symbols in this manual signal potentially dangerous conditions tothe mechanic or equipment. Read this manval care- fully, Know when these conditions can exist. Then take necessary steps to protect personnel a8 well as equipment. ‘This symbol warns of possible personal jury. ‘This symbol raters to possibe oqupment damage. Ineatos an operation, procedure or instruction that Is impertant for correct sarc. Fuels, electrical equipment, exhaust gases and moving engine pans present potential hazards that could result in personal injury. Take care when installing an engine brake. Always wear eye protection. ‘Always ue corect tools and proper procedures as oulined in this ‘manualSECTION 1 INTRODUCTION Housing Identification Each housing assembly is identified by a name tag which shows the ‘model number and part number. Te housing serial number is stamped on the top surface of the housing. See Fg. 1 Housing ‘Assemblies (Pkg) PN 420 (12 VO) Oraaor 420 (24 VOC) 014507 425 (12 V00) o1sa60 425 (24 VOC) 015840 425 (12 vo) o1esa2 425 (24 VDC) 016646 425(24 VOC Dual Leas) | ov6sst 425A (12 voo) 16658 425A (24 V0) ‘16860 425K(24 VOC Dual Lac) | 016867 “The Model 425A isthe current production engine brake forall Cam- mins 855 cu, in. engines except the 8§89NH/NT and 91 N14, ‘The ‘other engine brakes listed above are for service replacement. Consult the Model 420/125 parts manuel for specie parts ideatlicaion. Refer to Service Letter 342, Rev. A for specific aplication informs- Recommended Torque Values Exhaust Valve Crosshoad Adjusting ‘Serew Locknuts 25 bit. (95 Nem) Rocker Housing Studs TO bf (95 Nem) Engine Brake Hold down Nuts 60 bit (00 Nem) Slave Piston Adjusting Screw Locknuts 25 st. (35 Nv) Rocker Lever Adjusting Screw Locknuts 4 st (60 Ne) ‘Special Tools Jacobs Tools Feoler Gauge, P/N 003087 (.018 in) Foolor Gauge, PIN 015877 (.030 in) Feelor Gauge, PIN 015878 (.037 in) Slave Piston Clamp Faure, PINO17897 ‘Cummins Too! ‘STC Tappet Setting Tool, PN 3822648 Injector Torque Wrench, PN 3576552 General Tools Crowfoot Wronch 9/16 in, Cronfoot Wreneh 5 in Extra Deep Socket 58 in ‘SECTION:Fla. Fd ‘SECTION 2 ENGINE PREPARATION ‘Before installing the engine brake, engine identification must be ‘established to insure thatthe comect model engine brake is installed ‘on the engine. The engin used throughout his installation manual is an NTC-444, CPL 821. ‘The engine CPL numbers stamped on the idencaon tag located ‘on the engine gear case mounting flange (Pig 3)-Be sure the correct ‘engine brake models insted onthe engine. ean engine thoroughly before removing the rocker housing covers and gaskets. Injector and Valve Set Position Prepare the engine for injector, valve and slave piston adjustments that wil be dave Intron. ‘The following instructions are fom the Cummins Service Mana: 1 Tumbe crankshaft in the direction of rotation unl the "A" sarki aligned with the pointer on the gear cover. See Fig. 4 2, When “A” marks aligned with the pointer, the intake and exhaust valves should be closed for cylinder mumber 5. The Injector plunger for cylinder number 3 must be atthe top ofits ff no, tum the crankshaft anober 360 dg. and realign * mark with te pointe. the 3. When the valves for eylinder number 5 ae closed, the rocker levers fr cylinder number 5 willbe loose. Valve set marks used for this instruction were chosen for convenience, With exper- ‘ence, any valve set mark may be used SECTION?[Loosen the locknuts on the exhaust and injector rocker lever adjst- ing screws (Fig. 5). F.5 [Remove adjusting sews from exhaust and injector rocker levers {) Ihe rocker tver pads are not narrow as shown In Fig. 6, C . ‘then. é = {®) Therockor boxes must be removed andthe exhaust rocker 8 Iovere moe. Follow the nsretions on page 20n the mal {nance secon of tls manual, Move exhaust push rod aside and roate rocker lever upward ‘Remove the Cummins exhaust crossheads and install Cummins adjusting serews and locknuts into Jacobs crossheads (Fi 7). = 2 U hen replacing old crossheads with new Jacobs crosshoads, uso new Cummins Aajusting serews and locknuts. Fo.7 scobs Grosshead Crosshead Screw Adjustment Nove: CCrosshead adjustment should sways be ‘made before aterpting to adjust the waives. Install Jacobs crossheads and adjust as follows: 1 Lubricate the valve stems and te crosshead guide with clean Tube oi 2, Insal the erossheads onto the crosshead guides. The adjusting ‘screw must be toward the exhaust manifold, 3. Hold the crosshead down against the valve stem that is nearest the push rod. Tum the adjusting screw clockwise und it touches the valve stem Fg. 8. 4 ‘Hold ihe sere inthis position and torque the locknut 025 108. yg G5 Nem. NOTE: ‘5. Contin adjustment ofthe remaining exhaust valve crossheads ‘nan $7609 Torque Wrench Adopter Ie following the same procedure. Usd, tighten ockut to 2 Tb (90 Nem). ‘SECTION? 5Fo Cd Bw & Models 400,420, Model 420 425, .25A and others. ‘0800NT Pre 80 NHINT Engines Enginoe Flatt fla 13 Fi.10 Reinstall the Cummins exhaust rocker adjusting semw and locknut| into rocker lever. Locate adjusting screw into pushrod socket. See Fig.9, Install the Cummins locknut onthe Jace injector adjusting sorew and instal into injector rocker lever. Injector Adjusting Screws Note: ‘The Jacobs Injector adjusting sere for the Models 20, 425 and 425A Engle Brakes are ilfornt rom adjusting screws teed in other angie brake apptetions a. ‘sue the corre! eating Screws instaled. (caunow |] “These screws are not Itorchangesbia. Inataiation ofthe wrong screw wrest ‘engine and engine brake damage. Jacobs Oil Supply Screws Nove: “Thar ee currant to etloent ay “iecobs oi supply ecrows In usa fr Cur ‘nine NHINT spplcations. Be surethe cor ect aye sor ls etal. Soe Fg 1. Remove the Cummins solid rocker shaft locking serew and install the Jacobs hollow oil supply sere from kt Be sure top of serew is below the flat surface on rocker housing ig. 12). Fig.12 Remove the rocker housing capscrews from postions 1, 2 and 3.of| each rocker housing Fig. 13). sl eapacrowo at the donee rockar gasket ‘lured and new Focker ‘SECTION?Install special steel washers from kt into each hold-down bot hole (ig. 14), Put leading edge of washer into hole and press in fry ‘ntl washers seated. DO NOT use flat washers that were used with the rocker housing capscrews. Note: 100 NOT use special stool washers st tlons 2 and ofthe font housing, Fhe fan braces leeatedon topof therockar housing Refer to Fig. 18 or proper stud location and torque eaqunc, 0.14 ‘Tigduen suds in sequence to 30 1b. (40 Nem, hen retomue 1 70 Ibi. (05 Nem) [caution Use ot power tools may result in overtght ‘ong of hldlown studs Engle and an- ‘ne broke faura wl est. [Remove the rocker housing capscrews from postions 4,5 and 6 Install special steel washers and hold-down stds, Torque to 30 bf. (40 Nem), then retorgue to 70 Ibn (5 Nem, Refer wo Fig. 16 for location of optional length studs tht may be 1e- quired for accessory equipment. Fi. 15 ‘Stud Location and Torque Sequence “There are 18 extension studs of tee different lengths and up to ight spacers supplied in the stud and spacer groups. Refer othe ‘Jacobs Pars Manual for various avaiable combinations. ‘Stud and spacer locations and trquing sequences for the most . ‘common installations ae as follows: note: sm PN 019542 Stud 8 18 in. (6) PN g04199 Stud 7 in. (12), © PN 001294 Spacer (4) ‘ocker housing, thetwo epee steal wash- PN 013540 Stud 858 in. (Optional for special appications) fre are not required In postions 2 and. Fo. 18 ‘SECTION?Valve and Injector Adjustment Setting the Injoctor ($7) A special STC tppet tol, ST-3822648, must be sed to prevent compressing the tappet spring while setting the injector ovesead. (Compression ofthe tappet spring defeats the top stop feature and can result in premarure injector train and camshaft wear Fo.t7, “The tappet ool has a smal! ocatng pin designed fr insertion into the top ofthe STC tappt. Each tappet contains four evenly spaced holes to ensue that atleast one hale is easily acessible. Rotate the engine tothe cylinder tobe set, See "injector and Valve Set Posi tion” instructions on pages 4 and 5. ace the tool on the upper surface ofthe injector so that the tool straddles the top ofthe tappet (Fig. 17). Rotate the tool around the {appet unite locating pin canbe inserted into one ofthe four holes. Apply thumb pressure to the tool handle to hod the tppet piston in the maximum extended poston while sting the inject rocker lever set screw to Sor 6 bin Excessive force on the tool ean breathe locating pin off in a tappet hole. “The tool must be removed before baring the engine to prevent dam- aging tappet or the too, Bar in Dwsction| ‘Set Cylinder ‘of Rotation | Pulley Position) Injector Valve START A 3 5 av. To a 6 3 av. To c 2 6 a T0 A 4 2 av To 8 1 4 av To © 5 4 NOTE: Nore: For eating the lnjeciors on fixe ted or Check the angine deta pate for posse STC engines, the Cummins Injector torque ‘aration to the valve and injector edhst- ‘wrench, Cumin, PH 3578502, may be rants, Used. Thla wrench ie preset to ibn. ‘Salting the Injector (Fixed Timed) ‘Using the Cummins injector adjusting tool, PN'337659, set the in- {eciors 6 bin. (0.7 Nem), See Fig 18. Follow the sequence in the above chan. ‘After setting the injector, tighten the injector adjusting sorew Tocknuto 45 Ibt (61 Nem).Following the sequence in the chart on page 8, adjust the exhaust and intake valves. Insert the prope feel gauge betwoen the rocker ‘am and crosshead of the cylinder tobe adjusted (Fig. 19). Tum the adjusting sorew in until asight drag is flt onthe feeler gauge. Set intake valve clearance to 0.01 i, (0.28 mm). Set exhaust valve clearance to 0,023 in. (0.58 mm). NoTE: ‘The Cummins Injector adjusting too! may also be weed to adjust the valves With the fooler gauge Inserted, turn the adjusting ‘crew in unt th ool leks. ‘old the adjusting screw inthis positon and tighten locknut to 45, bf. (61 Ne, SECTIONS BRAKE HOUSING INSTALLATION (Check rocker housing surface to make sure itis lean and smooth. Install Jacobs gasket on rocker housing. Before placing brake units on engine, loosen and back out the slave piston adjusting screw uni slave piston is seated ints bore. Install ‘the rubber seal (from kt) in center of the web on the bottom of Fig, 24 engine brake housing (Fig. 21). Ifnecessary use a ite grease ro bold sea in place. Install engine brake units on engine. Units must go into place with- fut rocker lever interference. Install Jacobs spaces as required (Fig. 22), See STUD LOCATION AND TORQUE SEQUENCE on page 7 for spacer positions on housings. Fig 22 Install Jacobs hold-down nuts and torque to 60 Ib (80 Nom) fol- Towing the sequence shown in Fig. 23. [caution Use ot power tools may result in over {ightoningothokd-down nus. Engle brake housing ature wl reut. Fig.23 ‘SECTIONS 2,3 °Slave Piston Adjustment Procedure (CAUTION ‘Slave piston adjustment mus be made withthe engine stopped and ‘Te ofowing adjustmemt procedure must old, stabilized water temperature of 140°F (60°C) or below. Ex- ‘hast valves on te cylinder tobe adjusted must be in the closed position Slave Piston Cl (Correct slave piston clearance requires identifying the following: 1. CPL Number engine data pate on gear ase mousing Nange) anaemia Injector Timing Fixed Tumed or STC (valve lated fl ‘en pump side of engine) “@ 3._ Big Cam Identification (under cam follower housing) 4. Turbocharger Configuration (Fig. 24) ‘Measure 5 in. (127 mm) from the turbine ange and put a mark on the turbine housing. See Fig. 24(A). Use Vemier calipers to meas- ‘ure the width of the turbine housing a the Sin. (127 mim) mark. See Fig. 24 (B), Irth wid is greater han 3.6 in. @1 mm), thenitisa Fig. 24 twin entry turbine housing. If the wid is smaller than 3.6 in (91 mm), i single entry turbine housing. ‘Three lash adjustment tgs are included inthe Engine Brake its No tags are required for the Model 420. Select the appropriate lash adjustment ag and install under the Tocknut ofthe Awto-Lash adjusting sorew (Fig. 25). Install the appropriate tagon the number one cylinder. Discard the remaining tags. ‘A slave piston adjustment docal is included in the engine brake kit Follow the instructions on the bick of the decal nd instal iin a suitable place on the aftercooler manifold. Be sure to ut out the ad- jusumeats that donot apply to this instalation, ‘Back out the adjusting seew on the cylinder with he exhaust valves closed (Fig. 26) and insert the appropriate Jacobs feeler gauge be- ‘ween the slave piston and crosshead, See Chanson page 1. ‘Tum the adjusting sere in uni sight drag is felt onthe feeler szauge. Torque the locknut to 25 If. (5 Nem). 0 secTionsContinue turing engine in direction of rotation and set slave piston clearance onthe remaining cylinders in firing over. No? erowfoot wrench le usd, tighten oeknat te 22M (1 Nem), ‘Mode! 420 Stave Piston Clearance Po.27 CLEARANCE 0.018 slacobs Gauge IN 003087 ENGINE CONFIGURATION (PRE 88/89) NEW BIG CAM IV WITH Stop Timing Control ‘Mode! 425/425A Application/Slave Piston Clearance CLEARANCE 0.018, Jacobs Gauge in 003087 0.030 in. slacobs Gauge PIN 015877 0.037, ‘Jacobs Gauge in 015878, SECTION ENGINE CONFIGURATION (PRE 88/89) IG GAM WITH: DIVIDED ENTRY TURBO Fixed Timing Corto! (Includes NTE [European)) ‘Mechanical Variable Timing (MV) ‘SMALL CAM WITH DIVIDED ENTRY TURBO BIG CAN WiTH SINGLE ENTRY TURBO Fbced Timing Conto! Except CPL Nos. 393, 449, 831 and 588 BIG CAM Wire SINGLE ENTRY TURBO ‘CPL Nos, 393,449, S31 and 588 STEP TIMING CONTROL (STO) ‘CPL 806 NACIV se5/400/408 ‘GPL 821 NBCIV 444 ‘CPL 833 NBCIV 365/400 ‘GPL 1215 NBCIV 440 Pls (Recon) ‘SMALL CAM WITH: SINGLE ENTRY TURBO NOTURBO (Naturaly aspirated) "For Engines with Step Timing Control ‘An oll connection is require from the rea engine brake housing to the STC valve located on the fuel pump sie ofthe engine Fig. 28), “Ths sensing line allows the operation ofthe engine brake without incurring undue stress onthe Valve train and camshat. Fig. 28 | Remove hose that connects STC valve to the engine block (Fig 2). Cap of iting inthe block wit cap from Jacobs kit. ‘Remove the plug fom the rear engine brake housing. See Fig. 30, Install the Jacobs elbow iting into the rear bake housing and ‘tum until the O-ring is seated firmly against the housing. Be ‘sure the open end of the fiting is aimed downward ‘Connect one end ofthe Jacobs hose assembly tothe iting. ‘Tien jam sot securely. ‘SECTIONS6. Connect the other end tothe fiting on the STC valve as shown inFig 3, Route the hose slong the engine. Tighten the fiings teach end ofthe hose, Fo.31 7. ‘Secute hose to engine using clamps antes. See Fig. 32. This ‘minimizes stress and mechanical damage 1 hoses. ‘SECTION 4 Electrical System Installation ‘Clutch Swtten 1, Mount the clutch switch in the most convenient or accessible location: in eab under dash, underfloor whee! well o inthe bell, housing area ‘2. Install this switch with the switch actuator amin contact with the clutch dal arm or other clutch member. 3. Adjust the switch by moving it along the mounting bracket. The actuator arm should be deflected 1.015 in. 25-38 mm), ‘measured atthe tip ofthe actuator, when the latch peda sin the up (clutch engaged) pasion. See Fig. 33. 4, Check instalation by moving the clutch pedal, The switch Fig. 38 should click within the feeplay motion of the clutch pedal before actual clutch disengagement takes place '5. Cut wires proper length and secure them with tes. Connect the wites, Black lead to electrical power source, “The optional overtravel bracket should be used when the elute site i nstaled inthe wheel wel location ora location where a ‘buildup of road contamination (ce, mud, et) can stick to the actuator arn, SECTIONS 3, « Note: Forvebileawithautomstlctansmissons, fate to daobs serves letters of contact our nesrast dstbutor ryThe tuo! pump silich contacts are pro- tected agelnet arcing by ® ‘connected batwoon the los {erminaland ground, Locate. Ing to Fig. 34. (CAUTION ‘al lode ‘ide sweh lode accord: Improper connections to th awitch wl ‘rable engine brakes. ut in premature switch alureand nop Belore connecting the loads othe ouch, turn the vehicle inition on, tun engine brake swtich on and ongege the clutch {lun pedal up) tna votloRm met ‘aasure the volage at ach laa. The lead ‘wth «427 DC mist be attached to the ‘itch terminal that does not have the di- ‘ode sttachod. The loed withV DEmust be ‘Stached othe other ewiich terminal \CAUTION Donotbend actuating srmto Bending there wl aout fara of he em and tase of ing. [Acaurion ustowtch. In premature engine brak- (Check the uel pun thre shat to ar» ‘ure that tho throttle pedal wil move the ‘han tothe tl fel postion a the setting rm ter netaing Dash Switch Install the two dash switches in a convenient location in the cab, (Carefully measure and cut ll haresses to proper length. Thread ‘wires through the loom provided. Install receptacles at locations shown in wiring diagram furished in the kit Fuel Pump Switeh Fig. 24 1. Loosen the two cap screws onthe fuel pump housing and remove the upper screw. 2. Install the Jacobs fuel pump switch, The stoed area inthe ‘teh bracket is fr easier installation and for minor bracket sjusiments, Tighten the eap serews 3. Remove Cummins nut, washers and cap screw. Install he Jacobs te bolt, guide, actuating ever and nut. Install prt in correct onder. 4. With the dro shat inthe idle postion, move actuating arm until swith actuaes, Hold in his positon and torque mut to 10 it (14 Nem), See Fig. 35. ‘Alternate Switch and Throttle Lever Postions SECTION«425A WIRING DIAGRAM Optional Control Systems Jacobs offers thre differen systems for engine brake contro. [Besides te standard semi-automatic system, the customer has the choice of two added options: fully tomate conrol with a "iow speed” shut-of or fully matual contol with a "Foot Switch". Foot Switch ‘The Foot Switch i installed on the cab Moor within easy reach of the operators left foot After installation, light pressure on the top plat is al that i needed to operate the Jake Brake, The throttle Switch rem in the system fo ensure that fueling and engine braking donot occur atthe same time. Low Engine Speod Rotarder Cut-off System “The low engine speed rtarder cutoff system isa flly automatic ‘engine brake control system that senses engine speed (RPM) and electrically deactivates the engine brake at speeds below approxi- ‘mately 900 RPM, The low speed cut-off feature provides added “river convenience infrequent stop/tant operations, Additionally, the low speed cut-off feature suse for slip seat operations ‘where several drivers may operate one vehicle ‘The kit consists of a low speed retarer cut-off module and wiring harnesses, Te module canbe mounted inthe engine compartment ‘on the firewall or other convenient location. Complete instructions ate inlided in he kit SECTION « Fig.37 Fig. 38Wear eye protection and do not expose {your face over engine area Tako praca tons te prevent ot ekage down on the sngine. ‘Whenever angina ls running andvave cov- reremoved,ollplashinginthe engine brake area could cause peraonal Injury. SECTIONS ENGINE BRAKE OPERATIONAL CHECK “The Jacobs Engine Brake installation is now complete. Te follow ing procedures and adjustments shouldbe made. 1, Bleed brake units and check their operation, Start engine and allow to run 5 to 10 minutes. Accelerate engine w approximately 1800 RPM. Release throtle and then manually depress each solenoid armature, Repeat this procedure five o sixties to petit engine ol to fil the brake housing passages completely 2 Connect contol wires to teminal leadout assemblies in engine ‘brake housing. 3. With te engine shut down, check elecical sytem by turing ‘on ignition switch and the ON/OFF dash switch. Mave the three-poston dash switch from 1 to 2and, then, 3, In ptiton 1only the center housing solenoid valve should activate. In position 2, only font and rear housing solenoids should activate Imposition 3, all three housing solenoid should activate, 4. Using new Cummins gaskets, replace rocker housing covers and all previously removed pats. Atach the OPERATING TECHNIQUES decal ina convenient location on the dash, Fa.30 6 secnions‘SECTION 6 ENGINE BRAKE MAINTENANCE ¥ ‘ent wth angine running, Pareonal ry ‘The Jacobs Engine Brake is typically wouble-free and maint ey raul | nance-free device, However, periodic inspections are necessary and some maintenanc® is required. Use the folowing procedures to keep the engine bake in op condition, ‘This section wil cover how to property remove, clean and reinstall engine brake components. Use an OSHA approved cleaning solvent ‘when washing pasts, Be sure to coat parts with clean engine ol ‘when reinsaling them, Control Valve NoTE: Early syle housings use alt conto valve Remove control vate covers caretuy to ‘over plate tho capocraw: Use a 76 In ‘wrench te loosen the capsoram. Current houalnge have e washerike control valve over heldinpiae witharetaning ng. Use ‘etaning ring pera to remove. Se Fg 0. Carefully remove cover until spring pressure ceases, then remove the two contol valve springs 2. Using needle nose pliers, reach imo the bore and grasp the sem ‘of the contol valve Pull valve straight sp and out oft bore ig. 40). ‘3. Wash the consol valves with approved cleaning solvent. Push a wire through the hoe inthe base ofthe valve to he distance required to insure that the ball check is free. The ball should Lift ‘with ight pressure on te wire. Ifthe balls stuck, repace the ‘contol valve. Dry the valve with compressed ai and wipe clean with a paper towel 4, Thoroughly clean the control valve bore inthe housing, using clean paper towels. 5, Dip the control valves in clean lube ol, Dip the contol valves in clean lube oil and replace the valve into its bore. I binding ‘occurs, replace the contol valve. ~ 6. Replace pat in reverse order of removal stove Piston 1. Remove he lockmut fromthe save piston adjusting screw. Back emanates cut the adjusting stew unt he lve piston fly eaced Seen eee crtseatanee (crew is os ry comer ong Stuclone Ue te owed a andthe follow: ‘tela nat used, the sping could Se da 2. Use the sive piston clamp fixture, FV 17397, andthe fl ict nat und he ning cold te di ing poco fo emove and replace he save ion Soran SECTIONS ”‘Place the hole in the clamp fsture over the slave piston adjust ing screw. Replace lock, Tighten to hold fixture securely. ‘While holding the fixture in position, srew the holder down, ‘over the slave piston until the retainer is contacted. ‘Tum the handle slowly until he retainer is depresed about (0.040 in. (1 mm, elieving pressure agains the retaining ring Remove the retaining rng (Fig. 42) Use retaining rng pliers. ‘Back out the holder until the springs are lose. Remove fixture ‘Remove all components ensuring there is no binding or burs (Clean in an approved cleaning solvent, or replace as necessry. Nore: Be-sureall components rereassembied in broper order See Fig. #3. Reinstall piston, springs and retainer. ‘With the clamp fixture, compres the springs unite retainers bout 0.040 in. (1 mm) below the retaining ring groove. Rei stall te retaining rng. Be sure the retaining rng is fully seated inthe groove. CAUTION, Do not eave open potion of retalning ring _tignedwith opening tn housings Seo Fi. {4c Thiewilpermitihespringretainer tobe ‘coma lose when the anglnsbraka looper ‘tng. Serious engine damage wil recut. 10, Remove the clamp fixture slowly to insure proper seating of| retaining ring. Master Piston |, Remove the screw, wather and master piston spring fom the bottom of housing, Remove master piston from its bore using noodle nose plirs to ally pall the piston ou, if necessary. If binding occurs, check for burs or contaminants in lube ol. Clean in an p- proved solvent, Inspect the had face surface (Fg. 49). Pitted, chipped, cracked or galled pistons shouldbe replaced NOTE: 1 hard facing 12 damaged, inspect the corre: ‘ponding rocker arm adjusting screws fr ex {essive wear or ptng, Replace i damaged. 1. Reassemble in reverse order. When tightening the capscrew, ‘make certain the two spring tabs do not interfere with the sides (ofthe master piston center raised portion. See Fig. 46. No ‘Thotabs should ooqually paced tomthe raised piston area.Slave Piston Adjusting Screw (Auto- Lash) ‘Auto-tash 1, Loosen Auto-Lash adjusting Screw locknat and remove adjust Aciustng Sexow ing screw from housing. Part Numb 2, Inspect Auto-Lash adjusting screw, The plunger should protrede from the botom of the stew. Approximately 12 Ibs. (53 N) force is aquired to move the plunger. Be sure the retaining pin is flly engaged ints groove — Proton 3, Clean in an approved cleaning solvent or replace the entire Serew, as necessary. The screw assembly is nt to be serviced in = the field. TT Z caution. nee smbla oF tamper withthe Solenoid Valve 1. Disconnect solenoid hamess. Using 78 in. socket and exten- [caution sion, unserew solenoid valve. ‘Do not disassemble or tamper with the ‘solenoid valve, Engi damage could re: 2, Remove and discard the thee ubber seal ings the lower ring. sul. stays in the bottom ofthe Rousing solenoid bore, remove with & Piece of wire 3. Wash out the solenoid valve with approved cleaning solvent Use brush o clean the ol sereen. When clean, dry the valve with compressed ar, 4, Clean out the solenoid valve bore inthe housing. Use clean paper towels. Never use rags, as they may leave int and residue ‘which can plug the ol passageways ‘5. Using new solenoid sea ings, coat them with clean lube: Install the upper and center seal ring on the solenoid body and ‘the lower seal rng into the botom of the solenoid bore inthe housing, Fla. 6. Be sue the seals are seated propery. Carefully serew the sole- ‘oid into the housing without unseating the seals. Torque the valve to 60 bin (T Nem), Be careful not to ewist the seals while installing ‘SECTIONS: 1°Fa a8 Exhaust Rocker Arm Modification Engines built prior to 1980 may have exhaust rocker levers with ads that wil not it between the legs ofthe slave piston Seepage S. ‘Use Jacobs Grinding Gauge, PIN 001153, according othe following, procedure to modify the exhaust rocker lever, if ccessary 1 Remove the rocker lever housing. Refer to Fig 4. 2. Rotate the rocker levers so that he grinding gauge (1) will ‘mount on the topside ofthe rocker lever housing with he name plate side ou 3. Insert each exhaust rocker lever (4) through wide slot in gauge and secure the gauge with two housing capscrews (2). 4. Light grind both sides ofthe exhaust rocker lever unl the foot passes through the narrow slot (3) inthe gauge. [caution Donotoverheat the rocker love foot while {grnding, verhating wl daw the temper ftom the foot 5, Remove gauge and remove burs from rocker lever foot. 6. Clean rocker box and reinstall on engine using new gaskets Continue with engine preparation (Page 3) ‘SECTIONS