Installation Manual for Models C317 and C317A Engine Brakes ‘The Model C317A Jacobs" Engine Brake is designed and approved for use conall Cater Series 3175 engines. “The Modal 0317A replaces the former Model 0317. 4 Jct ke laa a AutoLt a apie Haters of Th Jeske inuoauicg Coney Javea Mae Rap. enn SACS Veri016 facets Company 22 East Dudey Town Road Bloomtietd, CT 06002 208-249-1441‘TABLE OF CONTENTS: SECTION 1 INTRODUCTION. 3 ‘Model and Sera fo, Location 3 “Torgue Vals: 3 SECTION 2 ENGINE PREPARATION a7 Exhaust Valve Bridge Adjusting Screw Replacamont ao. 4 Valve Bridge Instalaton ard Adjustment. 5 Valve and Injoctor Adjustments 67 SECTIONS BRAKE HOUSING INSTALLATION 79 Housing Installation 7 Slave Piston Adustment 8 Spacer Insaaion ° SECTION 4 CONTROL SYSTEM INSTALLATION. son 914 CGuich Swich 9,10 (ash and Conta Mosiulos nie Custom Corirel Schemave Diagram cone 1B (OEM Dash Switches (optional. 13 91 Modo! Year Swatch Group and lays 5.14 SECTIONS: ENGINE BRAKE OPERATION CHECK 1415 SECTIONS. ENGINE BRAKE MAINTENANCE 16-20 Housing Exploded View. 16 Solenoid Vai 7 ContolVaie, 7 Siave Piston 18 Master Piston 19 Slave Piston Adjusting Screw (Cp Valve) 20 SAFETY PRECAUTIONS ‘Tho fellowing symbols inthis manual signal potentially dangerous conditions tothe mechanie or equipment, Read this mantal ears fully. Know when those conditions ean exist. Then take necessary eps to protect personnel as well as equipment. ‘This symbol warns of possible personal injury. ‘This eymbot rotors o possi equips 5 damage. ‘an operation, procedure or Insrution that I important for ‘seven. Fuels, clectreal equipment, exhaust gases and movingengineparts ‘present potential hazards that could resultin personalinjury, Take fare when installing an engine brake. Always wear eye protection. Always use correct tools and proper procedures as outlined inthis manualSECTION INTRODUCTION Housing Identification "The model number forthe Engine Brake is est into the webon the topofthehousing See Fig. 1. The housing serial mamberis stamped ontheflat surface ofthe housing near thecontrl valve, Thehousing partnumber and slavelash sprinted on a nameplate located onthe top surface f the housing, Barly production hovsingehave the part number east int Une top surface ofthe housing. Fig t Engine Identification Engine SIN prefix “TLG" indicates 91 model year engine. The 91 ‘model yar engines requireadiferent slave piston adjustment than the pre model year engines, See page 8 for slave piston udjust- ment procedure. lestrical control systems also difer on 91 and pre-91 model year ‘engines, Control systom installation information begins on page 9 Engine serial number information is printed on the nameplate Tocated on the left rear side of the engine Bock, Tools Needed ‘There are no spocial tools required for installation of the Model (OB17A Jake Brake retarder. However, the Caterpillar Series 176 Engine and the Model C317A Jake Brake are of metric design and wore: wilrequive the ute merchant eae eee tos sehr ante eee Recommended Torque Values ‘elses sing no torus wrench sdopre Srocenaon wer sapere cote Pas Sine toed whore rence CHa ot zoen.crsim arene mua on ee Foor jen Ba pare aia {icimantucrrs washes ose Siotim Sosy OITA Ole ste ‘ie rth rq eh a apr feusytocaemntae cata Sk one beta wed fevsngeate-iwome. ext? oie ost ‘eiang Ble ton ‘ioe ester ‘Slave Piston Adjusting Screw Locknut 25 Ib. (35 Nem) ov Scrat Sen (rum) Senos See (rm) carrare "alvo Bio Adusing Screw Loctrut 18 Bt, (25 Nm) Ex. Rocke rm Adjusting Seow Lackrut 181 (25 N-m) Inetor Rocker am Aajusng Sew 4 lt (SSN) Model Differences. ‘Mounting methods for the C217A and C317 housings are dtferent Decauseof heheight difference shownin Figs.2A and 2B, Seebrake ‘housing installation section for specific installation procedures,Fas make Valves Fiat Fes SECTION 2 ENGINE PREPARATION Valve Cover Base ‘The photographs inthis manual show the valve cover base in place during engine brake installation, Production engines will be ‘equipped with a cover base (1) tht includes three suppart brackots (@) for containment ofthe injector wire harnesses, See Fig. 3. ‘The supportbrackets may preventaccesto the thee cylinder head ‘oles wich must be removed for the installation of three Jacobs bole. Because the injector harness support brackets are dificult to remove with the cover bate in place, it may be necessary to remove the valve cover baseto permit access tothe eylinder head bolts, Exhaust Valve Bridge Adjusting Screw Replacement Remove all aceasory equipment that is necessary to remove the rocker covers, ‘Remove the rocker covers, Note the valve arrangement shown in Fig 4. ‘Refer to Fig. 6. Looson th loknet (2) and the edjusting serew (1) on the exhaust rocker arm (3). ‘Loosen the lock on Uhe exhaust valve bridge adjusting screw. ‘Move the exhaust valve push rod aside to permit the rcker arm to De rotated [Remove the exhaust valve brig (2. See Fig. 6. Remove the Caterpillar adjusting serew (1) and locknet (2) and {install he Jacobs serow and pinassembly (4)and Jacobslosknut(6)- note: Instaithe screw andpinessembly sothstthe hexagon goof the screw is facing up wen, ‘he brago Is nstaled In tho engine. secTION2Valve Bridge Installation Lubricate the bridge dowel, bridge bore, tap pad and serew and pin assembly with clean lube el Install bridge assembly (1) onbridge dowel withthe adjusting eerew toward the rocker shaftas shownin Fig. This is 180deg, from the original position. Valve Bridge Adjustment While pressing straight down on the bridge pad (1), turn the ‘adjusting serew 2) clockwise until eontactis made withthe valve stem, Seo Fig 8 ‘Advance th serew an additional U8 tarn (48 deg) to etraighten the bridge onthe guide as shown in Fig. 8, Hold the adjusting serew in ‘this postion and tighten the leknst to 18 Ib. (25 Na, [caution Be eure the exhust valve Bdge (1) ls propery located on the exhaust Yalve Som (2) See Fig 10. The valve stom must {inthe counteroore of te bridge an the ‘side without the adjusting eerow:Fllre to do so wil result In serious engine somage. [Refer to Fig. 11 to determine the eylinder heed bolts (1) and rocker shaft bots (2) ta be removed, Note: Replace thethre eyiinder head bolt with ‘thedacobe bolls ONE ATA TIME. The wl Proven eylinder head datorton. Remove the ylinder hoad bolt and washer closest tothe intake ‘maingold, one per brake housing, ‘secon? Fig.9 Fig. 10singe ow gun sua than exten renveteattomihe Din end bol ole Refer o Fig. 12 inal he Caer washer 1 om te Jasbe ‘ner dol diate atte ble Tien the Bitte 8 Repeat the above procedure for the remaining two eylindor head bolts, one ata timo. Fig. 12 Install the cylinder hend bolt spacers (1) on the eylinder ead balts| and torque to 65 ID. (88 Nim). See Fig. 13 Modal 62174 Only nove: ‘The ofowing procedure applies oC317A housings only. For C317 applications soe heading "Medal C317 ONLY" on page 7. ‘Remove therockerleverbults at the six locations nexttotheexhaust ‘rocker levers Install the mounting stud essemblies (2) and torque 4070 Ib (95 Nom). Soo Fig. 18. | Valve And Injector Adjustments core ‘Male all ajastments withthe engine topped and cold. Follow Exhaust valve clearance adjustmont 12 the sequence inthe fllowing table: ‘required. Adjustments ofthe Iniake valve esranco and the Injectors will bo re: Valve And Injector Adjustment Sequence ‘quired only secoraing fo vehicle mileage ‘engine service narvals. Setintake Sot Exhaust Set Set Engine Vane Valve Injector onsite tea 135 356 Compression | op.esto 356 248 sea (Compression | ithe Valves o 0.015 i. 038 me) Extatat ates 0.025, (64 mm) Set Unt ctr o Zero iaranoo pus 1/21 (180 don.) Valve Clearance Adjustment | | egntegmateirenciiigeerintunatstis | ‘exhaust valve push rod (D. Insert the feeler gauge between the | rocker arm and valve bridge. Turn the rocker arm adjusting serew | ‘@)clock-wise until the proper clearance 4 isset.Holdthe adjusting | serew and torque the lockmut (3) to 18 Ib, (26 Nm) | “4 POT ajusttheintake and exhaust valves usingthe same procedure. Set ‘the intake valves to 0.015 in, (0.98 mm). Set the eshaust valves to ‘0.028 in, (0.64 mn. SECTION 2 |Injector Adjustment ‘Turn the injector adjusting serow (1) clockwiso until eontactismade with the injector (2). Turn the adjusting serew cleckwise an addi- tional 1/2 turn (180 deg) Hold the adjusting sere in this postion and tighten the loeknat 2 to 41 Ib. (65 Nm, note Rotate the engine 360 dog In retion of rotation and salut the remallng va ‘and Injectors folowing the sequence In Fo. tha above tabi. SECTIONS ENGINE BRAKE HOUSING INSTALLATION Housing Installation Position the engine brake housings on the mounting tud nuts and. sal the Jacobs holddown nats (1) on the brake mounting studs. ‘Do not tighten the nuts at this time, {asta he 70mm ongbols(2) through thehousingintothe spacers ag 4 (one per housing). Do not tighten bolts et, ‘Besureslavepistonfot(1)i aligned squarely over the ridge serew and pin assembly (2) to insure full entact of exhaust valve stem. Reposition the housing if necessary. First tighten old-down nuts (1) to 59 Ib. (80 Nem), ‘Tighten bolts (2) to 41 Ib. (55 Nm) Modal c217 only ra ‘The folowing 6 stops apply toModel 317 housings only and NOT fo the 217A, “Extended stu, PY 016065, has bao replaced hy ot PN 014800, It is rocommanded when ser ce the extended stud, P/N 016088, be replaced by bolt, PIN (014800, Use the following procedure for C817 housing installation, Fi, 19 ‘xcondos Stud P/N 016068 (Oblate) mM Bot Pvor4a00 ‘SECTION2,3Note: To aust the Injectors and valves the gine bake housings must be removed tnd the rocker assembly secured with Caer rocker pedoxtalcapscraws ‘cobs PI 014800 capscrow with 2 I ‘peoere,Jacabe PN O17595,Torquato 70 {be (08 Nem. note: Make the slave platon alustments with theongine stoppedand col. The oxhaust valves must be closed on the cylinder to bo adjusted. Follow the sequence Inthe ‘Slava Pleton Adjust abe 6. Po. 1, After injectors and valves have been adjusted remove th ‘tended studs, oF for new installations remove the Caterpillar rocker pedestal eapscrews 2 Inca the engine brake housing on th rocker pedestals, ‘8. Install the Jacobs bolt PA 014800 (2 per housing) into the housing and rocker pedestals 4, Install the Jacobs bot through the housing into the spacer on the eylinder head bot ‘Tighten blt at tho rocker podestals to 70 IbA. (95 Nim). ‘Tighten th bolt at the heed bolt spacer to 41 bf. (55 Nom). Slave Piston Adjustment Slave Piston Adjustment Sequonce Set slave Set Engine Paton No, oyerte 198 Compression op.ssto 248 (Compression Slove Piston Cleerance Satting Engine Mod. Yr. Clearance ‘Gauge Pt 2178 Peat 24S in 1.4mm) 19806 3178 an 150 n.(1.27 mm) 17002 ‘With the echaustvalves closed on the cylinder tobe adjusted insert ‘the proper Jacobs fecler gauge (2) botwoen the save piston and the ‘actuating pin (3) in the valve bridge adjusting seew. ‘Turn the slavepiston adjusting screw (1) inuntila slight dragis elt on the feel gauge. old the adjusting srewin this position and tighten the locknut to 25 Ib. (35 Nm) rig. 21 Rotate the engine 360 deg. and set the clearance on the remaining slave pistons. SECTIONS.Spacer Installation Be sure the sea! is seated inthe groove atthe bottom surface ofthe “Jacobs spacer. Se Fig 2. cay Sem Note: ‘A375 In. (85 mm) gop should be let bbtweon each end ofthe gasket and tha spacer. Install the three Jacobs spacers on the valve cover base Install the terminal leadout assemblies into the spacers and tighten ‘witha six point box wrench until seated against spacer. Connect the solenoid lead wires (1) to the terminal lead oats (2) in ‘the three spacers. See Fig. 24. SECTION 4 CONTROL SYSTEM INSTALLATION Clutch Switch - All Engine Applications Actutch switchs required for proper operation ofthe engine brake, ‘Vehicles that ave cruise contol wil inclade a elute aiteh inthe cruise control cieuit for operation ofthe eruse control, Vehiclos Without the eruise control option do not inelude a clteh site, Note: For vehices with crise contol (with elutch etch) ‘These applications wil not require installation af a Jaecbs clutch switch. The clutch switeh used for signaling the eraie control will provide a signal for proper engine brake operation withthe wiring anneeted as shown in the pro-91 custom control wiring diagram, See Fig. 30.1p not expose electrical components to [RIV Sealant. Eloctrial spark can cause FLAMIKABLE sealrts to gn, resuing In possible ire and personal Injury. Jr. 25 Vehlele without erulso control (no existing clutch sw: 1 Mountthecluteh witchin aconvenient, accessible location. Lo- ‘ations may inelude in cab under dash, underfloor whee! well leation or inthe area ofthe bell housing. ‘2. Install this switch with theswiteh actuator armin contact with the clutch pedal arm or other clutch member. [Keaurion Excooding15in. deflection ofthe actuator ‘smmay cause etch damage rsuling In gine bake mailunetion. Note: ‘The optional evertravel bracket (Fig. 25) should be used when tho cluich switch Inatalled Inthe Wheel wall locaton or & leeation where abulldup of read eontamt rato (leo, mud, ota.) can atlk to the ‘clus am. ‘Aajust the switch by moving the switeh along the mounting ‘racket, The actuator arm should be deflested 1.01.5, (25 ‘38 mm), measured atthe top ofthe actuator, when Une clutch pedal isin the up (clutch engaged) position. See ig. 26 |. Check installation by moving the clutch pedal. The switeh should click in the freeplay motion of the clutch pedal before actual clutch disengagement takes place, 0 | Locate theJ-1 electrical onnestor as shown in Fig. 27. Connect ‘one wire from the clutch switeh toa pin A" in the d-7 eletrieal ‘nmedtor, The other latch switch wire should be connected to pin "G' in the J-7 lectreal eonnestor. Pin "A and "@" have "pigtail" wires coming rom the annectar. Buttspicethe cluteh strteh wires to those "pigtail SECTION 4Custom Control System - Pre-91 Model Yoar Engines Dash Module 4, Lacateanarea onthe dash forthe dash control module and dill, az hole 2 Install the module and attach the bracket to the back of the ‘module withthe two nuts. See Fig 28 ‘3. Attach the ribbon harness tothe dash contro] module. See Page 14 for check out procedures, Control Module ‘Mount thecontrolmedule (Fig. 25)insidethecabsothat theharness will reach the dash module. Mount the module using two tapping serews. ‘Refer to the custom eontrol schematic forthe following electrical ‘eonneetions: Harness, PM O15E63, Connect the wire harness, PAN 015683, to the contral modal Wire Harness, PN 015604 1. Connect the wire harness, P/V 015684, to the Weatherpack® annocter on the control mode 2 Connect the RED wire to a 10 amp circuit breaker that is ‘controlled by the Key swite, 3, ‘The ORANGE wireis provided or use withan ant-skid system, ‘anti-skid is not use insulate the end and stare the wie, 4. The BROWN wire should be connected to the 4176 electronic control module, connection P-8 terminal C MODEL C317 and C317A CUSTOM CONTROL SCHEMATIC FOR PRE-91 ENGINE APPLICATIONS Fig. 20 Fig. 29 [Xcaurion De not overlghton nut, Sch tlre Bcauron ] Do not allow control mode to be une ‘mounted orto wrapped bah tho dash, Control module willbe steased end all ‘ure wl eau ‘Attach the rbbon exble from the dash ‘modulo the contra module and tighten the two” meunting ‘screws. Meurting screws are not Inchided nth Ke 1 tho optional OEM dash ewties are ‘used in pace of dash module, connect ne Purple and gray wires as shown nig. 3, sage] FEE =) Fig. 30 SECTION 4 "6. Connect the GREEN wire toa good ground. See Fig. 31, Proper operation ofthe Jke Brake engine Tetarer sbctricl control system a de. GROUND DIAGRAM - ALL APPLICATIONS Ponder om ecurg a good ground oon: foatonImeGhethwiemustbsatected aviary com {othe dedicated ground connection pont located tte tha elder head. See Fl iawiicld 51, Do ot use body bots or serows onthe aah. A poor ground wit cause Inter. 2 a {entenginobroe opratonand damagete e aun the contol modula Z y a strap a a= 3 tes Fig 31 ‘Connect wires to the terminal eadouts inthe spacers: YELLOW ‘wires to the front and rear spacers; BLUE wire to the center location. Optional Jacobs Switch Group ort ‘Use ofthe optional Jacobs swith group in place of the control module wil lminate {he dlagnosticroubl shooting fears ot the standard electronic ere ‘Switch group, PAN 017828, and harness, PIN 017263, may be used {nsteadofdach module PIN 018641, and cable, PAVO16906. Connect Inaeness, PIN 017263, between 017258 control module and 016684 hse 2 ‘SECTIONOptional OEM Dash Switches Vehiclo OEM dash switches may be substituted forthe dash control ‘module. The switebes are connected as shown in Fig. 33. Note: ‘Use of tho optional dash uiches In Place ‘of the dash contol module wi ‘himinat the dlagnoatle woubo shooting feature ofthe stander electronic eeu 91 Model Year Dash Switch Group ‘L. Locate an area on the dash for the dash ewiteh group and drill ‘02 i, hole 2. Install the switch group and attach the bracket with the two nuts as shown in Fig. 34. 3, Attach the harness to the dash switches as shown in the appropriate wiring diagram. See Fig. 36 or 87 on next page. Note: ¥ dosre, the two dash swtiches can be ‘mounted recy on the dash withthe {ho omvot ston onthe at andthe A ‘medion awh on the right. Relay Base ‘Mount the relay base (Fig 35) inside the cabs that the harness will reach the dash ewitehes Note: ‘Tho olay base canbe installed ervey to ‘the existing etecrical panel n many cabs ‘orattach the rela bese fo the trewall or ‘Suto location nade the ead, Solid State Relay For specific connection information refer tothe appropriate wiring iagram. See Fig. 36 or 37 on the allowing page. Forall applications: Connect tho GREEN wire to «good ground. See Fig. 3. Connect wire othe terminal leadouts inthe spacers: YELLOW wires to the front and rear spacers; BLUE wire to th center Tocation. ig. 2] Fi. 35 [Keaurion o not overtghtn nuts, Switch Flt eat 4 Proper operation ofthe dake Brake engine retard elects! eonirol system lo de. Pendant an securing a good ground con- Pectin The GREEN wire must bea {ached to a grounding etd located othe ‘the cylinder hed. Soe Fig 31. Donat use body bolts or screws onthe dash. A poor ‘ground ill cause ntarmitent engine Brake operationanddamagetothecontol ‘modula 1FOR 91 ENGINE APPLICATIONS - W/O ABS (ANTI- LOCK BRAKING SYSTEM) Fig. 26 FOR 91 ENGINE APPLICATIONS - With ABS (ANTI LOCK BRAKING SYSTEM) Fig 37 SECTIONS: ENGINE BRAKE OPERATION CHECK Custom Control System - ‘Models C317 and C317A on Pre-91 Engines ‘The electron controls for these Bngine Brakes include « dash ‘module, contral module and associated wire harnesses, See Section 4;pages 11 and 12for installation instructionsand.use thefollowing cheek out procedures. ‘SECTION 4, 5‘With the “ignition” switch turned on, the system is energized, The zd light wil be on indicating thatthe control module is"of®. See Fig. 384, ‘To turn the control module “on” press the on/ff button. The red light in the ONOFF quadrant will go off andthe green lghtin the 1LO quandrant will come on indicating that the retarder is opers- tional in the low mode, center housing only (2 eylinders). Soo Fig. 58, Pressing the MED botton wll ar off the light inthe LO quadrant and turn on the ligt in the MED quadrant indicating that the ‘etarderis operational in the MED mode, front and rear housings (Gelinders) See Fig. $8C. Pressing the HI button wll eause the ightin the MIED quadrant to gout and the lightin the HT quadrant ta eome on, indieating that the retarder is operational in the HI mode, all housings (6 ela ders). See Fig 38D. Bleed Engine Brake Housings 1 Start the engine and allow to run fora few minutes 2. Depress and release the engine brake solenoid dise several ‘times ta allow the housing tobe illed with ol. See Pig 39, 3, Watch the master piston tobe sure it is moving down onto the injector rocker arm pad. 4. Watch the savepiston assembly. tshouldmove down tecontact the pin in the exhaust valve serew. 5. Check each housing tobe sure they are functioning. 6. Shut down engine, Clean the gasket surface for the cover Rocker Cover Installation Be sure the sea is located inthe groove ofthe eover (Fg. 40) and install the coveron the spacer Install the Jacobs bltssixper cover, ‘Torque to 5 IbR, (7 Nem). ‘Tighten én steps to assure uniform compression ofthe seas SECTIONS: Fig.) Woar aye protection snd do not expose your face over the angine are. Take pro: sulla to pentent ol lange ont tho snglne. Whenever the engine is running withthe valve covers removed, oleplaahing nthe tnglne area could aus personal Inky.‘SECTION 6 ENGINE BRAKE MAINTENANCE Paar EXPLODED VIEW MODEL C317A HOUSING ASSEMBLY NoTE: ‘All component parte In the C317 and (0517A housing assemblies ar the same. ‘he Jase Engine Brak tpi a rate fie and maine Never rove any engin bake compo: nunc fon dere Hoeven pores apenas od Dentwttnengne ring, Pratl inary sme mantnantesreqien Une thetalovingpresdurestoeop yo thecagne bate nap conto ‘This section covers how to properly remove, cloan and reinstall ‘engine brale components. Use an OSHA approved cleaning solvent ‘when washing parts. Be sure to coat parts with clean engine oil ‘when reinstalling them. 6 SECTIONSSolenoid Valve Do not daassemble or tamper with the slo- old valve Engine damage could result The olenold valve Te not al eorvlaabla, 1. Disconnect solenoid harness Using 78 in, socket andestension, ‘unserow soleneid valve, 2 Removeand discerdthothreerubberseal rings. thelowerring staysin the botiom ofhousing solenoid bore, remave witha seal Pick, 8. Wash out the solenoid valve with approved cleaning solvent Use a brush to clean the ell sereen, When clean, dry the valve with compressed ai. Clean out the solenoid valve bore in the housing. Use clean paper towels, Never use rags, as they may leavelint and residue which ean plug the oll passageways. 4. Using new solenoid soal rings, coat them with clean Iube ol Install the upper and eentr seal ringon the solenoid body and the lower seal ring into the bettom of the solenaid bore in the housing. Se Fig. 43. 5. Besure the seals are seated properly, Carefully screw tho sale- ‘noid into housing without unseating the seals. Torque the valve 0 & Iba. (7 Nm. Bo careful not to twist the seals while FI: 4 installing, Fig. 2 Control Valve ‘Remove contol valve covers careuly to avold porsonelinjry. Control valve cov. 9 are under load trom the contre! valve springs. 1. Apply pressure on the control valve cover (1) and rotate the Fetaining ring ears tothe slot inthe housing Remove retaining ig. aa ing (2) using retaining ring pliers, See Fig. 44 and 45. 2, Slowly remove cover until spring pressure ceases, then remove the two eontrol valve springs (0, nsert (6) and oller (3, 8. Using needle nosepliers reach into the bore and grasp the tem ‘ofthe control valve (5). See Fig. 45, Remove conte valve, 4. Wash the control valves with approved cleaning salvent, Push ‘a wire into the hole in the bate of the valve to the distance ‘oquired to insure that the ball checks fee. Tho ball should it with light pressure on the wire, Ith bal is stuck replace the control valve, Dry the valve with compressed ar and wipe clean with a paper towel, Fig as ‘Throughly clean the control valve bore in the housing, using clean paper towels. SECTIONS: ame p19- 6 09 (3 ee8 a8 @ e 7Wear sstoty lassea. Remove stave piston careful. ‘The slave platon Ie retained by springs {Mat aro under heavy compression. I the following Instructions are not foloiad ‘andpropertooisnot used, the springs wil bo lscharged ith eneugh oreato cause personal injury. 1” Fig a6 5. Reassemble parts reversing the removal procedur, [caution ‘Be sure the control valve collar Instalind with thelonger sleeve area up. Soo Fig. 4. tho collar fs Installed upside down, on sine damage may result 6. Rotatetherotainingring ao that the ears relocated away rom, the slot in the housing as shown in Fg. 47 Slave Piston 4. Remove th leknut (8) onthe slave piston adjusting serew (D, Back out the adjusting xerew wnt the save piston retraced (erew is lose), 2, Place the hole in the clamp fixture (2) over the slave piston, adjusting ere. See Fig 48, ‘8. While holding the fixture in position, serew holder down over the slave piston 4 until the spring retainer (6 is contacted, 4. Tum the handle slowly until tho retainer is depressed to about ‘Vin. (1mm) relievingpressure against theretainingring(). {5 Remove the retaining ring. Use retaining ring pliers, Back out, the holder until the springs (7) are lose. Remove the fixture. {6 Remove all components ensuring there is no binding or burrs. Clean in an approved cleaning solvent. Inspect parts and ‘replace as necessary. . ‘20 sural component are rnssonbid In proper ender: S00 ig. 42 clamp fixtureoreinstall piston andsprings. Be sure retain- lng ring is placed on the retainer before serowing the clamp hhalder down over the slave piston. 8. Compress the slave piston springs down until the retainer is about 1/82 in. (1 mm) below the retaining ring groove Reinstall the retaining ring. Be ture the retaining rng sally seated in the groove, 9. Remove the clamp fixture slowly to insure proper seating of retaining ring SECTIONSMaster Piston Remove the anti-rotation pin assombly (3) and lock washer (2) from the housing. ‘Remove the master piston assembly (1). See Fig, 60 Note: ‘Tae master piston return spring Is con- {ained inside the master piston, Do not lanssomble tho master peton assembly Inthe fla, Inspect the master piston for damage. The piston surface most be {ree of score or wear marks, and must move freely inthe housing, bore. Visually inspect the spring to insure that itis not broken. See Fig. 5. ‘Refer to Fig. 62. Compress the return spring wsing a pick or probe (CD. White Holding the spring compressed, insert a small diameter pin 2) into the access hole and remove the probe. Insert the mastor piston into the housing bore, Install the anti rotation pin with the lockwasber into the housing and remave the pin so that the spring will be retained by the ai rotation pin ‘Tghton the anti-rotation pin with a 8/16 in. hex key wrench to 40 Ibin, (4.5 Nim). Seo Fig 63, “Move the piston in and out tobe sure it moves freely and thatthe spring returns the piston tothe bottom ofthe bore. SECTIONS ig. | Fig 51 Fig. 62Slave Piston Adjusting Screw (Clip Valve) Loosen slave piston adjusting sew locknut and remove adjusting screw from housing. See Fig. Nove: ‘Thopart number forthe srow soca at the top of the serow naxt to tha screw ‘vor sot. for tothe pats manual for oy Fig 5 pert number Ketiieation. [Acaurion Donet adjust or tamper with the adsting sro seb. Engine sanage cou ‘Clean in an approved cleaning solvent Inspect slave piston adjusting serow. The plunger should protrude from the bottm ofthe serew, have light spring pressure apparent ‘when depressed and should mave freely. See Fig. 55. Replace the entire serow assembly, ifany defect i found. Fig 85