User Manual

Page 5-52
200 BENCH PROCEDURES
pressure relay switch and related hardware. Its
purpose is to protect the Dynatard exhaust push
rod from overload and from possibly bending
during the transition from power mode to braking
mode. An overload condition occurs when the
turbocharger boost pressure in the inlet manifold
is greater than 25 psi (172.4 kPa). The pressure
delay switch momentarily restricts Dynatard
engine brake activation if turbocharger boost inlet
manifold pressure is above 24 psi (165.5 kPa).
PARTS REQUIRED FOR OVERLOAD
PROTECTION
앫 Dynatard pressure switch assembly
1MR3532*
앫 Engine brake wiring harness 41MR4381*
앫 Engine brake switch jumper wire
41MR21252
앫 Cylinder head capscrew 400GC39M4*
앫 Pressure switch clamp screw 66AM2*
앫 Wiring harness strap 48RU2313P1*
앫 Wiring harness strap 48RU2313P2
앫 Pressure switch clamp 83AX894*
앫 Engine brake switch harness bracket
72RU11120
앫 Engine brake switch harness clamp
83AX922
앫 Engine brake switch harness screw 64AM1
앫 Engine brake switch harness washer
271AM5007
앫 Engine brake switch harness nut 157AM2
*Required parts for V-MAC applications.
All parts listed are required for mechanical
applications.
Dynatard Overload Protection
System
INSTALLATION (E7 MECHANICAL ENGINES)
1. Remove air cleaner ducting.
2. Remove cylinder head covers.
3. Remove existing engine brake harness.
4. Remove No. 16 undrilled cylinder head
capscrew.
5. Lubricate and install cylinder head
capscrew, with a drilled hole, in No. 16
location.
6. Torque cylinder head capscrew to 205 lb-ft
(278 N•m) using torque wrench J 24407 or
equivalent.
7. Remove front 1/8 NPT pipe plug from inlet
manifold.
8. Install new Dynatard pressure delay switch
1MR3532 into pipe plug opening and tighten
with an open-end wrench.
9. Install new Dynatard wiring harness
41MR4381 using the following steps:
a. Lubricate connector O-rings and snap
connectors into cylinder heads.
b. Connect Dynatard wire harness
terminals to terminal post screws.
c. Connect Dynatard wire harness
terminal to Dynatard pressure delay
switch connection and route wire
through crossover loop connector
between heads.
10. Install valve covers.
11. Reuse three clamps, 83AX922, from old
engine brake harness and install on new
brake harness at appropriate locations.
12. Install clamp to Dynatard pressure delay
switch wire and position Dynatard engine
harness ground wire on clamp.
13. Install capscrew through clamp to No. 16
drilled cylinder head capscrew to securely
hold Dynatard pressure delay switch wire
and ground wire.
14. Attach wire tie(s) around Dynatard pressure
delay switch wire and fuel return jumper line
as needed.
15. Remove diode from existing Dynatard
injection pump throttle switch.
16. Install jumper wire No. 41MR21252 to
Dynatard injection pump throttle switch.
17. Install fuel injection line L-shaped bracket to
stud located on right side of engine block.
Secure engine brake lead to this bracket.
5-101.bk Page 52 Friday, March 17, 2006 11:05 AM