Plus | M-11 | Installation manual | Plus M-11 Installation manual

Plus M-11 Installation manual
Installation Manual For
ISM/ISM02/ISM07
M11/M11 Plus
Engines
Table of Contents
Safety Precautions
Section 1: Introduction..................................................... 3
Aftermarket Kits.................................................................
.3
Housing Identification...................................................... 3
Engine Identification........................................................ 3
Special Tools................................................................... 3
Automatic Transmissions................................................ 3
The following symbols in this manual signal potentially
dangerous conditions to the mechanic or equipment. Read
this manual carefully. Know when these conditions can exist.
Then, take necessary steps to protect personnel as well as
equipment.
Section 2: Engine Preparation...................................4 - 6
Crosshead and Adjusting Screws................................... 4
Exhaust Valve and Injector Adjustment............................ 5
Spacer Installation........................................................... 6
This symbol warns of possible personal injury.
Section 3: Engine Brake Housing Installation..........7 - 9
Brake Housing Installation............................................... 7
Slave Piston Adjustment................................................. 8
Slave Piston Lash Settings.............................................. 8
Installation of Oil Supply.................................................. 9
This symbol refers to possible
equipment damage.
Section 4: Electrical System Installation..............10 - 12
M11 CELECT™ Wiring Installation................................ 10
M11 CELECT™ Plus Wiring Installation........................ 11
ISM Wiring Harness...................................................... 11
ISM02 Wiring Harness.................................................. 12
Section 5: Engine Brake Operation Check.............13-14
Bleed and Operation Check.......................................... 13
Section 6: Engine Brake Maintenance..................15 -20
Theory of Operation...................................................... 15
Exhaust Blowdown....................................................... 15
Control Valve................................................................. 16
Solenoid Valve ............................................................. 18
Slave Piston Adjusting Screws (Reset).......................... 19
Ball Check.................................................................... 19
Master Piston................................................................ 20
Slave Piston.................................................................. 20
NOTE:
Indicates an operation, procedure
or instruction that is important for
correct service.
Fuels, electrical equipment, exhaust gases and moving
engine parts present potential hazards that could result in
personal injury. Take care when installing an engine brake.
Always use correct tools and proper procedures as outlined
in this manual.
See Driver’s Manual for proper engine brake driver techniques.
The cbrake by jacobs™ engine brake
is a vehicle slowing device, not a
vehicle stopping device. It is not a
substitute for the service braking
system. The vehicle’s service brakes
must be used to bring the vehicle to
a complete stop.
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 PLUS engines
Section 1: Introduction
Special Tools
Model 411/411C/D/E
Aftermarket Kits
P/N
3804584
3804585
3804586
3800765
4089395
4955458
Engine
M11/M11+
M11/M11+
M11/M11+
ISM
ISM02/04
ISM07
Brake
Model
411
411
411
411C
411D
411E
The following special tools should be available for the instal lation:
Description
12 V DC, S/L kit
24 V DC, S/L kit
24 V DC, D/L kit
12 V DC, D/L kit
12 V DC, S/L kit
12 VDC, S/L kit
1.
Injector adjusting tool: Torque wrench, Cummins
P/N 3376592
2.
Crowfoot: Cummins P/N 3823820
3.
Feeler gage/slave piston:
Cummins P/N 3871428, (0.015”)
Cummins P/N 3163172, (0.027")
*See Application Guide, P/N 3401804, for specific engine
model application information.
Housing Identification
A nameplate attached to the top surface of the engine brake
housing identifies the model number, part number, front or
rear housing and slave piston lash setting.
The housing serial number is stamped on the top surface of
the center master piston boss or on the nameplate.
For housing part number and other replacement part infor mation, refer to Cummins Bulletin No. 3698826, Jacobs
Parts Manual, P/ N 021475.
Engine Identification
Prior to engine brake installation, verify that engine is an
ISM, 2002 ISM, 2007 ISM, M11 or M11 Plus. The engine
identification is on the serial number plate located on the fuel
pump side below the rocker cover.
UNLESS OTHERWISE SPECIFIED, T HE
TORQUE VALUES LISTED IN THE TEXT
ARE DIRECT VALUES USING NO TORQUE
WRENCH ADAPTERS OR EXTENSIONS.
WHEN ADAPTERS OR EXTENSIONS ARE
USED WITH A TORQUE WRENCH, T HE
TORQUE VALUES MUST BE ADJUSTED
FOR THE SPECIFIC TOOLS BEING USED.
FOLLOW THE MANUFACTURER’ S RECOMMENDED PROCEDURES FOR THE TORQUE
WRENCH AND ADAPTER BEING USED.
Automatic
Transmissions
PRIOR TO INSTALLATION OF THE ENGINE
BRAKE ON VEHICLES WITH AUTOMATIC
TRANSMISSIO NS, WE RECOMME ND THAT
THE TRANSMISSIO N MANUFACTURER REPRESENTATIVE (DEALER) BE CONSULTED TO
BE SURE OF THE COMPATIBILITY OF THE
ENGINE BRAKE WITH THE SPECIFIC AUTOMATIC TRANSMISSIO N BEING USED.
CBRAKE BY JACOBS™ INSTALLATION MANUAL FOR CUMMINS ISM/ISM02, M11/M11 PLUS ENGINES
3
Section 2: Engine Preparation
Clean engine thoroughly. Remove engine valve cover and
gasket. Retain all parts.
NOTE:
REFER TO CUMMINS TROUBLESHOOTING & REPAIR MANUAL, SECTION 003-004 FOR OVERHEAD SET INFORMATION.
Crosshead and
Adjusting Screws
Cylinder 1, 3 and 5 Exhaust Valve Crosshead Replacement
and Injector Rocker Lever Adjusting Screws:
1. Rotate crankshaft by turning accessory drive shaft in
direction of rotation (clockwise, see Fig. 1). Align the
“A” valve set mark on the accessory drive pulley with
the pointer on the gear cover. Check the intake and exhaust valves of cylinder No. 1. All valves must be closed
(both crossheads loose) to make adjustments. If the
valves are not closed, rotate the engine one complete
revolution. The engine is now ready for valve and injector adjustments that will be made later.
2.Loosen locknuts and adjusting screws on injector and
exhaust valve rocker levers on cylinders 1, 3 and 5.
FIG. 1
CBRAKE by
JACOBS
CUMMINS
GUIDELESS
FIG. 2
NOTES: THE ROCKER LEVER FOR THE EXHAUST
VALVE CROSSHEAD IS THE LONGEST OF
THE THREE ROCKER LEVERS IN EACH
CYLINDER.
ALL M11 and ism ENGINES USE GUIDELESS CROSSHEADS (see fig. 2).
3. Remove the Cummins guideless exhaust valve crosshead from cylinders 1, 3 and 5 (see Fig. 3).
FIG. 3
DO NOT DISASSEMBLE THE ACTUATOR
PIN FROM THE JACOBS CROSSHEAD. THE
ASSEMBLY IS NOT SERVICEABLE IN THE
FIELD.
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 PLUS engines
4.Lubricate the actuator pins and valve stems with clean
lube oil and install the CBrake by Jacobs™ crossheads
over the exhaust valves. Locate the actuator pins on
the exhaust valves closest to the push rod side of the
engine (see Fig. 4).
5.The crosshead should move freely from side to side pivoting on the side without the actuator pin. No leveling
adjustment is required with guideless crossheads.
6. Remove the Cummins injector rocker lever adjusting
screws and install the CBrake by Jacobs™ injector
rocker lever adjusting screws and hex jam nut on cylinders 1, 3 and 5 (see Fig. 5).
7. Repeat steps 1 through 6 above for cylinders 2, 4 and 6.
FIG. 4
Exhaust Valve and
Injector Adjustment
NOTE:
OVERHEAD ADJUSTMENTS MUST BE MADE
WHEN THE ENGINE IS COLD: STABILIZED
COOLANT TEMPERATURE 140° F. (60° C.)
OR BELOW.
1. Refer to Fig. 6 to determine the correct order to set the
exhaust valve and injector adjustment.
2. Rotate the engine crankshaft clockwise to the desired
pulley position.
FIG. 5
Bar Engine
Dir. of Rotation
Pulley
Set Valves
Set Inj.
PositionCyl. No.Cyl. No.
Start
A
Advance to
B
Advance toC
Advance to
A
Advance to
B
Advance toC
1
5
3
6
2
4
1
5
3
6
2
4
FIG. 6
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 Plus engines
3. Place a 0.027” (0.68 mm) feeler gage between the
rocker lever and the crosshead of the exhaust valve
(see Fig. 7). Tighten the adjusting screw until a light
drag can be felt on the feeler gage. Hold the adjusting
screw and tighten the locknut to 45 lb.-ft. (61 N•m).
4.Turn the injector adjusting screw in and bottom the
injector plunger 3 to 4 times to remove fuel.
5. Bottom injector adjusting screw with a screwdriver.
6. Back out screw two flats (120°).
7. Hold screw and torque lock nut to 45 lb.-ft. (61 N•m).
8. Adjust valves and injectors in the same cylinder following the procedures in 1 through 7 above.
FIG. 7
Spacer Installation
1. MODEL 411 ONLY: Install two (2) electrical lead out
assemblies into spacer and torque to 10 lb.-ft.
(14 N•m) (see Fig. 8).
2. Install bulkhead fitting with seal into hole in spacer as
shown in Fig. 9. Seal must be located on the outside of
the spacer. Install nut and torque to 25 lb.-ft. (34 N•m).
3.Clean rocker housing. Cummins recommends the use
of RTV (Cummins P/N 3823494) between the rocker
housing and the spacer. If, however, you wish to use a gasket instead of the RTV, a gasket is included with
the kit.
FIG. 8
4. Starting from the center and proceeding outward on
both sides torque the capscrews to 15 lb.-ft. (20 N•m)
following the sequences shown in Fig. 10.
FIG. 9
13
9
5
1
3
7
11
17
14
15
18
10
6
2
4
8
12
16
FIG. 10
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 PLUS engines
Section 3: Brake Installation
Housing Installation
NOTE: ALSO REFERENCE CUMMINS TROUBLESHOOT-
ING & REPAIR MANUAL, SECTION 020-024 FOR ENGINE BRAKE FOR CLEANING, REMOVING, INSPECTING, INSTALLATION AND ADJUSTMENT.
Oil Supply Tube
1.Lubricate O-rings on oil supply tube and install into oil
supply hole in rear housing. Push tube in all the way
(see Fig. 11).
2. Install the O-ring adaptor into the front housing in the
location shown in Figure 12. Tighten the O-ring adaptor
as follows:
411
411C
411D
411E
24 lb.-ft
27 lb.-ft
27 lb.-ft
27 lb.-ft
FIG. 11
33 N•m
37 N•m
37 N•m
37 N•m
3. Make sure the slave piston adjusting screws on both
housings are backed out so all slave pistons are fully
retracted (screw is loose).
4. Place rear brake housing on rocker shaft supports for
cylinders 4, 5 and 6.
5. Install front housing so that the oil supply tube fits into
the oil supply hole of the front housing.
NOTE: No washers are used with the
CBRAKE BY Jacobs™ capscrews.
FIG. 12
6.Lubricate threads and underside of Jacobs hold-down
capscrews with clean lube oil.
7. Install the capscrews in the sixteen (16) locations and hand tighten following the sequence in Fig. 13.
Complete the sequence by tightening the capscrews
to 60 lb.-ft. (81 N•m).
MODEL 411, C, D, E
13
15
10
11
16
8
3
9
5
REAR
FRONT
12
2
14 6
1
4
7
FIG. 13
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 Plus engines
Slave Piston
Adjustment
PAY SPECIAL ATTENTION TO THIS ADJUSTMENT. TO ENSURE MAXIMUM BRAKE
OPERATING EFFICIENCY AND TO PREVENT
ENGINE DAMAGE, FOLLOW INSTRUCTIONS
CAREFULLY.
Slave Piston Lash Settings
Model
411
411
411C
411D
411E
FIG. 14
Engine
M11
M11 Plus
ISM
2002 ISM
2007 ISM
Setting
0.015”
0.015”
0.015"
0.015"
0.027"
1. Slave piston lash setting is printed on the housing
nameplate.
2. Slave piston adjustment must be made with the engine
stopped and cold (stabilized water temperature of 140°
F., 60° C., or below).
3. Exhaust valves on the cylinder to be adjusted must be closed.
FIG. 15
4. Install the appropriate feeler gage (.027" for 411E, .015"
for all others) between the slave piston and the actuating pin in the crosshead (see Fig. 14). Turn the slave
piston adjusting screw until a slight drag on the feeler
gage can be felt.
5. Hold screw in position with a screwdriver (see Fig.
15) (Model 411E ONLY - Hold screw in position with
wrench on hex head - See Fig. 15A). Torque locknut to
25 lb.-ft. (34 N•m)
OVERTORQUING LOCKNUT COULD SEIZE
RESET MECHANISM IN SLAVE PISTON
ADJUSTING SCREW. THIS WILL RESULT IN POOR ENGINE BRAKE PERFORMANCE.
(see note on page 3).
FIG. 15 A
NOTE:
After torquing the slave piston
adjusting screw locknut, check
the clearance with the feeler gage.
Readjust if necessary.
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 PLUS engines
Installation of Oil
Supply
DO NOT CONNECT THE ENGINE BRAKE OIL
SUPPLY TO THE SAME LOCATION USED
FOR THE TURBOCHARGER OIL SUPPLY.
SERIOUS ENGINE DAMAGE MAY RESULT.
1. Remove the plug from the rear, inboard filter head location and install the new fitting with seal ring. Tighten the
fitting to 27 lb.-ft. (37N•m) (Fig.16).
FIG. 16
KEEP HOSE CLEAR OF ALL POTENTIAL
HOT ENGINE COMPONENTS AND FREE
FROM RUBBING ON ENGINE OR CHASSIS.
A RUPTURED HOSE WILL SPRAY HOT OIL
AND COULD CAUSE HEAVY SMOKE OR FIRE
UPON HITTING HOT ENGINE COM­PONENTS.
2.Connect the external hose to the bulkhead fitting in the
spacer. Install the hose clamps and attach to the bolt in
the intake manifold (Fig.17).
note: 411e has 3 clips
instead of 4 as previous
models. Holding those
3 clips are two new
screws
* Model 411E has different clip
configuration - See note below
FIG. 17
3821783 15 lb.-ft
3036230
35 lb.-ft
3818060 40 lb.-ft *
arleady exists on engine
3. Route the hose behind the coolant filter and connect to
the O-ring adapter as follows:
411
411C
411D
411E
12 lb.-ft
19 lb.-ft
19 lb.-ft
19 lb.-ft
16 N•m
26 N•m
26 N•m
26 N•m
4. Install short hose between housing adaptor and bulkhead fitting. Torque fitting nuts as follows:
(Fig.18)
411
12 lb.-ft 16 N•m
411C 19 lb.-ft 26 N•m
411D 19 lb.-ft 26 N•m
411E 19 lb.-ft 26 N•m
CBRAKE by JACOBS
FRONT HOUSING
HOSE ASSEMBLY
Torque per
paragraph 3
BULKHEAD NUT
Torque per paragraph 4
Torque per
paragraph 3
SPACER
SEAL
BULKHEAD FITTING
WITH NUT
FIG. 18
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 Plus engines
Section 4: Electrical Installation
M11 CELECT™ Wiring Installation
NOTE:
ACTUATOR CONNECTOR
PIN 10
PIN 10
OEM
CONNECTOR
ORANGE
WHITE
PIN5
PIN 5
PIN 18
PIN C
TWOPOSITION
SWITCH
ON/OFF
POWER
SWITCH
HARNESS
JUMPER
CONNECTOR
PIN F
PIN G
PIN F
BLUE
ELECTRONIC
CONTROL
MODULE
YELLOW
SILVER
TERMINALS
RED
GOLD
TERMINALS
10 AMP - 12V
CIRCUIT BREAKER
OR FUSE
PIN G
PIN H
OEM INTERFACE
CONNECTOR
FRONT OF ENGINE
PINK
BROWN
PIN B
PIN H
GRAY
GREEN
GROUND
REAR HOUSING
FRONT HOUSING
PIN 30
PINK PIN 86
GREEN
PIN 85
BROWN
NOT
USED
YELLOW
PIN 87A
NOT USED
BLUE
NOT
USED
DIODE
NOT
USED
PIN 87
GRAY
FIG. 19
ALL CUMMINS M11 ENGINES HAVE ELECTRONIC CONTROLS (CELECT™).
Install the relay base under the dash at a convenient location
in order to make the following wiring connections:
1.Connect the RED wire from the input terminal (silver
coated) to a 10-amp, 12-volt circuit breaker electrical
source.
2.The BLUE wire should be connected from the output
side of the selector switch as shown in the diagram, to pin “G” of the Cummins interface connector.
IT IS EXTREMELY IMPORTANT THAT A
SECURE GROUND CONNECTION IS MADE.
FAILURE TO DO SO WILL RESULT IN POOR
ENGINE BRAKE OPERATION.
1.Connect the GREEN wire to a good engine ground.
2.Connect the PINK wire to the output side of the ON/
OFF brake switch.
3.Connect the GRAY wire to the input side of the selector
switch.
3.Connect the YELLOW wire from the output side of the
selector switch to pin “H” of the Cummins interface
connector.
4.The ORANGE wire is connected from the output side of
the on/off switch (gold plated terminal) to pin 10 of the
Cummins electronic control module.
5.Connect the WHITE wire from the input side of the
ON/OFF switch (gold plated terminal) to pin 5 of the
Cummins electronic control module.
4.Connect the BROWN wire to the Cummins interface
connector, pin “F”.
Additional electrical connections (wiring to be provided by
the installer):
10
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 PLUS engines
M11 Plus CELECT™
Plus Wiring Installation
(Model 411)
ELECTRICAL CONTROL SYSTEM
ENGINE BRAKE MODEL 411 FOR ’95 M11 PLUS ENGINE
PURPLE
A B
B A
PURPLE
REAR HOUSING
PIN 18
FRONT HOUSING
PIN 19
GRAY
PIN 28
PIN 5
ACTUATOR
PORT
28
2-POSITION
SWITCH
5
OEM
PORT
PIN 10
B
C
10
18
19
NOTE: ALL CUMMINS M11 PLus ENGINES HAVE
ELECTRONIC CONTROLS (CELECT
plus).
1. For proper wiring installation, make all electrical connections as shown in Fig. 20.
2.Connect brake wiring harness to Cummins ECM Interface Connector. Connect PURPLE and GRAY leads to
A
ELECTRONIC CONTROL
MODULE (ECMc)
ON/OFF
SWITCH
FIG. 20
15
14
13
ISM Wiring Installation
(Models 411C)
15 pin pass
thr ough connector
White wir e and
Black wi re
Brake Har ness
Red wire and
Black wire
Pass Thr ough Pin 13
Pass Thr ough Pin 14
Pass Thr ough Pin 15
For proper electrical wiring installation, make all electrical connections as shown in Figure 21, observing the following:
Fr ont Housing
Rear Housing
Actuator Pin 44 (Engine Brake #1)
Actuator Pin 15 (Engine Brake #2)
Actuator Pin 31 (Engine Brake Retur n)
Existing Engine Harness
OEM Pin 22 (LO)
OEM Pin 31(HI )
Installer Pr ovided
Wi re s
2 POSITION
SWITCH
9
31
22
C1
OEM POR T (KEY 04)
31 15
44
C2
C3
ACTUATOR POR T (KEY02) SENSOR POR T (KEY 03)
DCM570
1.Connect the Solenoid Harness to the existing engine injector harness under the valve cover. Connect the
RED lead on the Solenoid Harness to either terminal of
the solenoid on the rear housing. Connect the WHITE
lead to the solenoid on the front housing. Connect
one BLACK lead to each remaining terminal of both
solenoids.
2. All connections between the Cummins Electronic
Control Module and the engine brake ON/OFF and
HI/LOW switches are to be made with wiring provided
by the installer.
OEM Pin 9*
(Common)
ON/OFF
SWITCH
* Pin 10 or 19 can be used as alternates to Pin 9 for Common Ground.
FIG. 21
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 Plus engines
11
ISM02 Wiring
Installation
(Models 411D)
14
13
Brake Harness
White wire
Red wire
Pass Through Pin 13
Pass Through Pin 14
Front Housing
Rear Housing
Actuator Pin 32 (Engine Brake #1)
Actuator Pin 51 (Engine Brake #2)
For proper electrical wiring installation, make all electrical
connections as shown in Figure 22, observing the following:
Existing Engine Harness
OEM Pin 18(LO)
OEM Pin 08(HI)
Installer Provided
Wire s
2 POSITION
SWITCH
04
01
C3
03
51
32
34
08
18
02
C2
C1
OEM PORT (KEY 04)
1.Connect the solenoid harness to the existing engine injector harness under the valve cover. Connect the
RED lead on the solenoid on the rear housing. Connect
the WHITE lead to the solenoid on the front housing.
2. All connections between the Cummins Electronic
Control Module and the engine brake ON/OFF and
HI/LOW switches are to be made with wiring provided
by the installer.
ENGINE PORT (KEY 07)
OEM Pin 34*
(Common)
DCM870
NOTE:
ON/OFF
SWITCH
FIG. 22
12
Jacobs wiring is
not required on
ism07 (Model 411e)
- see vehicle oem
for wiring details
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 PLUS engines
Section 5: Brake Operation Check
The CBrake by Jacobs™ Model 411, 411C, 411D, & 411E
installation is now complete. The following procedures and
adjustments should be made.
Recheck the housing installation. Be certain no foreign
objects have been left behind and all correct clearance
requirements have been met.
Bleed and Operation
Check
WEAR EYE PROTECTION AND DO NOT
EXPOSE YOUR FACE OVER ENGINE AREA.
TAKE PRECAUTIONS TO PREVENT OIL
LEAKAGE DOWN ON THE ENGINE. WHEN
ENGINE IS RUNNING AND VALVE COVERS
ARE REMOVED, OIL SPLASHING IN THE
ENGINE BRAKE AREA COULD CAUSE PERSONAL INJURY.
For Wastgate and Non- Wastgate Engines
1. Assure that the control wires are connected to the
terminal assemblies in engine brake spacers
(411 only).
2.
Bleed brake housings and check their operation. Start engine and allow to run 5 to 10 minutes.
Put dash switch in “LO”. Accelerate engine to
approximately 1800 RPM and release throttle.
Only one solenoid valve should operate.
3. Repeating this procedure for position “HI”, both solenoids should operate. Repeat this procedure several
times to bleed brake housings for immediate operation.
For EGR/ VGT Engines
1. Bleed brake housings and check their operation. Start engine and allow to run 5 to 10 minutes.
Put dash switch in “HI”. Accelerate engine to
approximately 1800 RPM and release throttle.
Both solenoid valves should operate.
2. Repeat this procedure several times to bleed brake
housings for immediate operation.
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 Plus engines
13
Replace Rocker Lever Cover
1. Remove the gasket and inspect for damage.
2. If the gasket is not damaged, it can be used again. If
the gasket is damaged, it must be discarded and a new
one used.
3. Set the new Cummins gasket on the cover.
4. Install flat washer, new sleeve and new noise isolator on
the capscrew (see Fig. 23).
FIG. 23
5. Install the capscrew assemblies in the cover (Fig. 24).
6. Install the cover on the spacer and tighten the cover
capscrews to 130 lb.-in. (15 N•m) in the sequence
shown in Fig. 25.
NOTE: ALSO REFERENCE CUMMINS TROUBLE SHOOTING & REPAIR MANUAL, SECTION 003-011FOR ROCKER LEVER COVER
INSTALLATION.
FIG. 24
FIG. 25
14
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 PLUS engines
Section 6: Brake Maintenance
Theory of Operation
1.The energized solenoid valve permits engine lube oil to
flow under pressure through the control valve to both
the master piston and the slave piston.
Energizing the engine brake effectively converts a powerproducing diesel engine into a power-absorbing air
compressor. This is accomplished through motion transfer
using a master/slave piston arrangement which opens
cylinder exhaust valves near the top of the normal compression stroke, releasing the compressed cylinder charge to
exhaust.
2. Oil pressure causes the master piston to move down,
coming to rest on the injector rocker arm adjusting
screw.
3.The injector rocker arm adjusting screw begins upward
travel (as in normal exhaust cycle), forcing the master
piston upward and directing high pressure oil to the
slave piston. The ball check valve in the control valve
imprisons high-pressure oil in the master/slave piston
system.
The blowdown of compressed air to atmospheric pressure prevents the return of energy to the engine piston on
the expansion stroke. The effect is a net energy loss, since
the work done in compressing the cylinder charge is not
returned during the expansion process.
4.The slave piston, under the influence of the high-pressure oil moves down, momentarily opens the exhaust
valve while the engine piston is near its top dead-center position, releasing compressed cylinder air to the
exhaust manifold.
Exhaust Blowdown
Referring to Fig. 26, exhaust blowdown occurs as follows:
5.Compressed air escapes out to the atmosphere, completing a compression braking cycle.
SOLENOID
VALVE
CONTROL
VALVE
OIL IN
LOW
BALL
PRESSURE CHECK
OIL
VALVE
ADJUSTING
SCREW
HIGH
PRESSURE
OIL
MASTER
PISTON
SLAVE
PISTON
GUIDELESS
CROSSHEAD
EXHAUST
ROCKER
LEVER
INJECTOR
PUSHROD
EXHAUST VALVES
FIG. 26
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 Plus engines
15
The CBrake by Jacobs™ is a relatively trouble-free device.
However, inspections and routine maintenance will need to be made from time to time. Use the following procedures
to keep the engine brake in top condition.
This section will cover how to properly remove, clean and reinstall engine brake components. Use an OSHA-approved cleaning solvent when washing parts. Be sure to
coat parts with clean engine oil when reinstalling them.
SOLENOID
VALVE
SLAVE PISTON
ADJUSTING
SCREW
(RESET)
CONTROL
VALVE
Never remove any engine brake
component with engine running.
Personal injury may result.
Control Valve
Remove control valve covers carefully. Control valve covers are
under load from the control valve
springs. Remove with care to avoid
personal injury.
MASTER
PISTON
SLAVE
PISTON
FIG. 27
1. Apply pressure on the control valve cover and remove
retaining ring using retaining ring pliers (see Fig. 28).
FIG. 28
16
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 PLUS engines
2. Slowly remove cover until spring pressure ceases, then remove the control valve springs and collar (see Fig. 29).
3. Using needle-nose pliers, remove the control valve (see Fig. 30).
4. Wash the control valve with approved cleaning solvent.
Push a wire through the hole in the base of the valve
to ensure that the ball check is free. The ball should
lift with light pressure on the wire. If the ball is stuck or
there is no spring pressure, replace the control valve.
Dry the valve with compressed air and wipe clean with
a paper towel.
5.Thoroughly clean the control valve bore in the housing
using clean paper towels.
6.Dip the control valve in clean lube oil. Drop the valve
into its bore. If binding occurs, the control valve should
be replaced.
FIG. 29
7. Reassemble the parts, reversing the removal procedure. Be sure retaining ring ears are positioned
opposite the oil drain slot in the housing (see Fig. 31).
NOTE:
Be sure the control valve collar
is installed with the longer sleeve
area up (see BELOW). If the collar is
installed upside down, this brake
cylinder will not operate.
UP
FIG. 30
FIG. 31
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 Plus engines
17
Solenoid Valve
1.Disconnect the solenoid harness. Using a 3/4” socket and extension, unscrew the solenoid valve (see Fig. 32).
Do not disassemble or tamper with
the solenoid valve. Engine damage
could result.
2. Remove and discard the three rubber seal rings (Fig.
33). If the lower ring stays in the bottom of the housing
solenoid bore, remove with a seal pick.
FIG. 32
3. Wash out the solenoid valve with approved cleaning
solvent. Use a brush to clean the oil screen. Clean and
dry the valve with compressed air. Replace oil screen, if
necessary.
4.Clean out the solenoid valve bore in the housing. Use
clean paper towels. Never use rags, as they may leave
lint and residue which can plug the oil passageways.
5. Reinstall the solenoid using new seal rings. Seat lower
seal ring in the base of the solenoid valve bore. Wipe
clean lube oil into and around the bore. Place upper
and center seal rings on the solenoid valve body.
6. Be sure the seals are seated properly and carefully and
screw the solenoid into the housing without unseating
the seals. Torque the valve to 15 lb.-ft. (20 N•m) (see
Fig. 34).
UPPER SEAL
CENTER SEAL
LOWER SEAL
FIG. 33
FIG. 34
18
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 PLUS engines
Slave Piston Adjusting
Screws (Reset)
1.Loosen slave piston adjusting screw locknut and remove adjusting screw from housing (Fig. 35).
2.Clean adjusting screw in an approved cleaning solvent.
3. Inspect the slave piston adjusting screw. The plunger
should protrude from the bottom of the screw, have
light spring pressure apparent when depressed, and
should move freely (Fig. 36). Be sure the retaining ring
is fully engaged in its groove. Replace the entire screw
assembly if any defect is found.
FIG. 35
Do not readjust or tamper with the
adjusting screw assembly. Engine
damage could result.
Ball Check Valve
1. Remove hex socket pipe plug. Be careful during final
turns to avoid losing the spring and ball. Remove spring
and ball (Fig. 37).
2. Inspect, clean in an approved cleaning solvent and
replace as required.
FIG. 36
3. Reassemble, inserting first the ball, then the spring and
plug. Torque the plug to 106 lb.-in. (12 N•m).
Install parts in the order shown.
Improper installation may result in
engine damage.
FIG. 37
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 Plus engines
19
Master Piston
1. Remove the button-head screw, washer and master
piston spring from bottom of housing.
2. Remove the master piston from its bore using needlenose pliers. If binding occurs, check for burrs or
contaminants in the lube oil. Clean in an approved
cleaning solvent (Fig. 38).
NOTE:
Do not attempt to remove the master piston without first removing
the flat spring. Bending the spring
back too far can distort the spring
and would need to be replaced.
FIG. 38
3. Inspect the hard face surface. A pitted, chipped,
cracked or galled piston should be replaced. If the hard
facing is damaged, inspect the corresponding rocker
arm adjusting screws for excessive wear or pitting.
Replace if damaged.
4. Reassemble in reverse order. When tightening the capscrew, make certain the two spring tabs do not interfere
with the sides of the master piston center raised portion
(see Fig. 39). Torque the capscrew to
8 - 10 lb.-ft. (11 - 13 N•m).
NOTE:
The tabs should be equally spaced
from the raised piston area.
FIG. 39
Slave Piston
Wear safety glasses. Remove slave
piston carefully. The slave piston is
retained by springs that are under
heavy compression. If the following
instructions are not followed and
proper tools not used, the spring
could be discharged with enough
force to cause personal injury.
Remove the locknut on the slave piston adjusting screw.
Back out the adjusting screw until the slave piston is fully
retracted (screw is loose).
Use the slave piston removal tool and the following procedure to remove and replace the slave piston:
1. Place the hole in the clamp bracket over the slave piston adjusting screw (Fig. 40).
FIG. 40
20
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 PLUS engines
2. While holding the tool in position, screw the holder
down over the slave piston stem until the retainer is
contacted.
3.Turn the handle slowly until the retainer is depressed,
about 1/32” (1 mm), relieving pressure against the
retaining ring.
4. Remove the retaining ring using retaining ring pliers.
Back out the holder until the springs are loose. Remove
the tool (see Fig. 41).
5. Remove the retainer, spring and slave piston. Check for
nicks or burrs that could cause binding (see Fig. 42).
6.Clean the piston in an approved cleaning solvent. Run
a small wire through any holes. Replace the piston if the
ground surface on the outside diameter is scratched or
scored.
NOTE:
Be sure all components are reassembled in correct order.
FIG. 41
7. Install the slave piston into the bore. Install the springs
and retainer over the slave piston foot.
8. Use the removal tool to compress the slave piston and springs down until the retainer is about 1/32” (1 mm) below the retaining ring groove.
9. Slide the retaining ring over the threaded rod of the
removal tool and reinstall the retaining ring in its groove.
Be sure the retaining ring is fully engaged in the groove.
10. Remove the tool slowly to ensure proper seating of
retaining ring.
11. Assemble the locknut; do not tighten.
FIG. 42
cBRAKE BY JACOBS™ installation MANUAL for CUMMINS ISM/ISM02, M11/M11 Plus engines
21
Jacobs Vehicle Systems
22 E. Dudley Town Road
Bloomfield, CT 06002
U.S.A.
Cummins Inc.
Box 3005
Columbus, IN 47202-3005
U.S.A.
www.cummins.com
CELECT™ is a trademark of
Cummins Inc.
Bulletin 3698827
CBrake by Jacobs™ is a trademark of
Cummins Inc. and
Jacobs Vehicle Systems
Jacobs® is a registered trademark of
Jacobs Vehicle Systems
Printed in U.S.A. 01/07
© 2006 Cummins Inc.
For additional support, visit www.jacobsvehiclesystems.
Jacobs P/N 021474 Rev. E
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