Installation Manual For ISL98, ISL03, ISL07, ISC07 · CBRAKE BY JACOBS™ INSTALLATION MANUAL for...
Transcript of Installation Manual For ISL98, ISL03, ISL07, ISC07 · CBRAKE BY JACOBS™ INSTALLATION MANUAL for...
Installation Manual For ISL98, ISL03, ISL07, ISC07
� CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES
Table of ContentsSection 1: Introduction ................................................... 3 HousingIdentification..................................................... 3 EngineIdentification....................................................... 3 SpecialTools.................................................................. 3 AutomaticTransmissions............................................... 3
Section 2: Engine Preparation ..................................4 - 5 CrossheadandAdjustingScrews................................... 4Section 3: Engine Brake Housing Installation .........6 - 7 BrakeHousingInstallation.............................................. 6 SlavePistonAdjustment................................................ 6Section 4: Electrical System Installation .................8 - 9 WiringInstallation........................................................... 9Section 5: Engine Brake Operation Check ................. 10 BleedandOperationCheck......................................... 10
Section 6: Engine Brake Maintenance .................11 -17 TheoryofOperation..................................................... 11 ExhaustBlowdown...................................................... 11 ControlValve................................................................ 12 SolenoidValve............................................................ 14 SlavePistonAdjustingScrews..................................... 15 MasterPiston............................................................... 16 SlavePiston................................................................. 16
Safety PrecautionsThefollowingsymbolsinthismanualsignalpotentiallydangerousconditionstothemechanicorequipment.Readthismanualcarefully.Knowwhentheseconditionscanexist.Then,takenecessarystepstoprotectpersonnelaswellasequipment.
THISSYMBOLWARNSOfPOSSIBLEPER-SONALINJURY.
THISSYMBOLREfERSTOPOSSIBLEEqUIPMENTdAMAGE.
NOTE:INdICATESANOPERATION,PROCEdUREORINSTRUCTIONTHATISIMPORTANTfORCORRECTSERVICE.
fuels,electricalequipment,exhaustgasesandmovingenginepartspresentpotentialhazardsthatcouldresultinpersonalinjury.Takecarewheninstallinganenginebrake.Alwaysusecorrecttoolsandproperproceduresasoutlinedinthismanual.
SEEdRIVER’SMANUALfORPROPERENGINEBRAKEdRIVERTECHNIqUES.
THECBRAKEBYJACOBS™ENGINEBRAKEISAVEHICLESLOWINGdEVICE,NOTAVEHICLESTOPPINGdEVICE.ITISNOTASUBSTITUTEfORTHESERVICEBRAKINGSYSTEM.THEVEHICLE’SSERVICEBRAKESMUSTBEUSEdTOBRINGTHEVEHICLETOACOMPLETESTOP.
Aftermarket Kits
P/N Brake Model Engine Desc.4089653490 ISL 12VdCKit4089626490A ISL03 12VdCKit4089626490A ISL07 12VdCKit4089626490A ISC07 12VdCKit
CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES �
Section 1: IntroductionHousing IdentificationAnameplateattachedtothetopsurfaceoftheenginebrakehousingidentifiesthemodelnumber,partnumber,frontorrearhousingandhousingserialnumber.
forhousingpartnumberandotherreplacementpartinfor-mation,refertoCumminsBulletinNo.3401838,JacobsPartsManual,P/N026301.
Engine IdentificationPriortoenginebrakeinstallation,verifythatengineisanISLISL03,ISL07,orISC07.Theengineidentificationisontheserialnumberplatelocatedonthefuelpumpsidebelowtherockercover.
Application NotesEngineBrakesshouldnotbeusedincombinationwithanexhaustbrake.
for24voltapplications,ordertwo(2)of24Vsolenoidp/n4089625andstampthebrakedataplateas24V.
THE490ABRAKEISAPPROVEdfORUSEONTHEISC07ENGINEONLY.THE490ABRAKEISNOTAPPROVEdfORUSEONPRIORISCENGINEMOdELS
ISL03/ISL07/ISC07OntheISL03enginethevalvecovermustbereplacedwheninstallingaenginebrake.Thevalvecoverisnotincludedintheaftermarketkitandshouldbeorderedseperately.Replaceshortvalvecover3967770withtallcover3967777(frontfill),3967763with3967773(rearfill),or3967766with3967776(nooilfill).
ISLWheninstallinganenginebrakeontheISLengineanewturboactuatorisrequiredduetoincreasedbackpressure.Actuatorkit4030234neededforturbos3597581,3597586,3597600;kit4030233neededforturbos3597576,3597584.Allotherturbos—noactuatorchangeneeded.
Somevalvecoversarenotenginebrakecompatibleandwillneedtobereplacedduringinstallation.Pleaseverifyyourvalvecoveriscompatible.
Engine Brake Part Number Description Compatible
3945615 frontOilfill,ValveCover No 3945436 frontOilfill,ValveCover Yes 3945834 RearOilfill,ValveCover Yes 3945833 RearOilfill,ValveCover No 3945970 RearOilfill,ValveCover Yes 3945971 frontOilfill,ValveCover Yes 3991608 NoOilfill,ValveCover Yes
� CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES
Special ToolsThefollowingspecialtoolsshouldbeavailablefortheinstal-lation:
1. Torque6in-lbwrench,CumminsP/N3376592.
2. EngineBarringtoolCumminsP/N3824591.
3. feelergage/slavepiston: CumminsP/N3613681,(0.090”)
Recommended Torque ValuesMountingSpacer 60N.m(45lb-ft.)HexagonalflangeHead capscrew(P/N3945232) 60N.m(45lb-ft.)OilSupplyScrew 7N.m(5lb-ft.)HexagonalflangeHead capscrew(P/N3927064) 32N.m(23lb-ft.)Cap,AdjNut 35N.m(25lb-ft.)Nut,ValveAdj 35N.m(25lb-ft.)Nut,d-Lash 35N.m(25lb-ft.)
UNLESSOTHERWISESPECIfIEd,THETORqUEVALUESLISTEdINTHETExTAREdIRECTVALUESUSINGNOTORqUEWRENCHAdAPTERSORExTENSIONS.WHENAdAPTERSORExTENSIONSAREUSEdWITHATORqUEWRENCH,THETORqUEVALUESMUSTBEAdJUSTEdfORTHESPECIfICTOOLSBEINGUSEd.fOLLOWTHEMANUfACTURER’SRECOM-MENdEdPROCEdURESfORTHETORqUEWRENCHANdAdAPTERBEINGUSEd.
Automatic Transmissions
PRIORTOINSTALLATIONOfTHEENGINEBRAKEONVEHICLESWITHAUTOMATICTRANSMISSIONS,WERECOMMENdTHATTHETRANSMISSIONMANUfACTURERREPRESENTATIVE(dEALER)BECONSULTEdTOBESUREOfTHECOMPATIBILITYOfTHEENGINEBRAKEWITHTHESPECIfICAUTOMATIC
CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES �
Section 2: Engine PreparationCleanenginethoroughly.Removeenginevalvecoverandgasket.Retainallparts.
Crosshead and Adjusting Screws 1. Removetheplasticpumpdrivecoverlocatedonthe
frontoftheengine.Thiswillexposethefuelpumpgearsandtimingmarks(fig.1).
2. Usingthebarringtool,PartNo.3824591,rotatethecrankshafttoalignthemarkonthefuelpumpgearwiththetopdeadcentermarkonthegearcover(fig.2).
3. RemoveIntakerockerlevermountingstudsoncylin-ders1and4.Replacewithnewenginebrakeoilsupplystuds.Torqueto60N•m[45ft-lb].
4. Adjustintakelash0.305mm[0.012in]oncylinders1,2,and4.
NOTE:REfERENCEENGINEMANUALfORIN-STRUCTIONONSETTINGINTAKEVALVELASH.
5. RemoveexhaustrockerlevermountingstudsonCylin-ders1,3,and5.
6. RemoveexhaustcrossheadsandreplacewithCBrakebyJacobsCross™heads(fig.3).
7. Installnewexhaustrockerlevermountingstuds(thesewillaccepttheenginebrakemountingbolts).Torqueto60N•m[45ft-lb].
8. Removeexhaustrockeradjustingscrewlocknutoncylinders1,3,and5.Replacelocknutswithlongerlocknutprovidedinthekit.donottightenatthistime.
9. Adjusttheexhaustvalvelashto0.559mm[0.022in]oncylinders1,3,and5.Tightenlocknutto25N•m[20ft-lb].Installsphericalnutontolonglocknutandtorqueto40N•m[30ft-lb].
NOTE:REfERENCEENGINEMANUALfORIN-STRUCTIONONSETTINGExHAUSTVALVELASH.
10. Checkexhaustvalvelashoncylinders1,3,and5.Ad-justmentmayhavemovedwhentorquingthesphericalnut.Readjustasnecessary.
11. Usingtheenginebarringtool,PartNo.3824591,rotatethecrankshaft360degreestoalignthemarkonthefuelpumpgearwiththemarkonthegearcoverthatis180degreesawayfromtopdeadcenter(fig.4).
12. Adjustintakelash0.305mm[0.012in]oncylinders3,5,and6.
FIG. 1
FIG. �
FIG. �
FIG. �
� CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES
13. Removeexhaustrockerlevermountingstudsoncylin-ders2,4,and6.
14. RemoveexhaustcrossheadsandreplacewithCBrakebyJacobs™crossheads(fig.3).
15. Installnewexhaustrockerlevermountingbolts(thesewillaccepttheenginebrakemountingbolts).Torqueto60N•m[45ft-lb].
16. Removeexhaustrockeradjustingscrewlocknutoncylinders2,4,and6.Replacelocknutswithlongerlocknut.donottightenatthistime.
17. Adjusttheexhaustvalvelash(0.559mm/0.022in)oncylinders2,4,and6.Tightenlocknutto25N•m[20ft-lb].Installsphericalnutontolonglocknutandtorqueto40N•m[30ft-lb].
18. Inspectexhaustvalvelashoncylinders2,4,and6.Ad-justmentmayhavemovedwhentorquingthesphericalnut.Readjustasnecessary.
19.Installsixbrakemountingspacerstudsintopretappedholes.Torqueto60N•m[45ft-lb].
CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES �
Engine Brake Installation1. Makesurethehousingadjustingsleevesareflushwith
thebottomofthehousingorrecessed.
2. Applyoiltotheoilsupplyscrewo-ringsandslidehous-ingsdownandintoposition.
3. Place3mountingboltsinthemountingboltholesontheslavepistonsideofthebrakehousing(nexttoslavepistonadjustingscrews).Tightenthethreeboltsto7N•m[5ft-lb](fig.5).
4. Screwdownthethreehousingadjustingsleevesuntiltheyjustmakecontactwiththerockerarmpedestals.
5. Placethe3remainingmountingboltswithhardenedwashersintotheadjustingsleevesandhandtighten.Brakeshouldbeflatonrockerarmpedestalandspac-er.Torquethe6mountingboltsto32N•m[23ft-lb].
6. Installelectricalharnessfromeachenginebrakesole-noidtothespacerpass-throughconnector.
FIG. �
FIG. �
FIG. �
Section 3: Engine Brake
For ISL98 Only:Spacer Installation1. Cleanrockerhousing.Applysealanttospacer.Place
spaceronposition.
2. Handstartthefivespacerbolts(thesewillacceptthecoverscrews).Startingfromthecenterandpro-ceedingoutwardonbothsidestorquetheboltsto32N•m[23ft-lb].
� CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES
FIG. 9
FIG. �
Slave Piston Adjustment
NOTE: AdJUSTTHESLAVEPISTONCLEARANCEWITHTHEENGINESTOPPEdANdCOLd.STABILIzEdWATERTEMPERATUREOf140°f.(60°C.)ORBELOW.ExHAUSTVALVES,ONTHECYLINdERTOBEAdJUSTEd,MUSTBEINTHECLOSEdPOSITION.
1. TheTdCmarkonthefuelpumpgearshouldalreadybeat180degreesfromTdC.Inthispositiontheenginebrakeslavelashoncylinders2,4,and6canbeset.(fig.8)
2. Inserttheappropriatebrakelashfeelergauge(P/N3163681(0.090”)betweenthebrakeslavepistonandexhaustheadpinoncylinderone.
3. Usingthe6in-lbtorquewrench,P/N3376592,tightentheadjustingscrewuntilthetorquewrench“clicks”orifnotusingatorquewrench,untildragisfeltonthefeelergage.
4. Usingtwowrenchs,holdtheadjustingscrewandtightenthelocknutto35N•m[26ft-lb].Ifalightdragisnotfeltonthefeelergagereadjustasnecessary.
5. Repeatsteps2-4forcylinders4and6.
6. Usingthebarringtool,PartNo.3824591,rotatethecrankshafttoalignthemarkonthefuelpumpgearwiththetopdeadcentermarkonthegearcover(12o’clock)(fig29).
7. Whentheengineisinthetopdeadcenterposition,SlavePistonLashcanbesetoncylinders1,3,and5.
8. Repeatsteps2-4forcylinders1,3,and5.
9. Installtheplasticdrivecoverlocatedonthefrontoftheengine.
CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES 9
Section 4: Electrical Installation
FIG. 10
ISL Wiring Installationforproperelectricalwiringinstallation,makeallelectricalcon-nectionsasshowninfigure10,11,12and13observingthefollowing:
1. Connectthecompressionbrakejumperharnessconnectortotheexistingbreakoutfromtheenginehar-nessconnector.Connectthetwoleadstotheoutsideoftheenginebrakespacer.
FIG. 11
Wiring for Manual Transmissions
2. AllconnectionsbetweentheCumminsECM(Electronic ControlModule)andtheenginebrakeON/Offswitch
aremadewithwiringprovidedbytheinstaller.
3 OptionalHI/LOWswitchesaretobemadewithwiringprovidedbytheinstallerandpluggedinplaceofthejumperplug.
Wiring for Automatic Allison World AT & HT Transmissions
10 CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES
Wiring for Allison World Transmissions with WTEC III Controllers
Wiring for Allison 1000 and 2000 series Transmissions
FIG. 1�
FIG. 1�
CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES 11
TheCBrakebyJacobs™ISL98/ISL03/ISL07/ISC07engineinstallationisnowcomplete.Thefollowingproceduresandadjustmentsshouldbemade.
Recheckthehousinginstallation.Becertainnoforeignobjectshavebeenleftbehindandallcorrectclearancerequirementshavebeenmet.
Bleed and Operation Check
WEAREYEPROTECTIONANddONOTExPOSEYOURfACEOVERENGINEAREA.TAKEPRECAUTIONSTOPREVENTOILLEAKAGEdOWNONTHEENGINE.WHENENGINEISRUNNINGANdVALVECOVERSAREREMOVEd,OILSPLASHINGINTHEENGINEBRAKEAREACOULdCAUSEPER-SONALINJURY.
1. Assurethatthecontrolwiresareconnectedtotheterminalassembliesinenginebrakespacers.
2. Bleedbrakehousingsandchecktheiroperation.Startengineandallowtorun5to10minutes,oruntiltheenginehasreachproperoperatingtempature.Accelerateenginetoapproximately1800RPMandreleasethrottle.Bothsolenoidvalvesshouldoperate.
3. Repeatthisprocedureseveraltimestobleedbrakehousingsforimmediateoperation.
Replace Rocker Lever Cover
1. Installthenewgasketandcoveronthespacer.Tightenthecovercapscrewsstartingfromthecenterandwork-ingoutto12N•m[9ft-lb].(Seefig.14)
Section 5: Brake Operation Check
FIG. 1�
1� CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES
Section 6: Brake MaintenanceTheory of OperationEnergizingtheenginebrakeeffectivelyconvertsapower-producingdieselengineintoapower-absorbingaircompressor.Thisisaccomplishedthroughmotiontransferusingamaster/slavepistonarrangementwhichopenscylinderexhaustvalvesnearthetopofthenormalcompres-sionstroke,releasingthecompressedcylinderchargetoexhaust.
Theblowdownofcompressedairtoatmosphericpres-surepreventsthereturnofenergytotheenginepistonontheexpansionstroke.Theeffectisanetenergyloss,sincetheworkdoneincompressingthecylinderchargeisnotreturnedduringtheexpansionprocess.
Exhaust BlowdownReferringtofig.15,exhaustblowdownoccursasfollows:
1. Theenergizedsolenoidvalvepermitsenginelubeoiltoflowunderpressurethroughthecontrolvalvetoboththemasterpistonandtheslavepiston.
2. Oilpressurecausesthemasterpistontomovedown,comingtorestontheexhaustrockerarmadjustingscrew.
3. Theexhaustrockerarmadjustingscrewbeginsupwardtravel(asinnormalexhaustcycle),forcingthemasterpistonupwardanddirectinghighpressureoiltotheslavepiston.Theballcheckvalveinthecontrolvalveimprisonshigh-pressureoilinthemaster/slavepistonsystem.
4. Theslavepiston,undertheinfluenceofthehigh-pres-sureoilmovesdown,momentarilyopensoneexhaustvalvewhiletheenginepistonisnearitstopdead-cen-terposition,releasingcompressedcylinderairtotheexhaustmanifold.
5. Compressedairescapesouttotheatmosphere,com-pletingacompressionbrakingcycle.
FIG. 1�
OIL IN
SOLENOIDVALVE
CONTROLVALVE
ADJUSTINGSCREW
HIGHPRESSURE
OIL
MASTERPISTON
EXHAUSTPUSHROD
SLAVEPISTON
BALLCHECKVALVE
EXHAUST VALVES
EXHAUSTROCKERLEVER
GUIDELESSCROSSHEAD
LOWPRESSURE
OIL
CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES 1�
FIG. 1�
TheCBrakebyJacobs™isarelativelytrouble-freedevice.However,inspectionsandroutinemaintenancewillneedtobemadefromtimetotime.Usethefollowingprocedurestokeeptheenginebrakeintopcondition.
Thissectionwillcoverhowtoproperlyremove,clean andreinstallenginebrakecomponents.UseanOSHA-ap-provedcleaningsolventwhenwashingparts.Besuretocoatpartswithcleanengineoilwhenreinstallingthem.
NEVERREMOVEANYENGINEBRAKECOMPONENTWITHENGINERUNNING.PERSONALINJURYMAYRESULT.
NOTE:fIG.16ISACTUALISL03BRAKE.fIG.17-31 ARETYPICALBRAKECOMPONENTSANdNOT SPECIfICTOISL03.
Control Valve
REMOVECONTROLVALVECOVERSCARE-fULLY.CONTROLVALVECOVERSAREUNdERLOAdfROMTHECONTROLVALVESPRINGS.REMOVEWITHCARETOAVOIdPERSONALINJURY.
1. Applypressureonthecontrolvalvecoverandremoveretainingringusingretainingringpliers(seefig.17).
2. Slowlyremovecoveruntilspringpressureceases,thenremovethecontrolvalvespringsandcollar(seefig.18).
FIG. 1�
FIG. 1�
1� CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES
3. Usingneedle-nosepliersoramagnet,removethecon-trolvalve(seefig.19).
4. Washthecontrolvalvewithapprovedcleaningsolvent.Pushawirethroughtheholeinthebaseofthevalvetoensurethattheballcheckisfree.Theballshouldliftwithlightpressureonthewire.Iftheballisstuckorthereisnospringpressure,replacethecontrolvalve.drythevalvewithcompressedairandwipecleanwithapapertowel.
5. Thoroughlycleanthecontrolvalveboreinthehousingusingcleanpapertowels.
6. dipthecontrolvalveincleanlubeoil.dropthevalveintoitsbore.Ifbindingoccurs,thecontrolvalveshouldbereplaced.
7. Reassembletheparts,reversingtheremovalpro-cedure.Besureretainingringearsarepositionedoppositetheoildrainslotinthehousing(seefig.20).
NOTE:BESURETHECONTROLVALVECOLLARISINSTALLEdWITHTHELONGERSLEEVEAREAUP(SEEBELOW).IfTHECOLLARISINSTALLEdUPSIdEdOWN,THISBRAKECYLINdERWILLNOTOPERATE.
FIG. 19
FIG. �0
UP
CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES 1�
Solenoid Valve1. disconnectthesolenoidharness.Usinga3/4”socket
andextension,unscrewthesolenoidvalve(seefig.21).
dONOTdISASSEMBLEORTAMPERWITHTHESOLENOIdVALVE.ENGINEdAMAGECOULdRESULT.
2. Removeanddiscardtherubbersealrings(ISLholdsthreesealringsandISL03holdsonlytwo)(fig.22).Ifthelowerring(ISLonly)staysinthebottomofthehous-ingsolenoidbore,removewithasealpick.
3. Washoutthesolenoidvalvewithapprovedcleaningsolvent.Useabrushtocleantheoilscreen.Cleananddrythevalvewithcompressedair.Replaceoilscreen,ifnecessary.
4. Cleanoutthesolenoidvalveboreinthehousing.Usecleanpapertowels.Neveruserags,astheymayleavelintandresiduewhichcanplugtheoilpassageways.
5. Reinstallthesolenoidusingnewsealrings.Seatlowersealring(ISLonly)inthebaseofthesolenoidvalvebore.Wipecleanlubeoilintoandaroundthebore.Placeupperandcentersealringsonthesolenoidvalvebody.
6. Besurethesealsareseatedproperlyandcarefullyandscrewthesolenoidintothehousingwithoutunseatingtheseals.Torquethevalveto20N•m[15lb.-ft](seefig.23).
UPPER SEAL
CENTER SEAL
LOWER SEAL
FIG. ��
FIG. ��
FIG. �1
1� CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES
Slave Piston Adjusting Screws (D Lash)Loosenslavepistonadjustingscrewlocknutandremoveadjustingscrewfromhousing(fig.24).
Cleanadjustingscrewinanapprovedcleaningsolvent.
Inspecttheslavepistonadjustingscrew(dLash).Theplungershouldprotrudefromthebottomofthescrew,andmovefreely(fig.25).Besuretheretainingringisfullyengagedinitsgroove.Replacetheentirescrewassemblyifanydefectisfound.
dONOTREAdJUSTORTAMPERWITHTHEAdJUSTINGSCREWASSEMBLY.ENGINEdAMAGECOULdRESULT.
FIG. ��
FIG. ��
SLIDE PLUNGER
CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES 1�
Master PistonRemovethebutton-headscrew,washerandmasterpistonspringfrombottomofhousing.
Removethemasterpistonfromitsboreusingneedle-nosepliers.Ifbindingoccurs,checkforburrsorcontaminantsinthelubeoil.Cleaninanapprovedcleaningsolvent(fig.26).
NOTE:dONOTATTEMPTTOREMOVETHEMAS-TERPISTONWITHOUTfIRSTREMOVINGTHEfLATSPRING.BENdINGTHESPRINGBACKTOOfARCANdISTORTTHESPRINGANdWOULdNEEdTOBEREPLACEd.
Inspectthehardfacesurface.Apitted,chipped,crackedorgalledpistonshouldbereplaced.Ifthehardfacingisdamaged,inspectthecorrespondingrockerarmadjustingscrewsforexcessivewearorpitting.Replaceifdamaged.
Reassembleinreverseorder.Whentighteningthecapscrew,makecertainthetwospringtabsdonotinterferewiththesidesofthemasterpistoncenterraisedportion(seefig.27).Torquethecapscrewto12N•m[9ft-lb].
NOTE:THETABSSHOULdBEEqUALLYSPACEdfROMTHERAISEdPISTONAREA.
Slave Piston
WEARSAfETYGLASSES.REMOVESLAVEPISTONCAREfULLY.THESLAVEPISTONISRETAINEdBYSPRINGSTHATAREUNdERHEAVYCOMPRESSION.IfTHEfOLLOWINGINSTRUCTIONSARENOTfOLLOWEdANdPROPERTOOLSNOTUSEd,THESPRINGCOULdBEdISCHARGEdWITHENOUGHfORCETOCAUSEPERSONALINJURY.
Removethelocknutontheslavepistonadjustingscrew.Backouttheadjustingscrewuntiltheslavepistonisfullyretracted(screwisloose).
Usetheslavepistonremovaltoolandthefollowingproce-duretoremoveandreplacetheslavepiston:
1. Placetheholeintheclampbracketovertheslavepis-tonadjustingscrew(fig.28).
2. Whileholdingthetoolinposition,screwtheholderdownovertheslavepistonstemuntiltheretaineriscontacted.
FIG. ��
FIG. ��
FIG. ��
1� CBRAKEBYJACOBS™INSTALLATIONMANUALforCUMMINSISL,ISL03,ISL07,andISC07ENGINES
3. Turnthehandleslowlyuntiltheretainerisdepressed,about1/32”(1mm),relievingpressureagainsttheretainingring.
4. Removetheretainingringusingretainingringpliers.Backouttheholderuntilthespringsareloose.Removethetool.(seefig.29)
5. Removetheretainer,springandslavepiston.Checkfornicksorburrsthatcouldcausebinding.(seefig.30)
6. Cleanthepistoninanapprovedcleaningsolvent.Runasmallwirethroughanyholes.Replacethepistonifthegroundsurfaceontheoutsidediameterisscratchedorscored.
NOTE:BESUREALLCOMPONENTSAREREASSEMBLEdINCORRECTORdER.
7. Reassembleinreverseorder.
8. Usetheremovaltooltocompresstheslavepistonandspringsdownuntiltheretainerisabout1/32” (1mm)belowtheretainingringgroove(seefig.29).
9. Slidetheretainingringoverthethreadedrodoftheremovaltoolandreinstalltheretainingringinitsgroove.Besuretheretainingringisfullyengagedinthegroove.
10. Removethetoolslowlytoensureproperseatingofretainingring.
11. Assemblethelocknut;donottighten.
FIG. �9
FIG. �0
Jacobs Vehicle Systems22 East Dudley Town RoadBloomfield, CT 06002U.S.A.
Cummins Inc.Box 3005Columbus, IN 47202-3005U.S.A.
CELECT™isatrademarkofCumminsInc.Bulletin3401839
CBrakebyJacobs™´isatrademarkofCumminsInc.andJacobsVehicleSystems
Jacobs®isaregisteredtrademarkofJacobsVehicleSystems
PrintedinU.S.A.1/07©2005CumminsInc.andJacobsVehicleSystems For additional support visit: www.jacobsvehiclesystems.com
JacobsP/N026302Rev.d