Ism Freno de Motor

7/30/2019 Ism Freno de Motor

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Isaaio Maua ForISM/ISM02/ISM07

M11/M11 Pus

Eies



2 cBRAKE BY JAcOBS™ InStAllAtIOn MAnUAl FOR cUMMInS ISM/ISM02, M11/M11 PlUS EngInES

Table o ContentsSection 1: Introduction. 3

Aermarke Kis.................................................................

.3

Housi Ieiaio .....................................................3

Eie Ieiaio .......................................................3

Speia toos .................................................................. 3

Auomai trasmissios ............................................... 3

Section.2:.Engine.Preparation.4.-.6

crosshea a Ajusi Srews................................... 4

Ehaus Vave a Ijeor Ajusme ........................... 5

Spaer Isaaio .......................................................... 6

Section.3:.Engine.Brake.Housing.Installation.7.-.9

Brake Housi Isaaio ..............................................7

Save Piso Ajusme ................................................ 8

Save Piso lash Seis ............................................. 8

Isaaio o Oi Suppy ................................................. 9

Section.4:.Electrical.System.Installation.10.-.12

M11 cElEct™ Wiri Isaaio ...............................10

M11 cElEct™ Pus Wiri Isaaio........................11

ISM Wiri Haress .....................................................11

ISM02 Wiri Haress ................................................. 12

Section.5:.Engine.Brake.Operation.Check.13-14

Bee a Operaio chek .........................................13

Section.6:.Engine.Brake.Maintenance.15.-20

theory o Operaio ..................................................... 15

Ehaus Bowow ...................................................... 15

coro Vave ................................................................16

Soeoi Vave ............................................................18

Save Piso Ajusi Srews (Rese)..........................19

Ba chek ................................................................... 19

Maser Piso ............................................................... 20

Save Piso ................................................................. 20

Saety Precautions the oowi symbos i his maua sia poeiay

aerous oiios o he mehai or euipme. Rea

his maua areuy. Kow whe hese oiios a eis.

the, ake eessary seps o proe persoe as we as

euipme.

tHIS SYMBOl WARnS OF POSSIBlE PER-

SOnAl InJURY.

tHIS SYMBOl REFERS tO POSSIBlE

EqUIPMEnt dAMAgE.

NOTE:

IndIcAtES An OPERAtIOn, PROcEdURE

OR InStRUctIOn tHAt IS IMPORtAnt FOR

cORREct SERVIcE.

Fues, eeria euipme, ehaus ases a movi

eie pars prese poeia hazars ha ou resu i

persoa ijury. take are whe isai a eie brake.

Aways use orre oos a proper proeures as ouie

i his maua.

SEE dRIVER’S MAnUAl FOR PROPER En-

gInE 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 3

Section 1: Introduction

Model 411/411C/D/E Atermarket Kits.

P/N. Engine. Brake........Description

. . . . Model

3804584 M11/M11+ 411 12 Vdc, S/l ki

3804585 M11/M11+ 411 24 Vdc, S/l ki

3804586 M11/M11+ 411 24 Vdc, d/l ki

3800765 ISM 411c 12 Vdc, d/l ki

4089395 ISM02/04 411d 12 Vdc, S/l ki

4955458 ISM07 411E 12 Vdc, S/l ki

*See Appiaio guie, P/n 3401804, or spei eie

moe appiaio iormaio.

Housing Identifcation A amepae aahe o he op surae o he eie brake

housi ieies he moe umber, par umber, ro or

rear housi a save piso ash sei.

the housi seria umber is sampe o he op surae o

he eer maser piso boss or o he amepae.

For housi par umber a oher repaeme par ior-

maio, reer o cummis Buei no. 3698826, Jaobs

Pars Maua, P/n 021475.

Engine IdentifcationPrior o eie brake isaaio, veriy ha eie is a

ISM, 2002 ISM, 2007 ISM, M11 or M11 Pus. the eie

ieiaio is o he seria umber pae oae o he ue

pump sie beow he roker over.

Special Tools the oowi speia oos shou be avaiabe or he isa-

aio:

1. Ijeor ajusi oo: torue wreh, cummisP/n 3376592

2. crowoo: cummis P/n 3823820

3. Feeer ae/save piso:

cummis P/n 3871428, (0.015”)

cummis P/n 3133172, (0.027")

UnlESS OtHERWISE SPEcIFIEd, tHE

tORqUE VAlUES lIStEd In tHE tExt

ARE dIREct VAlUES USIng nO tORqUEWREncH AdAPtERS OR ExtEnSIOnS.

WHEn AdAPtERS OR ExtEnSIOnS ARE

USEd WItH A tORqUE WREncH, tHE

tORqUE VAlUES MUSt BE AdJUStEd

FOR tHE SPEcIFIc tOOlS BEIng USEd.

FOllOW tHE MAnUFActURER’S REcOM-

MEndEd PROcEdURES FOR tHE tORqUE

WREncH And AdAPtER BEIng USEd.

AutomaticTransmissions

PRIOR tO InStAllAtIOn OF tHE EngInE

BRAKE On VEHIclES WItH AUtOMAtIc

tRAnSMISSIOnS, WE REcOMMEnd tHAt

tHE tRAnSMISSIOn MAnUFActURER REP-

RESEntAtIVE (dEAlER) BE cOnSUltEd tO

BE SURE OF tHE cOMPAtIBIlItY OF tHE

EngInE BRAKE WItH tHE SPEcIFIc AUtO-

MAtIc tRAnSMISSIOn BEIng USEd.




Section 2: Engine Preparationcea eie horouhy. Remove eie vave over a

aske. Reai a pars.

NOTE:

REFER tO cUMMInS tROUBlESHOOtIng &

REPAIR MAnUAl, SEctIOn 003-004 FOROVERHEAd SEt InFORMAtIOn.

Crosshead and Adjusting Screws

cyier 1, 3 a 5 Ehaus Vave crosshea Repaeme

a Ijeor Roker lever Ajusi Srews:

1. Roae raksha by uri aessory rive sha i

ireio o roaio (okwise, see Fi. 1). Ai he

“A” vave se mark o he aessory rive puey wih

he poier o he ear over. chek he iake a e-haus vaves o yier no. 1. A vaves mus be ose

(boh rossheas oose) o make ajusmes. I he

vaves are o ose, roae he eie oe ompee

revouio. the eie is ow reay or vave a ije-

or ajusmes ha wi be mae aer.

2. loose okus a ajusi srews o ijeor a

ehaus vave roker evers o yiers 1, 3 a 5.

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 gUIdE-

lESS cROSSHEAdS (SEE FIg. 2).

3. Remove he cummis uieess exhaust.vave ross-

hea rom yiers 1, 3 a 5 (see Fi. 3).

dO nOt dISASSEMBlE tHE ActUAtOR

PIn FROM tHE JAcOBS cROSSHEAd. tHE

ASSEMBlY IS nOt SERVIcEABlE In tHEFIEld.

CBRAKE byJACOBS

CUMMINSGUIDELESS

FIG.1

FIG.2

FIG.3




4. lubriae he auaor pis a vave sems wih ea

ube oi a isa he cBrake by Jaobs™ rossheas

over he ehaus vaves. loae he auaor pis o

he ehaus vaves oses o he push ro sie o he

eie (see Fi. 4).

5. the rosshea shou move reey rom sie o sie piv-

oi o he sie wihou he auaor pi. no evei

ajusme is reuire wih uieess rossheas.

6. Remove he cummis ijeor roker ever ajusi

srews a isa he cBrake by Jaobs™ ijeor

roker ever ajusi srews a he jam u o yi-

ers 1, 3 a 5 (see Fi. 5).

7. Repea seps 1 hrouh 6 above or yiers 2, 4

a 6.

Exhaust Valve andInjector Adjustment

NOTE:.OVERHEAd AdJUStMEntS MUSt BE MAdE

WHEn tHE EngInE IS cOld: StABIlIZEd

cOOlAnt tEMPERAtURE 140° F. (60° c.)

OR BElOW.

1. Reer o Fi. 6 o eermie he orre orer o se he

ehaus vave a ijeor ajusme.

2. Roae he eie raksha okwise o he esire

puey posiio.

Bar Eie Puey Se Vaves Se Ij.

dir. o Roaio Posiio cy. no. cy. no.

Sar A 1 1

Avae o B 5 5

Avae o c 3 3

Avae o A 6 6

Avae o B 2 2

Avae o c 4 4

FIG.6

FIG.5

FIG.4




3. Pae a 0.027” (0.68 mm) eeer ae bewee he

roker ever a he rosshea o he ehaus vave

(see Fi. 7). tihe he ajusi srew ui a ih

ra a be e o he eeer ae. Ho he ajusi

srew a ihe he oku o 45 b.-. (61 n•m).

4. tur he ijeor ajusi srew i a boom he

ijeor puer 3 o 4 imes o remove ue.

5. Boom ijeor ajusi srew wih a srewriver.

6. Bak ou srew wo fas (120°).

7. Ho srew a orue ok u o 45 b.-. (61 n•m).

8. Ajus vaves a ijeors i he same yier oow-

i he proeures i 1 hrouh 7 above.

Spacer Installation1. MODEL.411.ONLY:.. Isa wo (2) eeria ea ou

assembies io spaer a orue o 10 b.-.

(14 n•m) (see Fi. 8).

2. Isa bukhea i wih sea io hoe i spaer as

show i Fi. 9. Sea mus be oae o he ousie o

he spaer. Isa u a orue o 25 b.-. (34 n•m).

3. cea roker housi. cummis reommes he use

o RtV (cummis P/n 3823494) bewee he roker

housi a he spaer. I, however, you wish o use

a aske isea o he RtV, a aske is iue wih

he ki.

4. Sari rom he eer a proeei ouwar o

boh sies orue he apsrews o 15 b.-. (20 n•m)

oowi he seuees show i Fi. 10.

913 5 1 3 7 11 15

10 6 2 4 8 12 16

17 18

14

FIG.8

FIG.9

FIG.7

FIG.10




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. lubriae O-ris o oi suppy ube a isa io oi

suppy hoe i rear housi. Push ube i a he way

(see Fi. 11).

2. Isa he O-ri aapor io he ro housi i he

oaio show i Fiure 12. t ihe he O-ri aapor

as oows:

411 24 b.- 33 n•m

411c 27 b.- 37 n•m

411d 27 b.- 37 n•m

411E 27 b.- 37 n•m

3. Make sure he save piso ajusi srews o boh

housis are bake ou so a save pisos are uy

rerae (srew is oose).

4. Pae rear brake housi o roker sha suppors or

yiers 4, 5 a 6.

5. Isa ro housi so ha he oi suppy ube s io

he oi suppy hoe o he ro housi.

NOTE:..

nO WASHERS ARE USEd WItH tHE

cBRAKE BY JAcOBS™ cAPScREWS.

6. lubriae hreas a uersie o Jaobs ho-ow

apsrews wih ea ube oi.

7. Isa he apsrews i he siee (16) oaios

a ha ihe oowi he seuee i Fi. 13.

compee he seuee by ihei he apsrews

o 60 b.-. (81 n•m).

FIG.11

FIG.12

FIG.13

Section 3: Brake Installation

FRONT

1 4 7

523

6

816

1491215

1310

11

REAR

MODEL 411, C, D, E




Slave Piston Adjustment

PAY SPEcIAl AttEntIOn tO tHIS AdJUSt-

MEnt. tO EnSURE MAxIMUM BRAKE

OPERAtIng EFFIcIEncY And tO PREVEnt

EngInE dAMAgE, FOllOW InStRUctIOnS

cAREFUllY.

Slave.Piston.Lash.Settings

. Model. Engine. Setting

411 M11 0.015”

411 M11 Pus 0.015”

411c ISM 0.015"

411d 2002 ISM 0.015"

411E 2007 ISM 0.027"

1. Save piso ash sei is prie o he housi

amepae.

2. Save piso ajusme mus be mae wih he eie

soppe a o (sabiize waer emperaure o 140°

F., 60° c., or beow).

3. Ehaus vaves o he yier o be ajuse mus

be ose.

4. Isa he appropriae eeer ae (.027" or 411E, .015"

or a ohers) bewee he save piso a he aua-

i pi i he rosshea (see Fi. 14). tur he save

piso ajusi srew ui a sih ra o he eeer

ae a be e.

5. Ho srew i posiio wih a srewriver (see Fi.

15) (Moe 411E OnlY - Ho srew i posiio wih

wreh o he hea - See Fi. 15A). torue oku o

25 b.-. (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).

NOTE:

AFtER tORqUIng tHE SlAVE PIStOn

AdJUStIng ScREW lOcKnUt, cHEcK

tHE clEARAncE WItH tHE FEElER gAgE.

REAdJUSt IF nEcESSARY.

FIG.15

FIG.14

FIG.15A




Installation o OilSupply

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 he pu rom he rear, iboar er hea oa-

io a isa he ew i wih sea ri. tihe he

i o 27 b.-. (37n•m) (Fi.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. coe he eera hose o he bukhea i i he

spaer. Isa he hose amps a aah o he bo i

he iake maio (Fi.17).

3. Roue he hose behi he ooa er a oe o

he O-ri aaper as oows:

411 12 b.- 16 n•m

411c 19 b.- 26 n•m

411d 19 b.- 26 n•m411E 19 b.- 26 n•m

4. Isa shor hose bewee housi aapor a buk-

hea i. torue i us as oows:

(Fi.18)

411 12 b.- 16 n•m

411c 19 b.- 26 n•m

411d 19 b.- 26 n•m

411E 19 b.- 26 n•m

SPACER

SEAL

BULKHEAD NUT

BULKHEAD FITTINGWITH NUT

HOSE ASSEMBLY

CBRAKE byJACOBSFRONT HOUSING

Torque per

paragraph 3

Torque per

paragraph 3 Torque per paragraph 4

FIG.17

FIG.16

FIG.18

* Model 411E has different clip

confguration - See note below

nOtE: 411E HAS 3 clIPS

InStEAd OF 4 AS PREVIOUS

MOdElS. HOldIng tHOSE

3 clIPS ARE tWO nEW

ScREWS

3821783 15 b.-

3036230 35 b.-

3818060 40 b.- *

areay eiss o eie




Section 4: Electrical Installation

M11 CELECT™ Wiring InstallationNOTE:.

All cUMMInS M11 EngInES HAVE ElEc-

tROnIc cOntROlS (cElEct™).

Isa he reay base uer he ash a a oveie oaio

i orer o make he oowi wiri oeios:

It IS ExtREMElY IMPORtAnt tHAt A

SEcURE gROUnd cOnnEctIOn IS MAdE.

FAIlURE tO dO SO WIll RESUlt In POOR

EngInE BRAKE OPERAtIOn.

1. coe he gREEn wire o a oo eie rou.

2. coe he PInK wire o he oupu sie o he On/

OFF brake swih.

3. coe he gRAY wire o he ipu sie o he seeor

swih.

4. coe he BROWn wire o he cummis ierae

oeor, pi “F”.

Aiioa eeria oeios (wiri o be provie by

he isaer):

1. coe he REd wire rom he ipu ermia (siver

oae) o a 10-amp, 12-vo irui breaker eeria

soure.

2. the BlUE wire shou be oee rom he oupu

sie o he seeor swih as show i he iaram,

o pi “g” o he cummis ierae oeor.

3. coe he YEllOW wire rom he oupu sie o he

seeor swih o pi “H” o he cummis ierae

oeor.

4. the ORAngE wire is oee rom he oupu sie o

he o/o swih (o pae ermia) o pi 10 o he

cummis eeroi oro moue.

5. coe he WHItE wire rom he ipu sie o he

On/OFF swih (o pae ermia) o pi 5 o he

cummis eeroi oro moue.

BLUE

FRONT OF ENGINE

PIN F

PIN G

PIN H

OEM INTERFACE

CONNECTOR

Y E L L O W

B L U E

GOLDTERMINALS

SILVERTERMINALS

ON/OFFPOWERSWITCH

TWO-POSITIONSWITCH

10 AMP - 12VCIRCUIT BREAKER

OR FUSE

RED

PINK

GRAY

GREEN

B R O W N

PIN F

PIN G

PIN H

GROUND

NOTUSED

NOTUSED

NOTUSED

PIN 87ANOT USED

PIN 85BROWN PIN 86

GREEN

PIN 87GRAY

DIODE

PIN 30PINK

PIN 18

PIN C

PIN 5

PIN 10

ELECTRONICCONTROLMODULE

HARNESSJUMPER

CONNECTOR

OEMCONNECTOR

ACTUATOR CONNECTOR

YELLOW

PIN B

PIN 10

PIN5 WHITE

ORANGE

FRONT HOUSINGREAR HOUSING

FIG.19




M11 Plus CELECT™Plus Wiring Installation(Model 411)

FIG.21

ISM Wiring Installation(Models 411C)

For proper eeria wiri isaaio, make a eeria o-

eios as show i Fiure 21, observi he oowi:

1. coe he Soeoi Haress o he eisi eie

ijeor haress uer he vave over. coe he

REd ea o he Soeoi Haress o eiher ermia o

he soeoi o he rear housi. coe he WHItE

ea o he soeoi o he ro housi. coe

oe BlAcK ea o eah remaii ermia o boh

soeois.

2. A oeios bewee he cummis Eeroi

coro Moue a he eie brake On/OFF a

HI/lOW swihes are o be mae wih wiri provie

by he isaer.

P a s s T h r o u gh P i n 1 3


ON/OFFSWITCH

OEM PORT (KEY 04) ACTUATOR PORT (KEY02) SENSOR PORT (KEY 03)

C1 C2 C3

DCM570

Actuator Pin 31 (Engine Brake Return)

Actuator Pin 15 (Engine Brake #2)Actuator Pin 44 (Engine Brake #1)

OEM Pin 22 (LO)

OEM Pin 31(HI )

OEM Pin 9*(Common)

2 POSITIONSWITCH

White wire andBlack wire

Red w ire andBlack wire

Rear Housing Front Housing

* Pin 10 or 19 can be used as alternates to Pin 9 for Common Ground.

Instal ler ProvidedWires

1514

Brake Harness

13

15 pin passthrough connector

44153122319


Existing Engine Harness

NOTE: All cUMMInS M11 Plus EngInES HAVE

ElEctROnIc cOntROlS (cElEct

pus).

1. For proper wiri isaaio, make a eeria o-

eios as show i Fi. 20.

2. coe brake wiri haress o cummis EcM Ier-

ae coeor. coe PURPlE a gRAY eas o

FIG.20

PURPLE

ELECTRICAL CONTROL SYSTEMENGINE BRAKE MODEL 411 FOR ’95 M11 PLUS ENGINE

GRAY

B C28

5

101819

A

ELECTRONIC CONTROLMODULE (ECMc)

OEMPORT

ACTUATORPORT

2-POSITIONSWITCH

ON/OFFSWITCH

FRONT HOUSING REAR HOUSING

PIN 10

PIN 5

PIN 28

P I N 1

8

PURPLE

P I N 1

9

B

AA B




ISM02 WiringInstallation(Models 411D)

For proper eeria wiri isaaio, make a eeria

oeios as show i Fiure 22, observi he oowi:

1. coe he soeoi haress o he eisi eie

ijeor haress uer he vave over. coe he

REd ea o he soeoi o he rear housi. coe

he WHItE ea o he soeoi o he ro housi.

2. A oeios bewee he cummis Eeroi

coro Moue a he eie brake On/OFF a

HI/lOW swihes are o be mae wih wiri provie

by he isaer.

................................................NOTE:

P a s s T h r o u gh P i

n 1 3

P a s s T h r o u gh P i

n 1 4

ON/OFFSWITCH

OEM PORT (KEY 04)C1

C2

DCM870

Actuator Pin 51 (Engine Brake #2)Actuator Pin 32 (Engine Brake #1)

OEM Pin 18(LO)

OEM Pin 08(HI )

OEM Pin 34*(Common)

2 POSITIONSWITCH

White wireRed wire

Rear Housing Front Housing

Installer ProvidedWires

14

Brake Harness

13

32

Existing Engine Harness

ENGINE PORT (KEY 07)

04

C301

0203

34 08 1851

FIG.22

JAcOBS WIRIng IS

nOt REqUIREd On

ISM07 (MOdEl 411E)

- SEE VEHIclE OEM

FOR WIRIng dEtAIlS




the cBrake by Jaobs™ Moe 411, 411c, 411d, & 411E

isaaio is ow ompee. the oowi proeures a

ajusmes shou be mae.

Rehek he housi isaaio. Be erai o orei

objes have bee e behi a a orre earaereuiremes have bee me.

Bleed and OperationCheck

WEAR EYE PROtEctIOn And dO nOt

ExPOSE YOUR FAcE OVER EngInE AREA.

tAKE PREcAUtIOnS tO PREVEnt OIl

lEAKAgE dOWn On tHE EngInE. WHEnEngInE IS RUnnIng And VAlVE cOVERS

ARE REMOVEd, OIl SPlASHIng In tHE

EngInE BRAKE AREA cOUld cAUSE PER-

SOnAl InJURY.

For.Wastgate.and.Non-.Wastgate.Engines

1. Assure ha he oro wires are oee o he

ermia assembies i eie brake spaers

(411 oy).

2. Bee brake housis a hek heir operaio.

Sar eie a aow o ru 5 o 10 miues.

Pu ash swih i “lO”. Aeerae eie oapproimaey 1800 RPM a reease hroe.

Oy oe soeoi vave shou operae.

3. Repeai his proeure or posiio “HI”, boh soe-

ois shou operae. Repea his proeure severa

imes o bee brake housis or immeiae operaio.

For.EGR/.VGT.Engines.

1. Bee brake housis a hek heir operaio.

Sar eie a aow o ru 5 o 10 miues.

Pu ash swih i “HI”. Aeerae eie o

approimaey 1800 RPM a reease hroe.

Boh soeoi vaves shou operae.

2. Repea his proeure severa imes o bee brake

housis or immeiae operaio.

Section 5: Brake Operation Check




Replace.Rocker.Lever.Cover

1. Remove he aske a ispe or amae.

2. I he aske is o amae, i a be use aai. I

he aske is amae, i mus be isare a a ew

oe use.

3. Se he ew cummis aske o he over.

4. Isa fa washer, ew seeve a ew oise isoaor o

he apsrew (see Fi. 23).

5. Isa he apsrew assembies i he over (Fi. 24).

6. Isa he over o he spaer a ihe he over

apsrews o 130 b.-i. (15 n•m) i he seuee

show i Fi. 25.

nOtE: AlSO REFEREncE cUMMInS

tROUBlE SHOOtIng & REPAIR

MAnUAl, SEctIOn 003-011FORROcKER lEVER cOVER

InStAllAtIOn.

FIG.25

FIG.24

FIG.23




Section 6: Brake Maintenance

Theory o OperationEerizi he eie brake eeivey overs a power-

proui iese eie io a power-absorbi air

ompressor. this is aompishe hrouh moio raser

usi a maser/save piso arraeme whih opes

yier ehaus vaves ear he op o he orma ompres-

sio sroke, reeasi he ompresse yier hare o

ehaus.

the bowow o ompresse air o amospheri pres-

sure preves he reur o eery o he eie piso o

he epasio sroke. the ee is a e eery oss, sie

he work oe i ompressi he yier hare is o

reure uri he epasio proess.

Exhaust BlowdownReerri o Fi. 26, ehaus bowow ours as oows:

1. the eerize soeoi vave permis eie ube oi o

fow uer pressure hrouh he oro vave o boh

he maser piso a he save piso.

2. Oi pressure auses he maser piso o move ow,

omi o res o he ijeor roker arm ajusisrew.

3. the ijeor roker arm ajusi srew beis upwar

rave (as i orma ehaus ye), ori he maser

piso upwar a irei hih pressure oi o he

save piso. the ba hek vave i he oro vave

imprisos hih-pressure oi i he maser/save piso

sysem.

4. the save piso, uer he ifuee o he hih-pres-

sure oi moves ow, momeariy opes he ehaus

vave whie he eie piso is ear is op ea-e-

er posiio, reeasi ompresse yier air o he

ehaus maio.

5. compresse air esapes ou o he amosphere, om-

pei a ompressio braki ye.

OIL IN

SOLENOID

VALVE

CONTROL

VALVE

ADJUSTING

SCREW

HIGH

PRESSURE

OIL

MASTER

PISTON

INJECTOR

PUSHROD

SLAVE

PISTON

BALL

CHECK

VALVE

EXHAUST VALVES

EXHAUST

ROCKER

LEVER

GUIDELESS

CROSSHEAD

LOW

PRESSURE

OIL

FIG.26




the cBrake by Jaobs™ is a reaivey roube-ree evie.

However, ispeios a rouie maieae wi ee

o be mae rom ime o ime. Use he oowi proeures

o keep he eie brake i op oiio.

this seio wi over how o propery remove, ea

a reisa eie brake ompoes. Use a OSHA-ap-

prove eai sove whe washi pars. Be sure o

oa pars wih ea eie oi whe reisai hem.

nEVER REMOVE AnY EngInE BRAKE

cOMPOnEnt WItH EngInE RUnnIng.

PERSOnAl InJURY MAY RESUlt.

Control Valve

REMOVE cOntROl VAlVE cOVERS cARE-

FUllY. cOntROl VAlVE cOVERS ARE

UndER lOAd FROM tHE cOntROl VAlVE

SPRIngS. REMOVE WItH cARE tO AVOId

PERSOnAl InJURY.

1. Appy pressure o he oro vave over a remove

reaii ri usi reaii ri piers (see Fi. 28).

CONTROL

VALVE

SOLENOIDVALVE

SLAVE PISTONADJUSTING

SCREW(RESET)

SLAVEPISTON

MASTERPISTON

FIG.27

FIG.28




2. Sowy remove over ui spri pressure eases,

he remove he oro vave spris a oar

(see Fi. 29).

3. Usi eee-ose piers, remove he oro vave

(see Fi. 30).

4. Wash he oro vave wih approve eai sove.

Push a wire hrouh he hoe i he base o he vave

o esure ha he ba hek is ree. the ba shoui wih ih pressure o he wire. I he ba is suk or

here is o spri pressure, repae he oro vave.

dry he vave wih ompresse air a wipe ea wih

a paper owe.

5. thorouhy ea he oro vave bore i he housi

usi ea paper owes.

6. dip he oro vave i ea ube oi. drop he vave

io is bore. I bii ours, he oro vave shou

be repae.

7. Reassembe he pars, reversi he remova pro-

eure. Be sure reaii ri ears are posiioeopposie he oi rai so i he housi (see Fi. 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.

FIG.29

FIG.30

FIG.31

UP




Solenoid Valve1. disoe he soeoi haress. Usi a 3/4” soke

a eesio, usrew he soeoi vave (see Fi. 32).

dO nOt dISASSEMBlE OR tAMPER WItH

tHE SOlEnOId VAlVE. EngInE dAMAgE

cOUld RESUlt.

2. Remove a isar he hree rubber sea ris (Fi.

33). I he ower ri says i he boom o he housi

soeoi bore, remove wih a sea pik.

3. Wash ou he soeoi vave wih approve eai

sove. Use a brush o ea he oi sree. cea a

ry he vave wih ompresse air. Repae oi sree, i

eessary.

4. cea ou he soeoi vave bore i he housi. Use

ea paper owes. never use ras, as hey may eave

i a resiue whih a pu he oi passaeways.

5. Reisa he soeoi usi ew sea ris. Sea ower

sea ri i he base o he soeoi vave bore. Wipe

ea ube oi io a arou he bore. Pae upper

a eer sea ris o he soeoi vave boy.

6. Be sure he seas are seae propery a areuy a

srew he soeoi io he housi wihou useai

he seas. torue he vave o 15 b.-. (20 n•m) (see

Fi. 34).

UPPER SEAL

CENTER SEAL

LOWER SEAL

FIG.34

FIG.33

FIG.32




Slave Piston AdjustingScrews (Reset)1. loose save piso ajusi srew oku a re-

move ajusi srew rom housi (Fi. 35).

2. cea ajusi srew i a approve eai sove.

3. Ispe he save piso ajusi srew. the puer

shou prorue rom he boom o he srew, have

ih spri pressure appare whe epresse, a

shou move reey (Fi. 36). Be sure he reaii ri

is uy eae i is roove. Repae he eire srew

assemby i ay ee is ou.

dO nOt REAdJUSt OR tAMPER WItH tHE

AdJUStIng ScREW ASSEMBlY. EngInE

dAMAgE cOUld RESUlt.

Ball Check Valve1. Remove he soke pipe pu. Be areu uri a

urs o avoi osi he spri a ba. Remove spri

a ba (Fi. 37).

2. Ispe, ea i a approve eai sove a

repae as reuire.

3. Reassembe, iseri rs he ba, he he spri a

pu. torue he pu o 106 b.-i. (12 n•m).

InStAll PARtS In tHE ORdER SHOWn.

IMPROPER InStAllAtIOn MAY RESUlt In

EngInE dAMAgE.

FIG.36

FIG.35

FIG.37




Master Piston1. Remove he buo-hea srew, washer a maser

piso spri rom boom o housi.

2. Remove he maser piso rom is bore usi eee-

ose piers. I bii ours, hek or burrs or

oamias i he ube oi. cea i a approve

eai sove (Fi. 38).

NOTE:

dO nOt AttEMPt tO REMOVE tHE MAS-

tER PIStOn WItHOUt FIRSt REMOVIng

tHE FlAt SPRIng. BEndIng tHE SPRIng

BAcK tOO FAR cAn dIStORt tHE SPRIng

And WOUld nEEd tO BE REPlAcEd.

3. Ispe he har ae surae. A pie, hippe,

rake or ae piso shou be repae. I he har

ai is amae, ispe he orrespoi roker

arm ajusi srews or eessive wear or pii.

Repae i amae.

4. Reassembe i reverse orer. Whe ihei he ap-

srew, make erai he wo spri abs o o ierere

wih he sies o he maser piso eer raise porio

(see Fi. 39). torue he apsrew o

8 - 10 b.-. (11 - 13 n•m).

NOTE:

tHE tABS SHOUld BE EqUAllY SPAcEd

FROM tHE RAISEd PIStOn AREA.

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 he oku o he save piso ajusi srew.

Bak ou he ajusi srew ui he save piso is uy

rerae (srew is oose).

Use he save piso remova oo a he oowi proe-

ure o remove a repae he save piso:

1. Pae he hoe i he amp brake over he save pis-

o ajusi srew (Fi. 40).

FIG.39

FIG.38

FIG.40




2. Whie hoi he oo i posiio, srew he hoer

ow over he save piso sem ui he reaier is

oae.

3. tur he hae sowy ui he reaier is epresse,

abou 1/32” (1 mm), reievi pressure aais he

reaii ri.

4. Remove he reaii ri usi reaii ri piers.

Bak ou he hoer ui he spris are oose. Removehe oo (see Fi. 41).

5. Remove he reaier, spri a save piso. chek or

iks or burrs ha ou ause bii (see Fi. 42).

6. cea he piso i a approve eai sove. Ru

a sma wire hrouh ay hoes. Repae he piso i he

rou surae o he ousie iameer is srahe or

sore.

NOTE:

BE SURE All cOMPOnEntS ARE REAS-

SEMBlEd In cORREct ORdER.

7. Isa he save piso io he bore. Isa he spris

a reaier over he save piso oo.

8. Use he remova oo o ompress he save piso

a spris ow ui he reaier is abou 1/32”

(1 mm) beow he reaii ri roove.

9. Sie he reaii ri over he hreae ro o he

remova oo a reisa he reaii ri i is roove.

Be sure he reaii ri is uy eae i he roove.

10. Remove he oo sowy o esure proper seai o

reaii ri.

11. Assembe he oku; o o ihe.

FIG.41

FIG.42



Cummins.IncBox.3005

Columbus,.IN.47202-3005

USA

wwwcumminscom

cElEct™ is a raemark o

cummis I.

Buei 3698827

For additional support visit www jacobsvehiclesystems

Jacobs.Vehicle.Systems22.E.Dudley.Town.Road

Bloomfeld,.CT.06002USA

cBrake by Jaobs™ is a raemark o

cummis I. a

Jaobs Vehie Sysems

Jaobs® is a reisere raemark o

Jaobs Vehie Sysems

P i i U S A 01/07

Ism Freno de Motor

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