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TecBrake

P.O. Box 27822Houston, Texas 77227

Installation

and PartsManual

Housing Replacement KitModel T440/A Engine Brakes

For Cummins91N14 Series Engines

Engine Brakes

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BRAKE HOUSINGINSTALLATION MANUAL

TECBRAKE MODEL T440/A ENGINE BRAKE

FOR CUMMINS 91N14 SERIES ENGINES

SECTION 1- INTRODUCTION

The TecBrake T440/A engine brake may be installed on

popular versions of the Cummins 91N14 series engine.It cannotbe installed on the Cummins 855, NTC/88NT,

94N14 model engines. Although the T440/A engine brakekit will fit on all 94N14 series engines, it should only be

installed on engines whose CPL numbers are included

in the Application Guide.

NOTICEThe TecBrake Engine Brake is designed as a device

for slowing a vehicle, not stopping it. It is to be used

in conjunction with, but not a substitute for the

vehicles service brakes. The service brakes mustbe in good operating condition and used to bringthe vehicle to a complete stop.

Special Tools

The following special tools are required for installation:1. Crowfoot wrench- 9/16"

2. Feeler gauge- 0.023"

Recommended Torque Values

Engine Brake Hold-down Nuts - 75 lbft (102 N*m)

Slave Piston Adj. Screw Nuts - 18 lbft (24 N*m)

1. Obtain the engines CPL number. Refer to theTecBrake Application Guide, which list all Cummins

engines on which the T440/A engine brake may beinstalled.

2. The T440/A brake may be installed on either 91N14mechanical (STC) or electronic (CELECT) engine

versions.

Section 2- Installing the Brake Housings-

1. Remove the existing engine brake housings. Discardthe hold-down capscrews.

2. Make sure rocker housing surfaces are clean and

smooth. Install the engine brake housing gaskets.

3. Before installing the brake housings, back out the

slave adjusting screws (located above the slave piston)so that the slave pistons are fully retracted (up).

4. Install the six capscrews into the housing.

Figure 1-1

5. Place the engine brake housing on the rocker housing.

Check rocker levers to be sure there is no interference.

Figure 1-2

6. Tighten the capscrews in steps following the torquing

sequence. Tighten to 75 lbft (102 N*m).

Slave Piston Adjustment

Adjustment of the slave piston adjusting screw is critical.

Proper adjustment is necessary in order to provide peakbraking efficiency without over stressing the engine.

Use one of the two following procedures:

Slave piston adjusting screw adjustment must be made

with the engine stopped and engine temperaturestabilized below 140 F.

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Figure 1-5

2. At idle; manually depress solenoid cap a few times.Repeat this procedure until the oil being exhausted down

the control valve is free of air.

3. Connect housing assemblies to the existing wiring.

FEELER GAUGE METHOD.

1. When the "A" or 1-6VS is aligned with the pointer, bothexhaust and intake valves should be closed for cylinder 5.

If both valves are not closed, rotate the engine one complete

revolution and re-align the "A" mark with the pointer. Verifythat the exhaust rocker lever is loose and can be moved

side to side.

2. Insert the 0.023" inches (0.58mm) feeler gauge betweenthe slave piston and the crosshead. Turn the adjusting screw

down until the correct clearance is obtained, and a light

drag on the feeler gauge can be felt. Hold the screw inposition and tighten the locknut to 18 lbft (24 N^m). Make

sure the feeler gauge can be reinserted.

3. Continue turning the engine in direction of rotation and

set the slave piston clearance for the next cylinders.

4. Install the nuts previously removed and tighten to 30lbft (40 N*m) in sequence as shown in Figure 1-4 then re-

torque to 60lbft (80M*m).

Operational Check

Installation of the brake housings is now complete.

Functioning of the brakes should be checked beforeproceeding further.

1. Start the engine and let it idle for a short time.

CAUTIONWear eye protection. When engine is running with valve

covers removed, oil splashing will occur. Take

precautions to prevent oil contaminating engine andengine compartment.

Figure 1-3

DIAL INDICATOR METHOD.

1. When the "A" or 1-6VS is aligned with the pointer,

both exhaust and intake valves should be closed for

cylinder 5. If both valves are not closed, rotate the engineone complete revolution and re-align the "A" mark with

the pointer. Verify that the exhaust rocker lever is looseand can be moved side to side.

2. Install a dial indicator over the slave piston adjustingscrew for the cylinder to be adjusted. Turn the adjusting

screw down until the slave piston contacts the crosshead.Zero the gauge on this position. Back out the slave piston

adjusting screw until the indicator shows 0.023 inch (0.58mm). Hold the screw in position and tighten the locknut

to 18 lbft (24 N*m).

3. Continue turning the engine in direction of rotation

and set the slave piston clearance for the next cylinders.

Figure 1-4

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ADJUSTING SCREWS

SCREW RECESSPART NO. COLOR DEPTH

TB934916 white 0.028"

HOUSING ASSEMBLY

HOUSING REPLACEMENT KIT CONTENTS:

PART NO. DESCRIPTION QTY./KIT

TB960020 HOUSING REPLACEMENT KIT 1 TB940066 PARTS & INSTALLATION MANUAL 1 TB940063 HOUSING ASSEMBLY T440/A 1 TJ016846 GASKET, BRAKE HOUSING 1 TJ016828 CAPSCREW (12 PT.) 6

Indented part numbers are included in parts under which they are indented.

MODEL T440/A HOUSING ASSEMBLYPart No.TB940063

REF. PART NO. DESCRIPTION QTY/HSG.

1 TJ011284 RING, RETAINER 22 TJ011252 COVER, CONTROL VALVE 23 TJ011253 SPRING, CONTROL VALVE, OUTER 24 TJ007500 SPRING, CONTROL VALVE, INNER 25 TJ011251 COLLAR, CONTROL VALVE 26 TJ011930 CONTROL VALVE 27 TB934916 ADJUSTING SCREW, WHITE 28 TB909354 NUT, JAM 29 TJ004205 SOLENOID VALVE (12 VOLTS) 1

10 TJ014619 HARNESS, SOLENOID 111 TJ001081 SEAL RING, UPPER 112 TJ001082 SEAL RING, MIDDLE 113 TJ001083 SEAL RING, LOWER 114 TB917366 TERMINAL ASSEMBLY 115 TB900029 MASTER PISTON (13/16") 216 TB900028 SPRING, FLAT 217 TJ001030 WASHER, PLAIN 218 TJ001492 CAPSCREW 219 TB934864 SLAVE PISTON ASSEMBLY 220 TB924867 SPRING, SLAVE PISTON, OUTER 221 TB924868 SPRING, SLAVE PISTON, INNER 222 TB924849 RETAINER, SPRING 223 TB902023 RING, RETAINER 2

TecBrake Inc. P.O. Box 27822 Houston, Texas 77227 1998 TecBrake Bulletin No. TB990168 11/18/98

Cummins and Celect are registered trademarks of Cummins Engine Co. Inc.