Intebrake TM
Engine Brake Tune-Up Kit
Signature, ISX, QSX15 Engines P/N 2882081
tune-up kit instructions
Tune-up Kit Contents
1
1
Illus
No. P/N Part Name Quantity
per kit
1 3686406 Solenoid, 12VDC Thread - 2 14
Terminal (Type II) 3 13
1 4024759 Solenoid, 12VDC S/L - 4
(Type I) 15
2 3871638 Seal, Solenoid Upper 3
3 4026537 Seal, Solenoid Center 3 5
5
4 3871218 Seal, Solenoid Lower 3
5 3685827 Manifold Clamp - Type II -
5 3104916 Manifold Clamp - Type I -
6 4298199 Lever -
7 3413129 Control Valve Assembly 6
8 2892986 Control Valve Spring 6 10
9
9 3413131 Control Valve Cover 6
8
10 3413132 Retaining Clip 6
7
11 3679921 Hex Nut - 6
11
12 2882738 Actuator Piston -
13 4298248 O-Ring (.426ID) 3
14 4298247 O-Ring (.614ID) 3
15 3902093 Screw, Socket (6MM10LG) -
NI NSS Instructions 1 12
NSS – Not Sold Separately
General Information Safety Precautions
These instructions describe how to properly remove, The following symbols in this manual signal conditions
clean and reinstall Jacobs Engine Brake components. TM
potentially dangerous to the mechanic or the
For additional information on the Cummins Signature, equipment. Read this manual carefully. Know when
ISX, and QSX15 engines see the Troubleshooting and these conditions can exist. Then take necessary steps
Repair Manual, Bulletin No. 3666239. to protect personnel as well as equipment.
The actuator piston lash and clearance settings listed THIS SYMBOL WARNS OF POSSIBLE
! WARNING
on page 4 of this manual are current as of this printing. PERSONAL INJURY.
THIS SYMBOL REFERS TO POSSIBLE
! CAUTION
Use OSHA-approved cleaning solvent for cleaning EQUIPMENT DAMAGE.
parts. Original parts to be reused should be inspected
for wear and replaced as required. Be sure to coat NOTE: INDICATES AN OPERATION, PROCEDURE OR
INSTRUCTION THAT IS IMPORTANT FOR CORRECT
parts with clean engine oil when reinstalling them. SERVICE.
The standard Cummins Service Parts Warranty applies
Fuels, electrical equipment, exhaust gases and moving
to the components of this Tune-up Kit.
engine parts present hazards that could result in personal
injury. Take care when installing equipment or parts.
Always wear safety glasses. Always use correct tools
and follow proper procedures as outlined in this manual.
2
TM
T U N E - U P K I T I N S T R U C T I O N S F O R I S X S E R I E S I N T E B R A K E
Instructions on the control valve cover, press down on the
assembly and lock the assembly into position with
NEVER REMOVE OR ADJUST ANY ENGINE
! WARNING
BRAKE OR COMPONENT WITH THE ENGINE
the snap ring.
RUNNING
4. R
epeat this procedure with the remaining control
valves.
Access Engine Brake
1. Thoroughly clean engine. Install Rocker Lever and Brake Assembly
2. R
emove the eight capscrews and isolators from CLEAR THE ROCKER LEVEL ASSEMBLY
! CAUTION
MOUNTING CAPSCREW HOLES OF OIL AND
the Rocker Cover. Remove the cover.
DEBRIS. EXTENSIVE DAMAGE CAN RESULT
IF THIS WARNING INSTRUCTION IS NOT
3. D
isconnect terminals on wiring harness from FOLLOWED.
terminals on the solenoids.
USE CARE WHEN HANDLING SHAFTS. ROCKER
1. Install the intake crossheads and exhaust
! CAUTION
LEVERS CAN FALL OFF THE SHAFT DURING crossheads with guide pins.
REMOVAL AND DAMAGE THE LEVERS.
2. Install the valve/brake rocker level assemblies
4. R
emove the valve and brake rocker lever shaft onto the cylinder head. Prior to bolting down a
capscrews, the solenoid manifold assembly, and shaft assembly, bar the engine over until the shaft
the rocker lever shaft assembles. Remove the is seated on all 4 pedestals. To bar the engine,
valve crossheads and crosshead guide pins. remove the oil filter tube and use a 3/4 inch drive
breaker bar with extension to rotate the engine.
NOTE: TO PREVENT INCREASED WEAR, MARK EACH
CROSSHEAD, GUIDE PIN, AND ROCKER LEVER SHAFT NOTE: THE VALVE/BRAKE ROCKER LEVER SHAFTS
ASSEMBLY AS IT IS REMOVED SO IT CAN BE INSTALLED HAVE A MACHINED FLAT ON THE FRONT END OF THE
BACK IN ITS ORIGINAL POSITION. SHAFT FOR DETERMINING THE PRECISE BRAKE ROCKER
LEVER POSITION. THE FRONT MOUNTING CAPSCREW
FOR EACH VALVE/BRAKE ROCKER LEVER SHAFT
5. Inspect the valve and brake rocker lever shaft for SHOULD BE INITIALLY TIGHTENED TO 13 N-M (115 IN-LB)
any excessive wear around the brake detent hole. TO PROPERLY SEAT THE FLAT OF THE SHAFT INTO ITS
No further disassembly is required to complete the MATING SADDLE.
removal and replacement of the brake parts. Coat
all parts to be installed with clean lube oil. 3. L
ubricate the lever shaft capscrews with clean
lube oil. Install remaining capscrews with washer
or solenoid manifold assemblies mount under the
Control Valve Removal and Replacement capscrews between cylinders 1 and 2, and also
between cylinders 2 and 3. On the rear shaft the
WEAR SAFETY GLASSES. REMOVE CONTROL solenoid manifold assembly mounts under the
! WARNING
VALVE COVERS (9) CAREFULLY TO AVOID capscrews between cylinders 4 and 5.
PERSONAL INJURY. COVERS ARE UNDER LOAD
FROM CONTROL VALVE SPRINGS (8). 4. T
ighten the front mounting capscrew for the shaft.
Torque Value – 68 N-m (50 ft-lb) Tighten the
1. U
se snap ring pliers to remove the snap ring, control remaining capscrews. Torque Value – 68 N-m
valve cover (9), spring (8), and control valve (7). (50 ft-lb)
2. Insert new control valve (7) into the control valve
bore. Move the control valve in the bore to insure
free movement and lubricate the assembly.
3. Insert the control valve spring (8), control valve
cover (9), and snap ring (10). With your thumb
3
oosen the capscrews one at a time 360 degrees
5. L 8. T
ighten the adjusting screw until drag on the
and tighten again using the torque plus angle feeler gage is felt. Proper drag means that there
method. Tighten capscrews from the center out to is no motion of the brake lever camshaft follower
30 N-m (22 ft-lb). Then rotate each capscrew 60 against the cam lobe.
degrees.
9. H
old the engine brake lever adjusting screw and
6. R
epeat this procedure for the remaining tighten the locknut 20N-m (15 ft-lb).
rocker shaft.
10. R
epeat the procedure with the remaining
cylinders.
Adjust Brake Lever Lash Setting 11. Replace the oil filler tube.
TO GET MAXIMUM BRAKE OPERATING
! CAUTION FOR THE MAXIMUM DURABILITY OF THE
EFFICIENCY AND TO PREVENT ENGINE
DAMAGE, YOU MUST FOLLOW THE BRAKE ASSEMBLY, CHECK THE RUNNING
INSTRUCTIONS IN THIS SECTION. CLEARANCES BETWEEN THE ACTUATOR
! CAUTION
PISTON AND THE EXHAUST VALVE CROSSHEAD
GUIDE PIN. WITH THE BRAKE ROCKER LEVER
1. T
he engine brake setting is to be made in the IN THE NEUTRAL POSITION, A.020” FEELER
same sequence as the firing order (1, 5, 3, 6, 2, 4). GAGE BLADE MUST PASS FREELY BETWEEN
THE ACTUATOR PISTON AND THE GUIDE
2. L
ocate the engine brake set marks on the outside PIN. IF NOT, LOOSEN THE SHAFT ASSEMBLY
of the vibration damper. AND ROTATE THE SHAFT IN THE DIRECTION
NECESSARY TO INCREASE THE RUNNING
CLEARANCES. RETORQUE THE SHAFT
3. T
he set marks are BRAKE SET 1-6, BRAKE SET
ASSEMBLY AS DESCRIBED ABOVE. (DESIRED
2-5, BRAKE SET 3-4: CLEARANCE = .060”).
a. “BRAKE SET 1-6”: cylinder 1 or 6 adjust
b. “BRAKE SET 2-5”: cylinder 2 or 5 adjust
Type-I Solenoid Seal Removal and
c. “BRAKE SET 3-4”: cylinder 3 or 4 adjust Replacement (Threaded Body)
4. U
sing a 3/4 inch drive breaker bar with extension,
1. R
emove the solenoid (1) using a 3/4” socket and
rotate the engine clockwise until set mark 1-6
discard three solenoid seals.
on the vibration damper aligns with the stamped
mark on the front gear cover. Check the engine 2. D
ip the seals in oil. Install the upper and center
brake lever on the given cylinder. When adjusting seal (2, 3) on the solenoid. Coat the inside of the
cylinder No. 1, both the intake and exhaust valves manifold with oil. Place the lower seals (4) in the
on cylinder No. 1 must be closed. The camshaft bottom of the manifold. The oil will keep the seals
follower of the brake lever must be on the inner from being twisted and/or cut during installation of
base circle of the valve camshaft lobe. If not, the solenoid into the manifold. Install the solenoid
rotate the engine one full revolution to set mark into the manifold. Tighten the solenoid to 20 N-m
1-6. (15 ft-lb) using a 3/4” socket.
5. P
ress the engine brake lever down to position 3. Install
the wiring harness support bracket into the
the lever camshaft follower in contact with the cylinder head.
camshaft.
4. Connect
the wiring harness terminals to the
6. L
oosen the locknut on the brake lever adjusting solenoid terminals.
screw, and back out the adjusting screw one turn.
7. S
et lash 7.0mm by inserting the feeler gage part
no. 3163530 between the bottom of the engine
brake actuator piston (12) and the top of the
exhaust valve guide pin on the exhaust valve
crosshead.
4
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T U N E - U P K I T I N S T R U C T I O N S F O R I S X S E R I E S I N T E B R A K E
Type-II Solenoid O-Ring Removal and
Replacement - (Push-In)
1. R
emove the solenoid (1) using a 5mm hex socket
and discard two solenoid o-rings.
2. Install the upper (14) and lower (13) o-ring on
the solenoid. Coat the o-rings with oil. Install the
solenoid into the manifold (5). Align the clamp
with manifold thread hole and install socket screw.
Tighten screw to 14 N-m (124 lb-in) using 5mm
hex socket.
3. C
onnect wiring harness nut-terminal to the
solenoid thread studs. Tighten nut terminal to 1.5
N-m (13 lb-in).
Replace Rocker Lever Valve Cover
1. Install the rocker lever cover gasket onto the
rocker lever cover.
2. Install
the rocker lever cover, eight capscrews, and
isolator assemblies. Tighten capscrews to 25 N-m
(18 ft-lb).
© Jacobs Vehicle Systems, Inc. Printed in the U.S.A. P/N 00-028281B Rev. B Rev. 3/11
