installation manual for isl98, isl03, isl07,...

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


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


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. �


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].


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].


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�


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


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


Slave Piston Adjusting Screws (D Lash)Loosenslavepistonadjustingscrewlocknutandremoveadjustingscrewfromhousing(fig.24).

Cleanadjustingscrewinanapprovedcleaningsolvent.

Inspecttheslavepistonadjustingscrew(dLash).Theplungershouldprotrudefromthebottomofthescrew,andmovefreely(fig.25).Besuretheretainingringisfullyengagedinitsgroove.Replacetheentirescrewassemblyifanydefectisfound.

dONOTREAdJUSTORTAMPERWITHTHEAdJUSTINGSCREWASSEMBLY.ENGINEdAMAGECOULdRESULT.

FIG. ��

FIG. ��

SLIDE PLUNGER


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. ��


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

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