TecBrake T430A Manuale utente

TecBrake

P.O. Box 27822

Houston, Texas 77227

Installation

Manual

ModelT430A Engine Brakes

For Cummins

NTC/88NT Series Engines

Engine Brakes

INSTALLATION MANUAL

TECBRAKE MODELT430A ENGINE BRAKE

FOR CUMMINS NTC/88NT SERIES ENGINE

SECTION 1- INTRODUCTION

The TecBrakeT430A engine brake may be installed on

popular versions of the Cummins NTC/88NT series

engine.It can not be installed on earlier versions of the

Cummins NTC series engines, which use a different

cylinder head configuration. The TecBrake application

chart can be used to identify the engine model and

determine if the engine is approved for installation of an

engine brake.

The Model T430A engine brake will fit on NTC/88NT

enginesequippedwith eitherFixedTimingorStepTiming

Control(STC).EarlierSTC engineapplications required

that the rear brake housing be connected to the Step

TimingControlValve.Thisisnot requiredontheTecBrake

Model T430A.

NOTICE

TheTecBrake 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

vehicle’s service brakes. The service brakes must

be in good operating condition and used to bring

the vehicle to a complete stop.

Material Required

The TecBrake kit includes all of the parts required to

make an installation on the most common engine

configurations.

Prior to making installation, determine the engine CPL

number to verify that the engine brake being installed is

correctforthe engine.The CPLnumbercan befoundon

the engine identification plate that is located on the

engine gear case flange.

SpecialTools

The following special tools are required for installation:

1. Crowfoot wrench- 9/16"

2. Crowfoot wrench- 5/8"

3. Socket, extra deep- 5/8"

4. Feeler gauge- 0.018"

5. STCTappet setting tool- Cummins Part No.3822648

RecommendedTorqueValues

Crosshead Adj. Screw locknuts - 25 lbft (35 N*m)

Engine Brake Hold-down Nuts - 60 lbft (80 N*m)

Rocker Housing Studs- 70 lbft (95 N*m)

Rocker Arm Adj. Screw Nuts - 45 lbft (60 N*m)

Slave Piston Adj. Screw Nuts - 25 lbft (35 N*m)

Fuel Pump Sw. Mtg. Brkt. Bolts- 100lbin (10 N*m)

SECTION 2 - ENGINE PREPARATION

Figure 2-1

1. Thoroughly clean engine before beginning

installation. Remove all engine components necessary to

permit access to cylinder heads. Remove valve covers.

It is not necessary to remove the rocker lever housing

to install the ModelT430A engine brake.

Figure 2-2

2. Rotate engine crankshaft to proper position for making

adjustments to Injector, exhaust valve, and slave pistons

later on.

3. Turn crankshaft clockwise until the "A" mark on the

accessory drive pulley is aligned with pointer on the gear

case cover.

4 At this point, the intake and exhaust valves should be

closed for cylinder No. 5 and the rocker levers should be

"loose". The injector plunger for cylinder No. 3 must also

be at the top of it’s travel. If it is not, turn the crankshaft

another 360 degrees and realign the "A" mark with the

pointer.

5. After the engine brake is installed the engine will be in

position to begin setting the injector, exhaust valve and

slave piston adjusting screws.

Figure 2-3

7. Move the exhaust push tube to one side; rotate the

exhaust rocker lever to permit removal of Cummins

crosshead.

8. Install the new TecBrake crosshead. Note that it

comes with a new crosshead adjusting screw and nut.

Lubricate the crosshead and guide with oil before

installation.Make sure the crosshead adjusting screw is

on the exhaust manifold side of the engine.

9. Adjust the crosshead by holding it down against the

valve stem nearest the push tube, then turn in the

adjusting screw until it touches the valve stem.

10. Hold the adjusting screw in place and tighten the

locknut to 25 lbft (35N*m). Repeat operation for all

crossheads

6. Remove the rocker arm adjusting screws from the

exhaust rockerlevers.Retain theCumminslocknutsand

screws.

Figure 2-4

11. Remove the injector adjusting screws from injector

rockerarm.InstalltheTecBrakeinjector adjustingscrews

(hex head) furnished in kit. Reuse the Cummins

adjusting screw lock nuts.

CAUTION

The injector adjusting screw used in the TecBrake

Model T430A has a 5/8" hex head and height of 2".

Earlier model engine brakes used either a 5/8" or 7/

16" hex head and were 2.2" in height.These screws

are not interchangeable.Use of the wrong screw will

result in damage to the engine and brake.

Figure 2-5

12. RemovetheCumminssolid rocker shaft lockingscrews

from the cylinder heads and replace them with the hollow

setscrewssuppliedinkit.Besure screwisbelowflatsurface

of the rocker housing when installed.

Figure 2-6

13.Remove three capscrews from each rocker housing in

positions1, 2, and 3 as indicated in Figure 2-6.

Do not

remove all six of the capscrews at the same time, as

this will permit the housing and gasket to move.

Figure 2-7

14. Install the special bearing washer into each rocker

housingcapscrewbolthole withthesmallerdiameter down.

NOTE: Bearing washers are not required in positions 2

and 5 if a fan brace is used.

15. Install studs supplied with kit in positions1, 2 & 3 as

indicated in Figure 2-6.Torque studs to 70 lbft (95 N*m).

16. Removecapscrewsfrom positions4,5 &6as indicated

in Figure 2-6. Install new studs and torque to 70 lbft).

SECTION 3 - VALVE AND INJECTOR ADJUSTMENT

Different procedures areusedin settinginjectorsonSTC

versus fixed timed engines. Refer to the Injector and

Valve Setting Chart (Figure 3-1) to determine the

crankshaftpositionwhen adjusting injectorsandexhaust

valves.

Injector andValve Setting- Crankshaft Position Chart

Bar in Direction Pulley Set Set

of Rotation Position Injector Valves

START A 3 5

ADVANCE TO B 6 3

ADVANCE TO C 2 6

ADVANCE TO A 4 2

ADVANCE TO B 1 4

ADVANCE TO C 5 1

Figure 3-1

1. If you did not previously position the crankshaft for

valveand injectoradjustments,turncrankshaftclockwise

until the “A”mark on the accessory drive pulley is aligned

with pointer on the gear case cover.

2. At this point, the intake and exhaust valves should be

closed for cylinder No. 5 and the rocker levers should be

“loose”.The injector plunger for cylinder No. 3 must also

be at the top of its travel. If it is not, turn the crankshaft

another 360 degrees and realign the “A” mark with the

pointer.

Setting Injectors

Figure 3-2

FixedTiming Control -

1.Setinjectoradjustingscrewsto6lbin.(0.7N*m)following

thesetting chart (Figure3-1).Cumminsinjector adjusting

tool (Part No. 3376592) may be used.

Figure 3-3

2. Tighten adjusting screw locknut to 45 lbft (60 N*m).

StepTiming Control -

A special tappet tool (Cummins No. ST-3822648) must be

used to set the STC style injectors. This tool has a small

locating pin that locates the tool in one of the four holes in

the tappet.

Figure 3-4

1. Place the tool on top of the tappet then rotate it until the

pin is inserted into one of the holes in the tappet. Apply

pressure to the tool handle in order to hold the tappet at the

maximum extended position.

2. Set the injector rocker arm adjusting screw to 5-6 lbin.

Remove tool before baring the engine to the next position

as indicated in the setting chart (Figure 3-1).

3. Tighten adjusting screw locknut to 45 lbft (60 N*m).

Setting Intake and ExhaustValves -

1. Using the setting chart (Figure 3-1), adjust the valves

using a feeler gauge between the rocker lever and the

crosshead. The exhaust valve clearance should be 0.023"

and the intake valve clearance should be 0.011".

Note: Some engines may have different valve and

injector adjustments. Check the engine data plate to

verify settings.

2. Tighten adjusting screw locknut to 45 lbft (60 N*m).

SECTION 4 - INSTALLINGTHE BRAKE-

Figure 4-1

1. Installthe enginebrakehousing gaskets.Make sure

that the oil supply slots align correctly with the oil supply

screws in the housings.

2. 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).

Figure 4-2

3. Place the engine brake housing on the rocker

housing. Check rocker levers to be sure there is no

interference.

Figure 4-3

4. Ifliftingor mountingbracketsareused,install spacers

as required.

Figure 4-4

5. Install the nuts provided in the kit and tighten to 30 lbft

(40N*m)in sequenceasshowninFigure4-5 thenre-torque

to 60lbft (80M*m).

Figure 4-5

Slave Piston Adjusting Screw

Two adjusting screws are provided with the kit.Refer to the

ApplicationchartshowninFigure 4-6to identifywhichscrew

should be used.The most commonly used screws (black)

arepre-installed inthe brake.Ifthechart callsforthe Beige

adjusting screw, they should be installed in place of the

other (black) screw.

APPLICATION CHART ADJUSTING SCREW

CPL NO. ENGINE MODEL PART NO. COLOR

827 NTC400 88NT TB924921 BEIGE

838 NTC315 88NT TB924922 BLACK

840 NTC350 88NT TB924922 BLACK

910 NTC444 88NT TB924921 BEIGE

1185 NTC400 88NT TB924921 BEIGE

1187 FLEET 285 88NT TB924922 BLACK

1188 NTC350 88NT STC TB924921 BEIGE

1210 NTC444 88NT STC TB924921 BEIGE

1211 NTC400 88NT STC TB924921 BEIGE

1256 NTC444 88NT TB924921 BEIGE

1280 NTC444 88NT TB924921 BEIGE

1285 NTC444 88NT TB924921 BEIGE

1286 NTC444 88NT TB924921 BEIGE

1352 FLEET 300 88NT TB924922 BLACK

Figure 4-6

Figure 4-7

2. Bleedair fromtheengine brakehousing.Accelerate

the engine to about 1800 RPM then release the throttle.

Quickly depress the solenoid as shown to cause the

brake to operate.This process should be repeated 5-6

timeson each brakeassemblyin order tofillthehousings

with lube oil.When all of the air has been removed the

brake should operate immediately when the solenoid is

depressed.

SECTION 5- ELECTRICAL SYSTEM INSTALLATION

Installation of the electrical system involves the mounting

of dash switches, a clutch switch, and a fuel pump switch.

An optional foot switch may be installed in place of the

clutch switch.Wiring harnesses are provided in the kit to

completethe installation.Referto thewiring diagramFigure

5-8.

Dash Switches

Dash switches should be installed in dash where they are

visible and convenient to operate.

1. Drillholesin dashto accommodateswitches andinstall

switches with proper name plates.

Clutch Switch

Itis recommendedthatthe clutchswitchbemountedinside

the vehicle cab to protect it from road contamination.

Figure 5-1

1. Mount the clutch switch in a convenient location near

the clutch pedal so that movement of the clutch pedal will

contact the clutch switch actuator arm. See Figure 5-1.

2. Adjust the clutch switch so that the actuator arm is

deflectedfrom 1"to1.5" (25mmto 38mm)when theclutch

is in the up (clutch engaged) position.

3. Check the switch by depressing the clutch.The switch

should "click" to an open electrical position as soon as the

free play in the clutch is taken up. When the clutch is

released, the switch should "click" to a closed electrical

position.

Optional Foot Switch

An optional foot switch may be used in place of the clutch

switch.The foot switch should be mounted on the cab floor

to the left of the clutch pedal and should be located so that

it can be conveniently operated with the drivers left foot.

Slave Piston Adjustment

Adjustmentof theslave pistonadjustingscrew iscritical.

Properadjustment isnecessaryin orderto provide peak

braking efficiency without over stressing the engine.

Slave piston adjusting screw adjustment must be

made with the engine stopped and engine

temperature stabilized below 140 ºF

1. Set engine brake valve lash using the adjusting

screw located above each slave piston. The engine

crankshaft must be rotated to allow the exhaust valve to

be fully closed prior to making adjustment on each

cylinder.

2. Back out the adjusting screw on each cylinder to be

adjusted.Using a0.018"feelergauge between theslave

pistonandthe exhaustcrosshead,turnin the slavepiston

adjusting screw until a slight drag is felt on the gauge.

3. Tighten the adjusting screw lock nut to 25 lbft (35

N*m) torque. Rotate the crankshaft, adjusting each

adjusting screw in firing order sequence.

Operational Check

Installation of the brake housings is now complete.

Functioning of the brakes should be checked before

proceeding further.

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

CAUTION

Wear eye protection. When engine is running with

valve covers removed, oil splashing will occur.Take

precautions to prevent oil contaminating engine and

engine compartment.

Fuel Pump Switch

Figure 5-2

1. Diode on fuel pump switch is wired for a negative

groundelectrical system.If vehicleuses apositiveground

system, the diode must be removed and reversed.

Figure 5-3

2. Remove nut, bolt and washer from bottom of fuel

pump operating lever.

Figure 5-4

3. Install the actuating arm on the fuel control throttle

levelusing thenut,bolt andwasherpreviouslyremoved.

Figure 5-5

4. Remove two fuel pump mounting screws from rear of

fuel pump as shown.

Figure 5-6

5. Attach the fuel pump switch and mounting bracket to

the fuel pump using the screws just removed. Tighten to

100 lbin (10N*m) torque.

Figure 5-7

6. Adjust actuating arm to contact switch when throttle is

in idle position. Switch should “click” as soon as throttle

leverismovedoffofidle position.

Check tobesure throttle

linkage moves freely after installation of fuel

pump

switch.

Figure 5-8

Wiring

A universal wiring harness and other miscellaneous wiring

materials are included in the kit.

1. Install solenoid harness by connecting one end to the

solenoid valve and the other to the inside terminal in the

spacer assembly.

2. Install the remainder of the wiring following the

instructions included with the universal wiring harness and

wiring diagram shown in Figure 5-8.

3. All wiring should be routed to avoid areas of high heat

and mechanical interference where chaffing could occur.

4. Check system to determine if voltage is present at

terminals in engine brake spacer assembly.Voltage should

be present when engine is not running, with ignition on,

clutch disengaged, throttle in idle position, and all dash

switches in the “on”position.

5. While monitoring voltage at terminals in the engine

brake spacer, operate the switches to determine if they are

functioning properly. Depressing either the clutch or the

throttle pedal should cause the voltage to be interrupted.

SECTION 6 - ENGINE BRAKE MAINTENANCE

Theengine brakeis designedtobe troublefree and does

not require special maintenance. During regularly

scheduled maintenance, or if a problem occurs, the

procedures described below should be followed.

CAUTION: Do not remove any engine brake

component while the engine running.This may result

in personal injury. Use only approved cleaning

solvents.

Solenoid Valve

1. Disconnect the electrical lead from the solenoid and

remove solenoid with a spanner wrench. Remove and

discard the three rubber seal rings.

2. Clean the filter screen and solenoid with solvent then

dry with low air pressure.

3. Clean solenoid bore with solvent and wipe dry with

paper towel. Be careful not to leave any lint or residue in

bore that may contaminate brake hydraulic components.

Figure 6-1

4. Reinstall solenoid valve using three new o-rings.Coat

solenoid body with engine lube oil and install upper and

center seal rings on solenoid body.Seat lower seal ring in

bottom bore of brake.

5. Carefully screw in solenoid valve, using care to assure

O-rings remain in position and are not twisted or “rolled”.

Figure 6-2

6. Tighten solenoid valve to 5 lbft (7 N*M) torque.

Control Valve

Figure 6-4

2. Remove control valve using needle nose pliers.

3. Wash control valve with solvent.

4. Push on the check valve ball with a small wire through

the hole in the bottom of the control valve to make sure

that there is spring tension on the ball.The ball should lift

freely with a small amount of force and return quickly to

the seat when the force is removed. Replace the control

valve if it is defective.

5. Dip the control valve in engine lube oil and install in

brake housing. Control valve should slide in without any

binding. Replace control valve if binding occurs.

Figure 6-5

6. Install both control valve springs in control valve bore

and install cover with hex head capscrew.

Slave Piston

1. Remove lock nut from slave piston adjusting screw.

2. Loosen slave piston adjusting screw until slave piston

seats on bottom of bore.

Figure 6-3

1. Remove hex head capscrews from control valve

covers.

CAUTION:Control valve covers are under load from

control valve springs. Use care when removing

control valve covers to avoid injury.

Figure 6-6

CAUTION: When removing slave pistons wear eye

protection and use proper tools. Slave piston springs

are highly compressed and may cause serious

personal injury if not removed with caution.

3. Install slave piston spring removal tool as illustrated.

Turn tool screw until all force is removed from spring

retainer.

4. Using retaining ring pliers, orient the retaining ring

end near slot in brake housing.

5. Compress the retaining ring with the retaining ring

pliers and remove it from the groove in the housing.

6. Loosen screw in spring removal tool slowly and

carefully to remove the spring tension. Remove the

retainer, springs and slave piston.

7. Check slave piston outside diameter ground surface

for burs or defects.

8. Clean all parts with approved solvent and lubricate

with engine oil.

Figure 6-7

9. Insert piston in bore. Piston must slide in bore

without binding. Replace if binding occurs.

10. Reassemble all parts in reverse order from

disassembly procedure.

Master Piston

1. Remove button head screw, washer and flat spring

from brake housing.

2. Remove master piston from bore.

3. Checkmasterpistonoutside diametergroundsurface

for nicks or burrs. Piston must slide in bore without

binding.Replace if binding occurs.Check top surface of

piston. Replace piston if there are cracks or pitting.

4. Cleanall parts withapprovedsolvent andlubricate

with engine oil.

Figure 6-8

5. Insert piston in bore. Piston must slide in bore without

binding. Replace if binding occurs.

6. Reassembleallparts inreverseorderfrom disassembly

procedure.

7. Make sure spring tabs are aligned with raised surface

on end of piston.

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