Summary of Contents for Jacobs CBRAKE 490
- Page 1 Model 490/490A Installation Manual ISL98, ISL03, ISL07, ISC07, ISL 2010, ISC 2010, ISL 2013, L9 2017, L9 2021 Engines INSTALLATION MANUAL...
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Page 2: Table Of Contents
For housing part number and other replacement part informa- tion, refer to Cummins Bulletin No. 3401838, Jacobs Parts Manual, P/N 026301. THIS SYMBOL WARNS OF POSSIBLE PER- Engine Identification SONAL INJURY. -
Page 3: Special Tools
Special Tools The following special tools should be available for the instal- lation: THE 490A BRAKE IS APPROVED FOR USE ON THE ISC07 AND ISC 2010 ENGINE ONLY. THE 490A Torque 6 in-lb wrench, Cummins P/N 3376592. BRAKE IS NOT APPROVED FOR USE ON PRIOR ISC ENGINE MODELS. -
Page 4: Section 2: Engine Preparation
TION ON SETTING INTAKE VALVE LASH. 5. Remove exhaust rocker lever mounting studs on Cylinders 1, 3, and 5. 6. Remove exhaust crossheads and replace with CBrake by Jacobs Crossheads (Fig. 3). ® 7. Install new exhaust rocker lever mounting studs (these will accept the engine brake mounting bolts). -
Page 5: Section 3: Engine Brake Housing Installation
14. Remove exhaust crossheads and replace with CBrake by Jacobs crossheads (Fig. 3). 15. Install new exhaust rocker lever mounting bolts (these will accept the engine brake mounting bolts). Torque to 60 N•m [45 ft-lb]. -
Page 6: Slave Piston Adjustment
Slave Piston Adjustment NOTE: ADJUST THE SLAVE PISTON CLEARANCE WITH THE ENGINE STOPPED AND COLD. STABILIZED WATER TEMPERATURE OF 140° F. (60° C.) OR BELOW. EXHAUST VALVES, ON THE CYLINDER TO BE ADJUST- ED, MUST BE IN THE CLOSED POSITION. 1. -
Page 7: Section 4: Electrical System Installation
Refer to Cummins service manual or contact your local Cummins service center for wiring installation infor- mation. Section 5: Brake Operation Check The CBrake by Jacobs engine installation is now Replace Rocker Lever Cover complete. The following procedures and adjust- ments should be made. -
Page 8: Section 6: Engine Brake Maintenance
Section 6: Brake Maintenance Theory of Operation lube oil to flow under pressure through the control valve to both the master piston and the slave piston. Energizing the engine brake effectively converts a power-producing diesel engine into a pow- 2. Oil pressure causes the master piston to move er-absorbing air compressor. -
Page 9: Control Valve
The CBrake by Jacobs is a relatively trouble-free device. However, inspections and routine mainte- nance will need to be made from time to time. Use the following procedures to keep the engine brake in top condition. This section will cover how to properly remove, clean and reinstall engine brake components. - Page 10 3. Using needle-nose pliers or a magnet, remove the control valve (see Fig. 15). 4. Wash the control valve with approved cleaning solvent. Push a wire through the hole in the base of the valve to ensure that the ball check is free.
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Page 11: Solenoid Valve
Solenoid Valve Disconnect the solenoid harness. Using a 3/4” socket and extension, unscrew the solenoid valve (see Fig. 17). DO NOT DISASSEMBLE OR TAMPER WITH THE SOLENOID VALVE. ENGINE DAMAGE COULD RESULT. Remove and discard the rubber seal rings (Fig. 18). -
Page 12: Slave Piston Adjusting Screws
Slave Piston Adjusting Screws (D Lash) Loosen slave piston adjusting screw locknut and remove adjusting screw from housing (Fig. 20). Clean adjusting screw in an approved cleaning solvent. Inspect the slave piston adjusting screw (D Lash). The plunger should protrude from the bottom of the screw, and move freely (Fig. -
Page 13: Master Piston
Master Piston Remove the button-head screw, washer and mas- ter piston spring from bottom of housing. Remove the master piston from its bore using nee- dle-nose pliers. If binding occurs, check for burrs or contaminants in the lube oil. Clean in an approved cleaning solvent (Fig. - Page 14 3. Turn the handle slowly until the retainer is depressed, about 1/32” (1 mm), relieving pres- sure against the retaining ring. 4. Remove the retaining ring using retaining ring pliers. Back out the holder until the springs are loose. Remove the tool. (see Fig. 25) 5.
- Page 15 Notes:...
- Page 16 CBrake by Jacobs is a trademark of Cummins Inc. and Jacobs Vehicle Systems, Inc. ® JACOBS VEHICLE SYSTEMS, INC. I 22 EAST DUDLEY TOWN ROAD BLOOMFIELD, CT USA 06002 I P/N 00-026302 REV E 12/2021 I ©2021 JACOBS VEHICLE SYSTEMS, INC.