TUNE-UPKITINSTRUCTIONS

Engine Brake Tune-Up Kit

For Cummins
Signature, ISX, QSX15 Engines
P/N 4025010
Tune-up Kit Contents
Illus.
No. P/N Part Name Quantity per kit
1 3871710 Solenoid, 12VDC D/L -
2 3871638 Seal, Solenoid Upper 3
3 4026537 Seal, Solenoid Center 3
4 3871218 Seal, Solenoid lower 3
5 3680937 Manifold Clamp -
6 3413098 Lever -
7 3413129 Control Valve Assembly 6
8 3413130 Control Valve Spring 6
9 3413131 Control Valve Cover 6
10 3413132 Retaining Clip 6
11 3679921 Hex Nut -
12 4026905 Actuator Piston 6
NI NSS Instructions 1

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™ potentially dangerous to the mechanic or equipment.
components. For additional information on the Read this manual carefully. Know when these
Cummins Signature, ISX, and QSX15 engines see the conditions can exist. Then take necessary steps to
Troubleshooting and Repair Manual, Bulletin No. protect personnel as well as equipment.
3666239.
THIS SYMBOL WARNS OF POSSIBLE
The slave piston clearance settings listed on page 4 PERSONAL INJURY.
of this manual are current as of this printing. THIS SYMBOL REFERS TO POSSIBLE
EQUIPMENT DAMAGE.
Use OSHA-approved cleaning solvent for cleaning
parts. Original parts to be reused should be NOTE: INDICATES AN OPERATION, PROCEDURE
inspected for wear and replaced as required. Be sure OR INSTRUCTION THAT IS IMPORTANT
FOR CORRECT SERVICE.
to coat parts with clean engine oil when reinstalling
them. Fuels, electrical equipment, exhaust gases and
moving engine parts present potential hazards that
The standard Cummins Service Parts Warranty
could result in personal injury. Take care when
applies to the components of this Tune-up Kit.
installing equipment or parts. Always wear safety
glasses. Always use correct tools and follow proper
procedures as outlined in this manual.

2 TUNE-UP KIT INSTRUCTIONS FOR ISX SERIES INTEBRAKE™

 2. With the new piston (12) positioned in the
Instructions rocker lever bore, turn the adjusting screw
counter clockwise until the piston is seated
NEVER REMOVE OR ADJUST ANY ENGINE in the lever bore. Install the locknut. Do not
BRAKE OR COMPONENT WITH THE
ENGINE RUNNING.
tighten.

3. Repeat this procedure with the remaining

levers.
Access Engine Brake
1. Thoroughly clean engine.
Control Valve Removal and
2. Remove the eight capscrews and isolators Replacement
from the Rocker Cover. Remove the cover.

3. Disconnect terminals on wiring harness from WEAR SAFETY GLASSES. REMOVE

CONTROL VALVE COVERS (9)
terminals on the solenoids (3 places). With your
CAREFULLY TO AVOID PERSONAL
hands about 18 inches apart, grasp engine INJURY. COVERS ARE UNDER LOAD FROM
brake wiring harness support frame and pull up CONTROL VALVE SPRINGS (8).
and out from cylinder head. Harness can be
laid over the side of the engine for the 1. Use snap ring pliers to remove the snap ring,
remainder. There is no need to remove the 8- control valve cover (9), spring (8), and control
way pass-thru connector from the cylinder valve (7).
head.
2. Insert new control valve (7) into the control
USE CARE WHEN HANDLING SHAFTS. valve bore. Move the control valve in the bore
ROCKER LEVERS CAN FALL OFF THE
SHAFT DURING REMOVAL AND DAMAGE
to insure free movement and lubricate the
THE LEVERS. assembly.

4. Remove the valve and brake rocker lever shaft 3. Insert the control valve spring (8), control valve
capscrews, the solenoid manifold assembly, cover (9), and snap ring (10). With your thumb
and the rocker lever shaft assemblies. Remove on the control valve cover, press down on the
the valve crossheads and crosshead guide assembly and lock the assembly into position
pins. with the snap ring.

4. Repeat this procedure with the remaining

NOTE: TO PREVENT INCREASED WEAR, MARK control valves.
EACH CROSSHEAD, GUIDE PIN, AND
ROCKER LEVER SHAFT ASSEMBLY AS IT IS
REMOVED SO IT CAN BE INSTALLED BACK
IN ITS ORIGINAL POSITION.
Install Rocker Lever and Brake
Assembly
5. Inspect the valve and brake rocker lever shaft
for any excessive wear around the brake
detent hole. No further disassembly is required CLEAR THE ROCKER LEVER ASSEMBLY
MOUNTING CAPSCREW HOLES OF OIL
to complete the removal and replacement of
AND DEBRIS. EXTENSIVE DAMAGE CAN
the brake parts. Coat all parts to be installed RESULT IF THIS WARNING INSTRUCTION IS NOT
with clean lube oil. FOLLOWED.

1. Install the intake crossheads and exhaust

Actuator Piston Removal and crossheads with guide pins.
Replacement
2. Install the valve/brake rocker lever assemblies
1. Remove the engine brake valve lash adjusting onto the cylinder head. Prior to bolting down a
screw locknut (11). Using a 3mm hex, turn the shaft assembly, bar the engine over until the
piston adjusting screw clockwise until the shaft is seated on all 3 pedestals. To bar the
piston comes out of the rocker lever bore. engine, remove the oil filler tube and use a ¾
inch drive breaker bar with extension to rotate
the engine.

TUNE-UP KIT INSTRUCTIONS FOR ISX SERIES INTEBRAKE™ 3

 2. Locate the engine brake set marks on the
outside of the vibration damper.
NOTE: THE VALVE/BRAKE ROCKER LEVER
SHAFTS HAVE A MACHINED FLAT ON THE
FRONT END OF THE SHAFT FOR
3. The set marks are BRAKE SET 1-6, BRAKE
DETERMINING THE PRECISE BRAKE SET 2-5, BRAKE SET 3-4:
ROCKER LEVER POSITION. THE FRONT “BRAKE SET 1-6”: cylinder 1 or 6 adjust.
MOUNTING CAPSCREW FOR EACH VALVE/ “BRAKE SET 2-5”: cylinder 2 or 5 adjust.
BRAKE ROCKER LEVER SHAFT SHOULD BE “BRAKE SET 3-4”: cylinder 3 or 4 adjust.
INITIALLY TIGHTENED TO 13 N•M [115IN-
LB] TO PROPERLY SEAT THE FLAT OF THE
SHAFT INTO ITS MATING SADDLE. 4. Using a ¾ inch drive breaker bar with
extension, rotate the engine clockwise until set
3. Lubricate the lever shaft capscrews with clean mark 1-6 on the vibration damper aligns with
lube oil. Install remaining capscrews with the stamped mark on the front gear cover.
washers or solenoid manifold assemblies. On Check the engine brake lever on the given
the front shaft, the solenoid manifold cylinder. When adjusting cylinder No.1, both
assemblies mount under the capscrews the intake and exhaust valves on cylinder No.1
between cylinders 1 and 2, and also between must be closed. The camshaft follower of the
cylinders 2 and 3. On the rear shaft the brake lever must be on the inner base circle of
solenoid manifold assembly mounts under the the valve camshaft lobe. If not, rotate the
capscrews between cylinders 4 and 5. engine one full revolution to set mark 1-6.

4. Tighten the front mounting capscrew for the 5. Press the engine brake lever down to position
shaft. Torque Value – 68 N•m [50 ft-lb] the lever camshaft follower in contact with the
Tighten the remaining capscrews.Torque camshaft.
Value – 68 N•m [50 ft-lb].
6. Loosen the locknut on the brake lever adjusting
5. Loosen the capscrews one at a time 360 screw, and back out the adjusting screw one
degrees and tighten again using the torque turn.
plus angle method. Tighten capscrews from
the center out to 30 N•m [22 ft-lb]. Then rotate 7. Insert the feeler gage part no. 3163530
each capscrew 60 degrees. (7.0 mm) between the bottom of the engine
brake actuator piston (12) and the top of the
6. Repeat this precedure for the remaining rocker exhaust valve guide pin on the exhaust valve
shaft. crosshead.

CAUTION- FOR MAXIMUM DURABILITY 8. Tighten the adjusting screw until drag on the
OF THE BRAKE ASSEMBLY, CHECK THE feeler gage is felt. Proper drag means that
RUNNING CLEARANCES BETWEEN THE
ACTUATOR PISTON AND THE EXHAUST VALVE
there is no motion of the brake lever camshaft
CROSSHEAD GUIDE PIN. WITH THE BRAKE ROCKER follower against the cam lobe.
LEVER IN THE NEUTRAL POSITION, A .020” FEELER
GAGE BLADE MUST PASS FREELY BETWEEN THE 9. Hold the engine brake lever adjusting screw
ACTUATOR PISTON AND THE GUIDE PIN. IF NOT,
LOOSEN THE SHAFT ASSEMBLY AND ROTATE THE
and tighten the locknut 20N•m [15 ft-lb].
SHAFT IN THE DIRECTION NECESSARY TO INCREASE
THE RUNNING CLEARANCES. RETORQUE THE 10. Repeat the procedure with the remaining
SHAFT ASSEMBLY AS DESCRIBED ABOVE. (DESIRED cylinders.
CLEARANCE = .060”).

11. Replace the oil filler tube.

Adjust Brake Lever Lash Setting
Solenoid Seal Removal and
TO GET MAXIMUM BRAKE OPERATING Replacement
EFFICIENCY AND TO PREVENT ENGINE
DAMAGE, YOU MUST FOLLOW THE 1. Remove the solenoid (1) using a 3/4" socket
INSTRUCTIONS IN THIS SECTION.
and discard three solenoid O-rings.
1. The engine brake setting is to be made in the
same sequence as the firing order (1 5 3 6 2 2. Dip the o-rings in oil. Install the upper and
4 ). center o-rings (2,3) on the solenoid. Coat the
inside of the manifold with oil. Place the lower

4 TUNE-UP KIT INSTRUCTIONS FOR ISX SERIES INTEBRAKE™

 o-rings (4) in the bottom of the manifold. The oil
will keep the rings from being twisted and/or
cut during installation of the solenoid into
manifold. Install the solenoid into the manifold.
Tighten the solenoid to 20 N•m [15 ft-lb] using
a 3/4" socket.

3. Install the wiring harness support bracket into

the cylinder head.

4. Connect the wiring harness terminals to the

solenoid terminals.

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].

TUNE-UP KIT INSTRUCTIONS FOR ISX SERIES INTEBRAKE™ 5

P/N 28281 Rev. A ©2000 Jacobs Vehicle Systems, Inc. Printed in U.S.A. Rev. 4/00