TecBrake T430A User manual

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.
1

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).
2

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).
3

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
4

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.
5

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.
6

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”.
7

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.
8

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.
9

TecBrake Inc. P.O.Box 27822 Houston, Texas 77227 ©1994 TecBrake, Inc. Bulletin No.TB990125 8/10/95