Engine Brakes

Installation and Parts Manual

Housing Replacement Kit Model T440/A Engine Brakes For Cummins 91N14 Series Engines

TecBrake P.O. Box 27822 Houston, Texas 77227

BRAKE HOUSING INSTALLATION MANUAL

TECBRAKE MODEL T440/A ENGINE BRAKE FOR CUMMINS 91N14 SERIES ENGINES
SECTION 1- INTRODUCTION The TecBrake T440/A engine brake may be installed on popular versions of the Cummins 91N14 series engine. It can not be installed on the Cummins 855, NTC/88NT, 94N14 model engines. Although the T440/A engine brake kit will fit on all 94N14 series engines, it should only be installed on engines whose CPL numbers are included in the Application Guide.

Figure 1-1 5. Place the engine brake housing on the rocker housing. Check rocker levers to be sure there is no interference.

NOTICE The TecBrake 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 vehicles service brakes. The service brakes must be in good operating condition and used to bring the vehicle to a complete stop.
Special Tools The following special tools are required for installation: 1. Crowfoot wrench- 9/16" 2. Feeler gauge- 0.023" Recommended Torque Values Engine Brake Hold-down Nuts Slave Piston Adj. Screw Nuts 75 lbft (102 N*m) 18 lbft (24 N*m) Figure 1-2 1. Obtain the engines CPL number. Refer to the TecBrake Application Guide, which list all Cummins engines on which the T440/A engine brake may be installed. 2. The T440/A brake may be installed on either 91N14 mechanical (STC) or electronic (CELECT) engine versions. 6. Tighten the capscrews in steps following the torquing sequence. Tighten to 75 lbft (102 N*m). Slave Piston Adjustment Adjustment of the slave piston adjusting screw is critical. Proper adjustment is necessary in order to provide peak braking efficiency without over stressing the engine. Use one of the two following procedures:

Section 2- Installing the Brake Housings1. Remove the existing engine brake housings. Discard the hold-down capscrews. 2. Make sure rocker housing surfaces are clean and smooth. Install the engine brake housing gaskets. 3. 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). 4. Install the six capscrews into the housing.

Slave piston adjusting screw adjustment must be made with the engine stopped and engine temperature stabilized below 140 F.

FEELER GAUGE METHOD. 1. When the "A" or 1-6VS is aligned with the pointer, both exhaust and intake valves should be closed for cylinder 5. If both valves are not closed, rotate the engine one complete revolution and re-align the "A" mark with the pointer. Verify that the exhaust rocker lever is loose and can be moved side to side. 2. Insert the 0.023" inches (0.58mm) feeler gauge between the slave piston and the crosshead. Turn the adjusting screw down until the correct clearance is obtained, and a light drag on the feeler gauge can be felt. Hold the screw in position and tighten the locknut to 18 lbft (24 N^m). Make sure the feeler gauge can be reinserted. 3. Continue turning the engine in direction of rotation and set the slave piston clearance for the next cylinders. 4. Install the nuts previously removed and tighten to 30 lbft (40 N*m) in sequence as shown in Figure 1-4 then retorque to 60lbft (80M*m). 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.

Figure 1-3 DIAL INDICATOR METHOD. 1. When the "A" or 1-6VS is aligned with the pointer, both exhaust and intake valves should be closed for cylinder 5. If both valves are not closed, rotate the engine one complete revolution and re-align the "A" mark with the pointer. Verify that the exhaust rocker lever is loose and can be moved side to side. 2. Install a dial indicator over the slave piston adjusting screw for the cylinder to be adjusted. Turn the adjusting screw down until the slave piston contacts the crosshead. Zero the gauge on this position. Back out the slave piston adjusting screw until the indicator shows 0.023 inch (0.58 mm). Hold the screw in position and tighten the locknut to 18 lbft (24 N*m). 3. Continue turning the engine in direction of rotation and set the slave piston clearance for the next cylinders.

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.

Figure 1-4

Figure 1-5 2. At idle; manually depress solenoid cap a few times. Repeat this procedure until the oil being exhausted down the control valve is free of air. 3. Connect housing assemblies to the existing wiring.

HOUSING REPLACEMENT KIT CONTENTS:

PART NO. TB960020 TB940066 TB940063 TJ016846 TJ016828 DESCRIPTION QTY./KIT 1 1 1 1 6

ADJUSTING SCREWS
SCREW PART NO. TB934916 COLOR white RECESS DEPTH 0.028"

HOUSING REPLACEMENT KIT PARTS & INSTALLATION MANUAL HOUSING ASSEMBLY T440/A GASKET, BRAKE HOUSING CAPSCREW (12 PT.)

Indented part numbers are included in parts under which they are indented.

MODEL T440/A HOUSING ASSEMBLY Part No.TB940063

REF. PART NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 TJ011284 TJ011252 TJ011253 TJ007500 TJ011251 TJ011930 TB934916 TB909354 TJ004205 TJ014619 TJ001081 TJ001082 TJ001083 TB917366 TB900029 TB900028 TJ001030 TJ001492 TB934864 TB924867 TB924868 TB924849 TB902023 DESCRIPTION QTY/HSG. 2 2 2 2 2 2 2 2 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2

RING, RETAINER COVER, CONTROL VALVE SPRING, CONTROL VALVE, OUTER SPRING, CONTROL VALVE, INNER COLLAR, CONTROL VALVE CONTROL VALVE ADJUSTING SCREW, WHITE NUT, JAM SOLENOID VALVE (12 VOLTS) HARNESS, SOLENOID SEAL RING, UPPER SEAL RING, MIDDLE SEAL RING, LOWER TERMINAL ASSEMBLY MASTER PISTON (13/16") SPRING, FLAT WASHER, PLAIN CAPSCREW SLAVE PISTON ASSEMBLY SPRING, SLAVE PISTON, OUTER SPRING, SLAVE PISTON, INNER RETAINER, SPRING RING, RETAINER

HOUSING ASSEMBLY

Cummins and Celect are registered trademarks of Cummins Engine Co. Inc. TecBrake Inc. P.O. Box 27822 Houston, Texas 77227 1998 TecBrake Bulletin No. TB990168 11/18/98