Installation Manual T430A - TecBrake

1 Box 27822 Houston, Texas 77227 InstallationManualModel T430A Engine BrakesFor CumminsNTC/88NT series EnginesEngine BrakesINSTALLATION MANUALTECBRAKE MODEL T430A ENGINE BRAKEFOR CUMMINS NTC/88NT series ENGINESECTION 1- INTRODUCTIONThe TecBrake T430A engine brake may be installed onpopular versions of the Cummins NTC/88NT seriesengine. It can not be installed on earlier versions of theCummins NTC series engines, which use a differentcylinder head configuration. The TecBrake applicationchart can be used to identify the engine model anddetermine if the engine is approved for Installation of anengine Model T430A engine brake will fit on NTC/88 NTengines equipped with either Fixed Timing or Step TimingControl (STC).

2 Earlier STC engine applications requiredthat the rear brake housing be connected to the StepTiming Control Valve. This is not required on the TecBrakeModel TecBrake Engine Brake is designed as a devicefor slowing a vehicle, not stopping it. It is to be usedin conjunction with, but not a substitute for thevehicle s service brakes. The service brakes mustbe in good operating condition and used to bringthe vehicle to a complete RequiredThe TecBrake kit includes all of the parts required tomake an Installation on the most common to making Installation , determine the engine CPLnumber to verify that the engine brake being installed iscorrect for the engine.

3 The CPL number can be found onthe engine identification plate that is located on theengine gear case ToolsThe 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- "5. STC Tappet setting tool- Cummins Part Torque ValuesCrosshead 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 PREPARATIONF igure clean engine before beginninginstallation.

4 Remove all engine components necessary topermit access to cylinder heads. Remove valve is not necessary to remove the rocker lever housingto install the Model T430A engine 2-22. Rotate engine crankshaft to proper position for makingadjustments to Injector, exhaust valve, and slave pistonslater Turn crankshaft clockwise until the "A" mark on theaccessory drive pulley is aligned with pointer on the gearcase At this point, the intake and exhaust valves should beclosed for cylinder No. 5 and the rocker levers should be"loose". The injector plunger for cylinder No. 3 must alsobe at the top of it s travel. If it is not, turn the crankshaftanother 360 degrees and realign the "A" mark with After the engine brake is installed the engine will be inposition to begin setting the injector, exhaust valve andslave piston adjusting 2-37.

5 Move the exhaust push tube to one side; rotate theexhaust rocker lever to permit removal of Install the new TecBrake crosshead. Note that itcomes with a new crosshead adjusting screw and the crosshead and guide with oil beforeinstallation. Make sure the crosshead adjusting screw ison the exhaust manifold side of the Adjust the crosshead by holding it down against thevalve stem nearest the push tube, then turn in theadjusting screw until it touches the valve Hold the adjusting screw in place and tighten thelocknut to 25 lbft (35N*m). Repeat operation for allcrossheads6. Remove the rocker arm adjusting screws from theexhaust rocker levers.

6 Retain the Cummins locknuts 2-411. Remove the injector adjusting screws from injectorrocker arm. Install the TecBrake injector adjusting screws(hex head) furnished in kit. Reuse the Cumminsadjusting screw lock injector adjusting screw used in the TecBrakeModel 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 " in height. These screwsare not interchangeable. Use of the wrong screw willresult in damage to the engine and 2-512. Remove the Cummins solid rocker shaft locking screwsfrom the cylinder heads and replace them with the hollowset screws supplied in kit. Be sure screw is below flat surfaceof the rocker housing when three capscrews from each rocker housing inpositions1, 2, and 3 as indicated in Figure 2-6.

7 Do notremove all six of the capscrews at the same time, asthis will permit the housing and gasket to 2-714. Install the special bearing washer into each rockerhousing capscrew bolt hole with the smaller diameter : Bearing washers are not required in positions 2and 5 if a fan brace is Install studs supplied with kit in positions1, 2 & 3 asindicated in Figure 2-6. Torque studs to 70 lbft (95 N*m).16. Remove capscrews from positions 4, 5 & 6 as indicatedin Figure 2-6. Install new studs and torque to 70 lbft).2 SECTION 3 - VALVE AND INJECTOR ADJUSTMENTD ifferent procedures are used in setting injectors on STCversus fixed timed engines.

8 Refer to the Injector andValve Setting Chart (Figure 3-1) to determine thecrankshaft position when adjusting injectors and and Valve Setting- Crankshaft Position ChartBar in DirectionPulleySetSetof RotationPositionInjectorValvesSTARTA35 ADVANCE TOB63 ADVANCE TOC26 ADVANCE TOA42 ADVANCE TOB14 ADVANCE TOC51 Figure 3-11. If you did not previously position the crankshaft forvalve and injector adjustments, turn crankshaft clockwiseuntil the A mark on the accessory drive pulley is alignedwith pointer on the gear case At this point, the intake and exhaust valves should beclosed for cylinder No. 5 and the rocker levers should be loose . The injector plunger for cylinder No.

9 3 must alsobe at the top of its travel. If it is not, turn the crankshaftanother 360 degrees and realign the A mark with InjectorsFigure 3-2 Fixed Timing Control -1. Set injector adjusting screws to 6 lbin. ( *m) followingthe setting chart (Figure 3-1). Cummins injector adjustingtool (Part No. 3376592) may be 3-32. Tighten adjusting screw locknut to 45 lbft (60 N*m).Step Timing Control -A special tappet tool (Cummins No. ST-3822648) must beused to set the STC style injectors. This tool has a smalllocating pin that locates the tool in one of the four holes inthe 3-41. Place the tool on top of the tappet then rotate it until thepin is inserted into one of the holes in the tappet.

10 Applypressure to the tool handle in order to hold the tappet at themaximum extended Set the injector rocker arm adjusting screw to 5-6 tool before baring the engine to the next positionas indicated in the setting chart (Figure 3-1).3. Tighten adjusting screw locknut to 45 lbft (60 N*m).Setting Intake and Exhaust Valves -1. Using the setting chart (Figure 3-1), adjust the valvesusing a feeler gauge between the rocker lever and thecrosshead. The exhaust valve clearance should be "and the intake valve clearance should be ".Note: Some engines may have different valve andinjector adjustments. Check the engine data plate toverify Tighten adjusting screw locknut to 45 lbft (60 N*m).