Installation Manual T455B C - TecBrake

1 Box 27822 Houston, Texas 77227 InstallationManualModel T455B /C Engine BrakesFor CumminsN14 series EnginesEngine BrakesINSTALLATION MANUALTECBRAKE MODEL T455B /C ENGINE BRAKEFOR CUMMINS N14 Plus SERIESThe TecBrake T455B /C engine brake may be installedon popular versions of the Cummins N14 Plus seriesengine. It can not be installed on the Cummins 855,88NT, 91N14 STC, 91N14 Celect or 94N14 modelengines. It should only be installed on engines whoseCPL numbers are included in the Application Model T455B /C replaces the former ModelT455 1- INTRODUCTIONNOTICEThe TecBrake Engine Brake is designed as a devicefor slowing a vehicle, not stopping it.

2 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. 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. 7/16 12 point socket2. Feeler gauge Recommended Torque ValuesEngine Brake Hold-down screws -70 lbft (95 N*m)Slave Piston Adj.

3 Screw Nuts -25 lbft (35 N*m)Valve Cover capscrews - 9 lbft (12N*m)NOTICEI njector adjusting screws and exhaust crossheadsare not replaced on this 2- ENGINE PREPARATIONF igure clean engine before beginning all engine components necessary to permit accessto cylinder heads. Remove valve covers, save the the pipe plug from the center web of each rockerlever housing to allow oil flow into the engine brake 3- BRAKE HOUSING INSTALLATIONF igure 3-11. Install the engine brake housing gaskets. Make surethat the oil supply slots align correctly with the oil supplyscrews in the Before installing the brake housings, back out theslave adjusting screws (located above the slave piston)so that the slave pistons are fully retracted (up).

4 3. Place the three engine brake housings on the rockerhousings. Check rocker levers to be sure there is 3-24. Install the six mounting screws into each engine 3-35. Tighten the capscrews to 35 lbft (48 N*m) insequence as shown in Figure 3-3 then re-torque to 70lbft(95N*m).Slave Piston Adjusting ScrewRefer to the Application Chart shown in Figure 3-4 toidentify which screw should be orange adjusting screws are preinstalled in the CHARTADJUSTING SCREWCPL MODELPART NO. COLOR2025N14 435 ESP PlusTB900032 Orange2026N14 370 ESP PlusTB900032 Orange2027N14 330 ESP PlusTB900032 Orange2389N14 330 ESP PlusTB900039 Purple2390N14 370 ESP PlusTB900032 Orange2391N14 435 ESP PlusTB900032 Orange2398N14 370/460E PlusTB900032 Orange2590N14 330 ESP PlusTB900039 Purple2591N14 370 ESP PlusTB900032 Orange2592N14 435 ESP PlusTB900032 OrangeFigure 3-4 Slave Piston AdjustmentAdjustment of the slave piston adjusting screw is adjustment is necessary in order to provide peakbraking efficiency without over stressing the piston adjusting screw adjustment must be madewith the engine stopped and engine temperaturestabilized below 140 oF

5 (60oC).A) Dial Indicator MethodFigure engine brake valve lash using the adjusting screwlocated above each slave piston. The engine crankshaftmust be rotated to allow the exhaust valve to be fully closedprior to making adjustment on each a dial indicator over the slave piston adjustingscrew for the cylinder to be adjusted. Turn the screw downuntil the slave piston contacts the crosshead. Zero the dialindicator on this position. Back out the adjusting screw untilthe dial shows ( ). the adjusting screw lock nut to 25 lbft (35 N*m)torque. Rotate the crankshaft, adjusting each adjustingscrew in firing order ) Feeler Gauge MethodFigure 3-61. Set engine brake valve lash using the adjustingscrew located above each slave piston.

6 The enginecrankshaft must be rotated to allow the exhaustvalve to be fully closed prior to making adjustmenton each Back out the adjusting screw on each cylinderto be adjusted. Using a " feeler gaugebetween the slave piston and the exhaustcrosshead, turn in the slave piston adjusting screwuntil a slight drag is felt on the Tighten the adjusting screw lock nut to 25 lbft(35 N*m) torque. Rotate the crankshaft, adjustingeach adjusting screw in firing order CheckInstallation of the brake housings is now of the brakes should be checked beforeproceeding Start the engine and let it idle for a short air from the engine brake the engine to about 1800 RPM thenrelease the throttle.

7 Quickly depress the solenoid asshown to cause the brake to operate. This processshould be repeated 5-6 times on each brakeassembly in order to fill the housings with lube all of the air has been removed the brakeshould operate immediately when the solenoid eye protection. When engine is running withvalve covers removed, oil splashing will precautions to prevent oil contaminatingengine and engine 4- ELECTRICAL SYSTEM INSTALLATIONI nstallation of the electrical system involves themounting of ON/OFF dash switches that have gold-plated contacts. Wiring harnesses and wiring diagramare provided in the control group to complete theinstallation.

8 Refer to the wiring diagram Figure SwitchesDash switches should be installed in dash where theyare visible and convenient to Drill holes in dash to accommodate switches andinstall switches with proper name To check the electrical system, start the activate engine brake with the ON/OFF Celect low speed shut off will prevents the enginebrake from coming on at idle. Accelerate until theengine reach 1800 RPM and release the throttle. Thecenter engine brake housing should operate with oneON/OFF switch. Repeat this operation for theremaining 2 and 3 positions. The front and rear brakehousings should operate with the other ON/OFFswitch, and all three engine brake housings shouldoperate with both ON/OFF switches.

9 After thisprocedure, shut down To complete the Installation , reinstall the Cumminsvalve cover gaskets, replace valve covers, and allpreviously removed parts. Torque valve covercapscrews to 9 lbft (12 N*m).4 Figure 4-1 SECTION 5 - ENGINE BRAKE MAINTENANCEF igure 5-1 The engine brake is designed to be trouble free and doesnot require special maintenance. During regularlyscheduled maintenance, or if a problem occurs, theprocedures described below should be Do not remove any engine brake component whilethe engine running. This may result in personal only approved cleaning the electrical lead from the solenoid andremove solenoid with a spanner wrench.

10 Remove anddiscard the three rubber seal the filter screen and solenoid with solventthen dry with low air solenoid bore with solvent and wipe dry withpaper towel. Be careful not to leave any lint or residue inbore that may contaminate brake hydraulic solenoid valve using three new solenoid body with engine lube oil and install upperand center seal rings on solenoid body. Seat lower sealring in bottom bore of Carefully screw in solenoid valve, using care to assureO-rings remain in position and are not twisted or "rolled".6 Figure 5-36. Tighten solenoid valve to 5 lbft (7 N*M) ValveFigure 5-41. Press down on control valve cover to relieve Remove retaining ring using retaining ring Slowly remove the cover until spring pressure ceases,then remove the two control valve springs and Remove control valve using needle nose Wash control valve with Control valve covers are under load from control valvesprings.