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  • Installation Manual For Model 401A 401B 401C

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    Frank Ortiz
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    Installation Manual for Model 401A 401B 401C

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    Installation Manual for Model 401A 401B 401C

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    Installation Manual for Model 401A 401B 401C

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    830 views28 pages

    Installation Manual For Model 401A 401B 401C

    Uploaded by

    Frank Ortiz
    Installation Manual for Model 401A 401B 401C

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    Installation Manual for EERAKE Model 401A, 401B, and 401C GENERAL INFORMATION ‘This manual contains installation and maintenance information for Jacobs® Engine Brake Models 401A, 401B and 401C. The Model 401A originalyreleasedtor the NTC 476 twin turbo automotive engines has been replaced by the Model 4018, For spectic engine-engine brake application information on all Cummins NH Series Engines see the Engine Brake Applicaiton guide on Page 3 of this manual. Correct application must always be determined by Cummins C.P.L. Number. ‘Jacobs service publications must be consulted for addtional application and maintenance information which may have become available since this manual was printed. SAFETY PRECAUTIONS The following symbols in this manual signal potontially Do not work on this equiament when mentally or physically dangerous conditions to the macharis or equipment. Road fatigued. Aways wear eye protection thismanvalcareuly. Know when these conditons can exist s ye weareye pe Then, take necessary steps to protect personnel as wel as, Fuels, electrical equipment, exhaust gases and moving parts, equipment ‘resent pototial hazards that could result in personal inuy. ‘Take care wiion instaling an engine brake. Always uso (NRE T'S SYMeOL warns oF correct tools and proper procedures as outlined in this POSSIBLE PERSONAL manval INJURY. THE JAKE BRAKE® IS A VEHICLE SLOWING DEVICE, NOT A VEHICLE STOPPING DEVICE. IT caution | THIS SYMBOL REFERS TO 1S NOT A SUBSTITUTE FOR THE SERVICE CAUTION | POSSIBLE EQUIPMENT BRAKING SYSTEM, THE VEHICLE’S SERVICE DAMAGE. BRAKES MUST BE USED TO BRING THE VEHICLE MPLETE STOP. This productis covered by U.S. patent No. 4,473,047. TOA Cor Foreign patents issued or applied for. Saves a Truckload The Jacobs Manufacturing Company Vehicle Equipment Division Bloomfield, CT 06002 U.S.A. Section 1 TABLE OF CONTENTS INTRODUCTION Method of Driving a vehicle Equipped with a Jacobs Engine Brake Engine Brake Housing Par Number Identiication — Special Tools ‘Automatic Transmissions —————-—— Model Number Identification. ——————_—______ ENGINE PREPARATION a - BRAKE HOUSING INSTALLATION Slave Piston Adjustment Procedure. ———————— Valve Set Mark Alignment Injector and Valve Set Position ———————— ELECTRICAL SYSTEM INSTALLATION Dash Switches—————-— Clutch Switch —_———— Fuel Pump Switch Wiring Diagram———— Optional Controls —————-________ ENGINE BRAKE OPERATION CHECK tt ENGINE BRAKE MAINTENANCE = —___ Control Valve — Solenoid Valve ——— Ball Check Valve Slave Piston Slave Piston Adjusting Screw (RESET) Master Piston Crosshead Adjusting Screw —— ret, P ENGINE BRAKE APPLICATION GUIDE FOR NH/NT CUMMINS ENGINES ENGINE TYPE BRAKE MODELS ‘CURRENT EARLY BRAKE MODELS 258 |4o1B|401c| 420 20 | 30 | 30E 400 hoon|sora) NH Series 5 1/8 Bore ‘Small Cam NH Single Entry Turbo ‘Small Cam Ill Single Entry Turbo Divided Entry Turbo Big Cam! Single Entry Turbo Divided Entry Turbo Big Cam ll Single Entry Turbo Divided Entry Turbo NTC 475 Twin Turbo Big Cam i Single Entry Turbo Divided Entry Turbo Big Cam V Single Entry Turbo Divided Entry Turbo CPL 794 Divided Entry Turbo CPL 795, New Big Cam IV Fixed Timing™* CPL 832 CPL796 cPL797 New Big Cam IV Step Timing Control CPL 806 CPL 821 CPL 833 Jacob's Current production models are 25B, 401B, 401C and 420. Single Entry Turbocharger Cummins Models: HT48, HT3B, T46B, T46, T50, ST50, VT5O. Divided Entry Turbocharger Cummins Model: HT3B. Divided Entry Turbocharger Model-Schwitzer: 4LHR. Note that the HT3B Turbo Charger may be either divided entry or single entry. * Replace Slave Piston Adjusting Screws, PIN 009916, with Auto-Lash® , PIN 013369. ** Big Cam IV with “Fixed Timing” requires the Model 401C with .021 Slave Piston Adjustment. SECTION 4 INTRODUCTION ‘SCHEMATIC DIAGRAM OF ENGINE BRAKE OPERATION aust : RooKeR Tine Fue cube even postion Pum Swe circu wudiroa Sac Swen SnEARER PUsHROD ik artery SCHEMATIC DIAGRAM OF ENGINE BRAKE OPERATION THEORY OF OPERATION — Simply stated, energizing the Engine Brake etfectivaly converts a power-producing diesel engine into a power- absorbing air compressor. This is accomplished through motion transfer using a master-slave piston arrangement, which opens cylinder exhaust valves ear the top of the normal compression stroke, releasing the compressed oylinder charge to exhaust. ‘The blowdown of compressed air to atmospheric pressure prevents the return of energy to the engine piston on the expansion stroke, the effect being a net energy foss since the work done in compressing the cylinder charge is not returned during the expansion process, EXHAUST BLOWDOWN — felerring 0 the schematic drawing, exhaust blowdown occurs as tollows: 4. Energizing the solenoid valve permits engine lube oil to flow under pressure through the contra! valve to ‘both the master piston and the slave piston. 2. Oil pressure causes the master piston to move down, coming to rest on injector rocker arm adjusting screw. 3. The injector rocker arm adjusting screw begins ‘upward travel (as in normal injection cycle) forcing the master piston upward and creating a high-pressure TEAL VALVES oll flow to the slave piston. ‘The ball check valve in the control valve imprisons high-pressure oll in the master- slave piston system 4, The siave piston under the influence of the high pressure cit flow moves down, momentarily opening ‘one of the exhaust valves, while the engine piston is, ‘near its top dead center position, releasing compressed cylinder air to the exhaust manifold 5. Compressed air escapes to atmosphere completing acompression braking cycle, METHOD OF DRIVING A VEHICLE EQUIPPED WITH A JACOBS ENGINE BRAKE Itis easy to learn the proper method of driving a vehicle equipped with Jacobs Engine Brake, The Engine Brake is most effective at rated engine speeds, therefore gear selection is very important. Gearing down the vohicle, within the limits of rated engine speed, makes the Engine Brake a more effective retarder. Maximum retarding occurs with the selection of the lowest gear that prevents exceeding rated engine speed. SECTION 1 INTRODUCTION (Cont’d.) Each Engine Brake kit contains a progressive switch thal provides two, four, or six cylinder operation of the Engine Brake. This switch provides the operator with greater flexibility in selecting the amount of retarding ngeded for various road and load conditions, For more information on driving with the Jake Brake® Retarder read your Jacobs Drivers Manual. To get a detailed presentation on driving with the Jacobs Engine Brake consult your Jacobs Distributor. ENGINE BRAKE MODEL AND HOUSING IDENTIFICATION Each engine brake housing assembly has an identification tag showing model number and part number. Packaged housing assemblies have a different part number than the housing assembly When ordering a replacement housing assembly, the packaged housing assembly part number must be used. See Table below. This Installation Manual should be used in conjunction with Jacobs Parts Manual, Form #3001, when additional replacement part information is required The Parts Manual can be obtained from your Jacobs distibutor. The following reference table can be used to determine proper housing assembly part numbers. Packaged Housing ‘Assombiy No. Housing Assy (Order by these No. (Tag) numbers) o7a004 013001 orsi22 013121 013143 o1gt4a SERIAL NUMBER The housing serial numbers stamped on the housing near the identification tag ON ieee Crrrerreeer iy) Brake housing model no., part no. and serial number locations, RECOMMENDED TORQUE VALUES Exhaust Valve Crosshead Adjusting Screw Locknuts 25ibHt (35 Nem) Rocker Housing Studs ‘Toloft (95 Nem) Engine Brake Holddown Nuts

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