Installation Manual For ISM/ISM02/ISM07 M11/M11 Plus Engines
Table of Contents Safety Precautions Section 1: Introduction..................................................... 3 Aftermarket Kits................................................................. .3 Housing Identification...................................................... 3 Engine Identification........................................................ 3 Special Tools................................................................... 3 Automatic Transmissions............................................
Section 1: Introduction Special Tools Model 411/411C/D/E Aftermarket Kits P/N 3804584 3804585 3804586 3800765 4089395 4955458 Engine M11/M11+ M11/M11+ M11/M11+ ISM ISM02/04 ISM07 Brake Model 411 411 411 411C 411D 411E The following special tools should be available for the instal lation: Description 12 V DC, S/L kit 24 V DC, S/L kit 24 V DC, D/L kit 12 V DC, D/L kit 12 V DC, S/L kit 12 VDC, S/L kit 1. Injector adjusting tool: Torque wrench, Cummins P/N 3376592 2. Crowfoot: Cummins P/N 3823820 3.
Section 2: Engine Preparation Clean engine thoroughly. Remove engine valve cover and gasket. Retain all parts. NOTE: REFER TO CUMMINS TROUBLESHOOTING & REPAIR MANUAL, SECTION 003-004 FOR OVERHEAD SET INFORMATION. Crosshead and Adjusting Screws Cylinder 1, 3 and 5 Exhaust Valve Crosshead Replacement and Injector Rocker Lever Adjusting Screws: 1. Rotate crankshaft by turning accessory drive shaft in direction of rotation (clockwise, see Fig. 1).
4. Lubricate the actuator pins and valve stems with clean lube oil and install the CBrake by Jacobs™ crossheads over the exhaust valves. Locate the actuator pins on the exhaust valves closest to the push rod side of the engine (see Fig. 4). 5. The crosshead should move freely from side to side pivoting on the side without the actuator pin. No leveling adjustment is required with guideless crossheads. 6.
3. Place a 0.027” (0.68 mm) feeler gage between the rocker lever and the crosshead of the exhaust valve (see Fig. 7). Tighten the adjusting screw until a light drag can be felt on the feeler gage. Hold the adjusting screw and tighten the locknut to 45 lb.-ft. (61 N•m). 4. Turn the injector adjusting screw in and bottom the injector plunger 3 to 4 times to remove fuel. 5. Bottom injector adjusting screw with a screwdriver. 6. Back out screw two flats (120°). 7. Hold screw and torque lock nut to 45 lb.
Section 3: Brake Installation Housing Installation NOTE: ALSO REFERENCE CUMMINS TROUBLESHOOT- ING & REPAIR MANUAL, SECTION 020-024 FOR ENGINE BRAKE FOR CLEANING, REMOVING, INSPECTING, INSTALLATION AND ADJUSTMENT. Oil Supply Tube 1. Lubricate O-rings on oil supply tube and install into oil supply hole in rear housing. Push tube in all the way (see Fig. 11). 2. Install the O-ring adaptor into the front housing in the location shown in Figure 12.
Slave Piston Adjustment PAY SPECIAL ATTENTION TO THIS ADJUSTMENT. TO ENSURE MAXIMUM BRAKE OPERATING EFFICIENCY AND TO PREVENT ENGINE DAMAGE, FOLLOW INSTRUCTIONS CAREFULLY. Slave Piston Lash Settings Model 411 411 411C 411D 411E FIG. 14 Engine M11 M11 Plus ISM 2002 ISM 2007 ISM Setting 0.015” 0.015” 0.015" 0.015" 0.027" 1. Slave piston lash setting is printed on the housing nameplate. 2. Slave piston adjustment must be made with the engine stopped and cold (stabilized water temperature of 140° F.
Installation of Oil Supply DO NOT CONNECT THE ENGINE BRAKE OIL SUPPLY TO THE SAME LOCATION USED FOR THE TURBOCHARGER OIL SUPPLY. SERIOUS ENGINE DAMAGE MAY RESULT. 1. Remove the plug from the rear, inboard filter head location and install the new fitting with seal ring. Tighten the fitting to 27 lb.-ft. (37N•m) (Fig.16). FIG. 16 KEEP HOSE CLEAR OF ALL POTENTIAL HOT ENGINE COMPONENTS AND FREE FROM RUBBING ON ENGINE OR CHASSIS.
Section 4: Electrical Installation M11 CELECT™ Wiring Installation NOTE: ACTUATOR CONNECTOR PIN 10 PIN 10 OEM CONNECTOR ORANGE WHITE PIN5 PIN 5 PIN 18 PIN C TWOPOSITION SWITCH ON/OFF POWER SWITCH HARNESS JUMPER CONNECTOR PIN F PIN G PIN F BLUE ELECTRONIC CONTROL MODULE YELLOW SILVER TERMINALS RED GOLD TERMINALS 10 AMP - 12V CIRCUIT BREAKER OR FUSE PIN G PIN H OEM INTERFACE CONNECTOR FRONT OF ENGINE PINK BROWN PIN B PIN H GRAY GREEN GROUND REAR HOUSING FRONT HOUSING PIN 30 PINK PI
M11 Plus CELECT™ Plus Wiring Installation (Model 411) ELECTRICAL CONTROL SYSTEM ENGINE BRAKE MODEL 411 FOR ’95 M11 PLUS ENGINE PURPLE A B B A PURPLE REAR HOUSING PIN 18 FRONT HOUSING PIN 19 GRAY PIN 28 PIN 5 ACTUATOR PORT 28 2-POSITION SWITCH 5 OEM PORT PIN 10 B C 10 18 19 NOTE: ALL CUMMINS M11 PLus ENGINES HAVE ELECTRONIC CONTROLS (CELECT plus). 1. For proper wiring installation, make all electrical connections as shown in Fig. 20. 2.
ISM02 Wiring Installation (Models 411D) 14 13 Brake Harness White wire Red wire Pass Through Pin 13 Pass Through Pin 14 Front Housing Rear Housing Actuator Pin 32 (Engine Brake #1) Actuator Pin 51 (Engine Brake #2) For proper electrical wiring installation, make all electrical connections as shown in Figure 22, observing the following: Existing Engine Harness OEM Pin 18(LO) OEM Pin 08(HI) Installer Provided Wire s 2 POSITION SWITCH 04 01 C3 03 51 32 34 08 18 02 C2 C1 OEM PORT (KEY 04)
Section 5: Brake Operation Check The CBrake by Jacobs™ Model 411, 411C, 411D, & 411E installation is now complete. The following procedures and adjustments should be made. Recheck the housing installation. Be certain no foreign objects have been left behind and all correct clearance requirements have been met. Bleed and Operation Check WEAR EYE PROTECTION AND DO NOT EXPOSE YOUR FACE OVER ENGINE AREA. TAKE PRECAUTIONS TO PREVENT OIL LEAKAGE DOWN ON THE ENGINE.
Replace Rocker Lever Cover 1. Remove the gasket and inspect for damage. 2. If the gasket is not damaged, it can be used again. If the gasket is damaged, it must be discarded and a new one used. 3. Set the new Cummins gasket on the cover. 4. Install flat washer, new sleeve and new noise isolator on the capscrew (see Fig. 23). 5. Install the capscrew assemblies in the cover (Fig. 24). 6. Install the cover on the spacer and tighten the cover capscrews to 130 lb.-in.
Section 6: Brake Maintenance Theory of Operation 1. The energized solenoid valve permits engine lube oil to flow under pressure through the control valve to both the master piston and the slave piston. Energizing the engine brake effectively converts a powerproducing diesel engine into a power-absorbing air compressor.
The CBrake by Jacobs™ is a relatively trouble-free device. However, inspections and routine maintenance will need to be made from time to time. Use the following procedures to keep the engine brake in top condition. This section will cover how to properly remove, clean and reinstall engine brake components. Use an OSHA-approved cleaning solvent when washing parts. Be sure to coat parts with clean engine oil when reinstalling them.
2. Slowly remove cover until spring pressure ceases, then remove the control valve springs and collar (see Fig. 29). 3. Using needle-nose pliers, remove the control valve (see Fig. 30). 4. Wash the control valve with approved cleaning solvent. Push a wire through the hole in the base of the valve to ensure that the ball check is free. The ball should lift with light pressure on the wire. If the ball is stuck or there is no spring pressure, replace the control valve.
Solenoid Valve 1. Disconnect the solenoid harness. Using a 3/4” socket and extension, unscrew the solenoid valve (see Fig. 32). Do not disassemble or tamper with the solenoid valve. Engine damage could result. 2. 3. Remove and discard the three rubber seal rings (Fig. 33). If the lower ring stays in the bottom of the housing solenoid bore, remove with a seal pick. FIG. 32 Wash out the solenoid valve with approved cleaning solvent. Use a brush to clean the oil screen.
Slave Piston Adjusting Screws (Reset) 1. Loosen slave piston adjusting screw locknut and remove adjusting screw from housing (Fig. 35). 2. Clean adjusting screw in an approved cleaning solvent. 3. Inspect the slave piston adjusting screw. The plunger should protrude from the bottom of the screw, have light spring pressure apparent when depressed, and should move freely (Fig. 36). Be sure the retaining ring is fully engaged in its groove. Replace the entire screw assembly if any defect is found. FIG.
Master Piston 1. Remove the button-head screw, washer and master piston spring from bottom of housing. 2. Remove the master piston from its bore using needlenose pliers. If binding occurs, check for burrs or contaminants in the lube oil. Clean in an approved cleaning solvent (Fig. 38). NOTE: Do not attempt to remove the master piston without first removing the flat spring. Bending the spring back too far can distort the spring and would need to be replaced. 3. Inspect the hard face surface.
2. While holding the tool in position, screw the holder down over the slave piston stem until the retainer is contacted. 3. Turn the handle slowly until the retainer is depressed, about 1/32” (1 mm), relieving pressure against the retaining ring. 4. Remove the retaining ring using retaining ring pliers. Back out the holder until the springs are loose. Remove the tool (see Fig. 41). 5. Remove the retainer, spring and slave piston. Check for nicks or burrs that could cause binding (see Fig. 42). 6.
Jacobs Vehicle Systems 22 E. Dudley Town Road Bloomfield, CT 06002 U.S.A. Cummins Inc. Box 3005 Columbus, IN 47202-3005 U.S.A. www.cummins.com CELECT™ is a trademark of Cummins Inc. Bulletin 3698827 CBrake by Jacobs™ is a trademark of Cummins Inc. and Jacobs Vehicle Systems Jacobs® is a registered trademark of Jacobs Vehicle Systems Printed in U.S.A. 01/07 © 2006 Cummins Inc. For additional support, visit www.jacobsvehiclesystems. Jacobs P/N 021474 Rev.
