ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 020-004   Engine Brake Assembly

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.

Disconnect the wiring harness from the electrical connectors in the rocker lever housing.

NOTE: It is easier to remove the wire from the rocker lever housing after the brake is removed.

Unplug the wires from the brake solenoid.

NOTE: Use only grade 12.9 mounting capscrews for engine brake assemblies. Verify all mounting capscrews are grade 12.9. If any capscrews are found that are not grade 12.9, replace the capscrews.

Remove the six mounting capscrews and flat washers from one or both of the engine brake assemblies, as required.

NOTE: Engines with an engine serial number (ESN) of 73001424 and higher use a bracket underneath the mounting capscrews above cylinders 1 and 4 in place of a hardened washer. This bracket is used to route the solenoid wire away from moving parts and prevent wire chaffing.

Remove the brake assembly or assemblies, as required.

Remove the rocker lever housing, if necessary. Refer to Procedure 003-013 in Section 3.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

Clean the engine brake assembly with solvent and a brush.

Inspect the engine brake assembly for cracks or any other damage.

If necessary, check and set the valve lash prior to installing the engine brake. Refer to Procedure 003-004 in Section 3.

To install the engine brake specific crossheads and rocker lever hold-downs. Refer to Procedure 003-008 in Section 3.

If necessary, install the rocker lever housing and mounting bolts. Refer to Procedure 003-013 in Section 3.

At the intake mounting stud (cylinder 1 and/or cylinder 4) lubricate the oil adapter and o-ring with lubricating oil.

Install the engine brake overhead assembly.

NOTE: Make sure the oil supply adapter at the intake manifold stud is fitted into the oil supply hole in the brake assembly.

CAUTION  Use only grade 12.9 mounting capscrews for engine brake assemblies. Verify all mounting capscrews are grade 12.9. If any capscrews are found that are not grade 12.9, replace the capscrews.

Install the six 10-mm mounting capscrews (three for the front brake assembly, three for the rear brake assembly) with flat washers at the brake mounting spacers (exhaust side of engine) and hand-tighten.

NOTE: Engines with an engine serial number (ESN) of 73001424 and higher use a bracket underneath the mounting capscrews above cylinders numbers 1 and 4 in place of a hardened washer. This bracket is used to route the solenoid wire away from moving parts and prevent wire chaffing.

NOTE: Do not tighten the capscrews to their final torque specification at this time.

Turn the adjusting sleeves in the engine brake housing until they make contact with the rocker arm pedestals. No preload must be imparted on the housing.

Install the six 10-mm mounting capscrews (three for the front brake assembly, three for the rear brake assembly) with flat washers (intake side of the engine).

NOTE: Engines with an engine serial number (ESN) of 73001424 and higher use a bracket underneath the mounting capscrews above cylinders 1 and 4 in place of a hardened washer. This bracket is used to route the solenoid wire away from moving parts and prevent wire chaffing.

Tighten the six 10-mm mounting capscrews for the front brake assembly and the six 10-mm mounting capscrews for the rear brake assembly.

NOTE: No tightening sequence is required but the capscrews can be tightened in a crossing sequence.

Install the wires to the terminals on the inside of the spacer.

NOTE: The longer wire must be connected to the front engine brake solenoid. It is possible to install the wires in the incorrect orientation, which will result in an interference with the rocker levers.

NOTE: On engines equipped with a bracket to prevent the wire from chaffing, secure the wire to the bracket, Part Number 4890404.

Connect the wires from the terminals on the inside of the spacer to the solenoid.

Remove the rocker lever cover. Refer to Procedure 003-011.

Use barring tool, Part Number 3824591, to rotate the crankshaft to align the mark on the fuel pump gear with the top dead center mark on the gear cover.

When the engine is in the top dead center position, brake lash can be set on cylinders 1, 3, and 5.

Use two wrenches to hold the adjusting nut and loosen the lock nuts on the brake at cylinders 1, 3, and 5.

Brake Lash – Feeler Gauge Method

Insert the appropriate brake lash feeler gauge between the brake slave piston and exhaust crosshead pin on cylinder 1.

NOTE: If the correct size feeler gauge is not available there is an alternate dial indicator method for setting the brake lash following in this procedure.

Use the 0.68 N•m [6 in-lb] torque wrench, Part Number 3376592, to tighten the adjusting nut until the torque wrench “clicks” or until drag is felt on the feeler gauge.

Remove the feeler gauge. Use two wrenches to hold the adjusting nut and tighten the locknut.

Repeat for cylinders 3 and 5.

Use the engine barring tool, Part Number 3824591, to rotate the crankshaft 360 degrees to align the mark on the fuel pump gear with the mark on the gear cover that is 180 degrees away from top dead center.

When the engine is in position, brake lash can be set on cylinders 2, 4, and 6.

Insert the appropriate brake lash feeler gauge between the brake sleeve piston and the exhaust crosshead pin on cylinder 2.

Use a 6 in-lb torque wrench, Part Number 3376592, to tighten the adjusting nut until the torque wrench “clicks” or until drag is felt on the feeler gauge.

Remove the feeler gauge. Use two wrenches to hold the adjusting nut and tighten the locknut.

Repeat for cylinders 4 and 6.

The following method can be used instead of the feeler gauge method if a feeler gauge of the proper size is not available.

Use barring tool, Part Number 3824591, to rotate the crankshaft to align the mark on the fuel pump gear with the top dead center mark on the gear cover.

Brake Lash – Dial Indicator

Tighten the backlash adjusting nut on cylinder 1 until resistance is felt. Place the dial indicator tip on the adjusting nut and zero the dial indicator. Turn the lash adjusting nut in a counterclockwise direction until the appropriate lash is reached.

Use two wrenches to hold the adjusting nut and tighten the locknut.

Repeat for cylinders 3 and 5.

Use engine barring tool, Part Number 3824591, to rotate the crankshaft 360 degrees to align the mark on the fuel pump gear with the mark on the gear cover that is 180 degrees away from top dead center.

When the engine is in position, brake lash can be set on cylinders 2, 4, and 6.

Tighten the backlash adjusting nut on cylinder number 2 until resistance is felt. Place the dial indicator tip on the adjusting nut and zero the dial indicator. Turn the lash adjusting nut in a counterclockwise direction until the appropriate lash is reached.

Use two wrenches, hold the adjusting nut and tighten the locknut.

Repeat for cylinders 4 and 6.

Install the plastic fuel pump drive cover located on the front of the engine.

Install the rocker lever cover.

Refer to Procedure 003-011 in Section 3.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Operate the engine and verify proper engine brake operation.