12
Installation Manual For ISC, ISL, ISC03 And ISL03 Engines ®

Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

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Page 1: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

Installation ManualFor ISC, ISL, ISC03 And

ISL03 Engines

®

Page 2: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

2 CUMMINS® E BRAKE FOR ISC,ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL

Table of Contents1. Installation of the E Brake Assembly ................ 3

2. Pneumatic Group Installation .......................... 5

3. Installation of the Controls ............................... 7

4. Final Test ........................................................ 11

Application NotesA. The E Brake for the ISC, ISL, ISC03 and ISL03

engine is designed for vehicles equipped with theCummins ISC and ISL Series engines (allhorsepower ratings). The kit is available in twoturbo-mount versions and an in-line version.

For a turbo mount application, there must be aminimum of 3" clearance from any exhaustcomponent to the vehicle firewall or body after theE Brake is installed. The E Brake housing extendsapproximately 3" from the turbo outlet. If thevehicle does not have the required clearance, youmust install the in-line kit, Cummins P/N 3800372for ISC and ISL engines and Cummins P/N4089623 for ISC03 and ISL03.

For Turbo-mount applications, determine the typeof mounting joint on the vehicle turbocharger. Thetype of mounting joint can be determined by theconnection adapter part number, which is cast intothe adapter housing. See Figure 1 for an illustrationof the half Marmon, full Marmon types and a list ofadapter part numbers. In ISC and ISL engines, forfull Marmon applications, install kitP/N 3800415, for half Marmon applications, installkit P/N 3800414. In ISC03 and ISL03 engines, forfull Marmon applications, install kit P/N 4089624.

B.Vehicles with Allison Transmissions: Wheninstalling the E Brake on vehicles equipped with anAllison transmission, refer to E Brake ApplicationNote 93-1, Bulletin 3698668, for detailedinformation.

C. Selecting a Pneumatic Group: Vehicles that do nothave an on-board air supply require the installationof an auxiliary air supply system. When an air supplyis required, order the Pneumatic Group with AirSupply, P/N 3806237. Follow installation instructionsincluded with the Pneumatic Group with Air Supply.For vehicles that have an on-board air supply, orderPneumatic Group P/N 3806238. Follow theinstallation instructions included in this manual.

Safety PrecautionsThe following symbols in this manual signal potentiallydangerous conditions to the mechanic or equipment.Read this manual carefully. Know when theseconditions can exist. Then, take necessary steps toprotect personnel as well as equipment.

THIS SYMBOL WARNS OF POSSIBLEPERSONAL INJURY.

THIS SYMBOL REFERS TO POSSIBLEEQUIPMENT DAMAGE.

NOTE: INDICATES AN OPERATION, PROCEDUREOR INSTRUCTION THAT IS IMPORTANT FORCORRECT SERVICE.

Fuels, electrical equipment, exhaust gases and movingengine parts present potential hazards that could resultin personal injury. Take care when installing an exhaustbrake. Always use correct tools and proper proceduresas outlined in this manual.

THE CUMMINS E BRAKE IS AVEHICLE SLOWING DEVICE, NOT AVEHICLE STOPPING DEVICE. IT IS

NOT A SUBSTITUTE FOR THE SERVICE BRAKINGSYSTEM. THE VEHICLE’S SERVICE BRAKES MUSTBE USED TO BRING THE VEHICLE TO A COMPLETESTOP.

Half Marmon joint (ISC and ISL Only)

Exhaust Brake Turbo Outlet

Exhaust Brake Turbo Outlet

Full Marmon joint

ISC/ ISLAftermarket KitP/N 3800414AssemblyP/N 3944862

ISC/ ISLAftermarket KitP/N 3800415AssemblyP/N 3944865

ConnectionAdapterP/N 3537979

ConnectionAdapterP/N 3539060

FIG. 1

ISC03/ ISL03Aftermarket KitP/N 4089624AssemblyP/N 3969392

bn310
The E Brake for the ISC, ISL, ISC03 and ISL03
bn310
engine is designed for vehicles equipped with the
bn310
Cummins ISC and ISL Series engines (all
bn310
horsepower ratings). The kit is available in two
bn310
turbo-mount versions and an in-line version.
bn310
Same comments as other manual.
Page 3: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

CUMMINS® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3

1. Installation of the E Brake AssemblyFor turbo-mount models, follow the procedure in 1A. For in-line models, follow the procedure in 1B.

NOTE: INSTALLATION PROCEDURES FOR THE HALF-MARMON TURBO MOUNT, FULL MARMON TURBO MOUNT ANDCOMBINATION MARMON TURBO MOUNT APPLICATIONS ARE IDENTICAL EXCEPT FOR PARTS USED.

ISC/ ISL: PART NUMBERS FOR THE FULL MARMON-TYPE TURBO MOUNT ARE ASSEMBLY P/N 3944865, GASKET P/N3944864, AND CLAMP, P/N 3944863. PART NUMBERS FOR THE HALF MARMON-TYPE TURBO MOUNT AREASSEMBLY P/N 3944862, GASKET P/N 3944864, AND CLAMP, P/N 3945092.

ISC03/ ISL03: PART NUMBERS FOR THE FULL MARMON-TYPE TURBO MOUNT ARE ASSEMBLY P/N 3969392, GASKET P/N 3944864, AND CLAMP, P/N 3944863.

WATER IN THE SOCKET JOINT, DO NOT INSTALLTHE E BRAKE WITH THE AIR CYLINDER LOCATEDBENEATH THE MAIN HOUSING.

5. When the E Brake assembly is properlypositioned, torque the clamp bolts to 70 - 80lb-in. (8 - 9 N•m).

6. Connect the original exhaust pipe to the EBrake housing. Use the original clampremoved in step 1 for half-Marmon brakes,and use clamp P/N 3927060 for full-Marmonand Combo brakes. Tighten enough to looselyhold the parts in place.

7. Make the connection to the muffler using theparts (flex pipe and clamp) removed when theinstallation began. With the clamps still loose,align the exhaust system. Ensure that there isproper clearance between the exhaust system,including the E Brake and the engine andchassis. Now torque all the “V” clamps to 70 -80 lb-in. (8 - 9 N•m).

Proceed to Section 2, Pneumatic Group Installation.

1A. Turbo-mount E Brake Installation

Refer to Figure 2 for the following procedures.

1. Loosen the “V” clamp holding the originalexhaust pipe to the turbo. Remove the exhaustpipe. If installing a half-Marmon brake, retainthe clamp for later use. For full-Marmon andCombo brakes, discard the clamp. Inspect theexhaust pipe for any sign of rust or damage.Replace if necessary.

2. In most installations, the exhaust pipe must beshortened to allow installation of the E Brakehousing. The most convenient method is tomodify the exhaust pipe length at a slip joint.Using a torch, heat the pipe sufficiently todisassemble the slip joint. Then remove therequired length of exhaust pipe.

3. The E Brake assembly is mounted to the turbooutlet using the gasket and clamp provided (seeFigure 2). The gasket is coated with anadhesive to ease installation. Remove thebacking from the adhesive and apply thegasket to the turbo outlet, taking care to centerthe gasket.

NOTE: ENSURE THE GASKET IS CENTEREDDURING INSTALLATION OF THE E BRAKE.GASKETS NOT CENTERED CORRECTLYDURING INSTALLATION CAN CAUSEUNNECESSARY RESTRICTION OF EXHAUSTFLOW AND POSSIBLE LOSS OF POSITIVEPOWER, OR A LEAK DURING BRAKING ANDLOSS OF BRAKING POWER

4. Position the E Brake so the air cylinder is eitherabove the E Brake housing or on the side ofthe housing opposite the engine, and mount tothe turbo using the clamp provided.

TO PREVENT EXPOSURE TOEXCESSIVE HEAT, DO NOT INSTALLTHE E BRAKE WITH THE AIR

CYLINDER FACING THE ENGINE SIDE OF THEHOUSING. TO PREVENT ACCUMULATION OF

2

3

4

1

3

4

5

FIG 2

Page 4: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

4 CUMMINS® E BRAKE FOR ISC,ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL

1B. In-line E Brake Installation

1. Loosen the “V” clamps holding the originalexhaust pipe arrangement in place. Removethe exhaust pipe, inspect for any sign of rust ordamage. Replace if necessary.

2. Select a location in the exhaust pipe for theE Brake. Locate the E Brake between themuffler and turbocharger. The E Brake shouldbe as close to the turbocharger as possiblewhile maintaining a minimum distance of 8”from the turbocharger. Where possible, mountthe E Brake in a near vertical orientation withthe E Brake air cylinder facing the front of thevehicle. This will ensure a flow of air over thecylinder (see Figure 3).

DO NOT ATTEMPT TO MOUNT THEE BRAKE ANY CLOSER THAN 8”(20.32 CM) TO THE TURBOCHARGER.

DO NOT LOCATE THE E BRAKE SO THE AIRCYLINDER IS IN A HORIZONTAL POSITION BELOWTHE MAIN HOUSING.

3. Lay the exhaust pipe on the ground or benchwith the E Brake and exhaust pipesleeves, P/N 3929059 (see Fig. 4) and markthe pipe section to be removed. Cut out thenecessary pipe section, ensuring the cut issquare to the pipe. Weld the sleeve to the twoexhaust pipe lengths.

NOTE: WELD THE SLEEVES TO THE PIPECAREFULLY. THE WELDED JOINT BETWEENTHE TURBO AND THE EXHAUST BRAKEHOUSING WILL BE SUBJECTED TO HIGHINTERNAL PRESSURE. ANY EXHAUST GASLEAKAGE WILL CAUSE A SIGNIFICANT LOSSOF PERFORMANCE.

4. Reinstall the exhaust pipe section to theturbocharger using gasket, P/N 3929070. Thegasket is coated with an adhesive to easeinstallation. Remove the backing from theadhesive and apply the gasket to the turbooutlet, taking care to center the gasket. Installthe original “V” clamp and tighten enough toloosely hold the parts in place.

NOTE: ENSURE THE GASKET IS CENTERED DURINGINSTALLATION OF THE E BRAKE. GASKETSNOT CENTERED CORRECTLY DURINGINSTALLATION CAN CAUSE UNNECESSARYRESTRICTION OF EXHAUST FLOW ANDPOSSIBLE LOSS OF POSITIVE POWER, OR ALEAK DURING BRAKING AND LOSS OFBRAKING POWER

5. Install the E Brake at the other end of thissection of pipe using gasket, P/N 3870865,and “V” clamp, P/N 3929073. Orient the

E Brake so that air cylinder bracket is facingaway from the turbocharger. Make sure thatthe gasket is installed on the locating pilot onthe E Brake inlet. Tighten the “V” clampenough to loosely hold the parts in place.

6. Install the second section of exhaust pipe withthe sleeve, P/N 3929059 , attached and clampto the E Brake outlet using the “V” clamp,P/N 3929060. No gasket is needed betweenthe E Brake and this pipe section.

7. Make the connection to the muffler using theparts (flex pipe and clamp) removed when theinstallation began. With the clamps still loose,align the exhaust system. Ensure that there isproper clearance between the exhaust system,including the E Brake and the engine andchassis. Now torque all the “V” clamps to 70 -80 lb-in. (8 - 9 N•m).

FIG. 3

FIG. 4

ORIGINALEQUIPMENT

ORIGINALEQUIPMENT

WELD

WELD

Page 5: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

CUMMINS® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 5

2. Pneumatic Group InstallationNOTE: INSTALLATION OF THE E BRAKE REQUIRES

AN AIR SUPPLY ON THE VEHICLE. IF THEVEHICLE IS NOT EQUIPPED WITH AN AIRSUPPLY, AN AUXILIARY AIR SUPPLY MUST BEINSTALLED. FOR THESE CASES, INSTALL THEPNEUMATIC GROUP WITH AIR SUPPLY, P/N3806237, AND THE AIR SUPPLY ELECTRICALHARNESS GROUP, P/N 3803918. FORVEHICLES WITH AN ON-BOARD AIR SUPPLY,INSTALL PNEUMATIC GROUP P/N 3806238.SEE THE APPLICATION NOTES ON PAGE 2 OFTHIS MANUAL FOR MORE INFORMATION.

BLEED THE AIR TANK OF THE VEHICLEBEFORE STARTING THISINSTALLATION.

A. Compression Fitting AssemblyInstructions

Use the following guidelines when installingcompression fittings.

1. Cut the tubing ends squarely.

2. Insert the tubing into the fitting until it bottomson seat. Tighten nut with wrench until onethread remains visible on the fitting.

B. Hose Assembly Instructions

Use the following guidelines when installingcompression fittings.

1. Determine the required length of the hose,ensuring that the minimum bend radius is 2”(51 mm).

2. Cut the hose squarely with a fine toothhacksaw or cutoff wheel.

2. Put the socket in a vise. Screw the hosecounterclockwise into socket until it bottoms,then back off 1/4 turn.

5. Lubricate the nipple thread and inside of thehose liberally with a heavy oil or Aeroquip hoseassembly lube, Aeroquip P/N 222070.

6. Screw nipple clockwise into socket and hose.Leave 1/32” (0.8 mm) to 1/16” (1.6 mm)clearance between the nipple hex and socket.

Route the air tubing carefully and clamp usingthe clamps provided. Avoid tight bends andensure there is no possibility of abrasionthrough contact with chassis components.

C. Installing the Pneumatic Group

NOTE: VEHICLES EQUIPPED WITH HYDRAULICBRAKES REQUIRE INSTALLATION OF THEPNEUMATIC GROUP WITH AIR SUPPLY, P/N3806237, AND THE AIR SUPPLY ELECTRICALHARNESS GROUP, P/N 3803918. REFER TOTHE INSTRUCTIONS INCLUDED IN THE KITWHEN INSTALLING THE AUXILIARY AIRSUPPLY.

1. Install the protection valve at the air tank outletchosen for the E Brake air supply, using theproper pipe fittings (see Figure 5 on the nextpage).

NOTE: USE TEFLON® PIPE THREAD COMPOUND ONALL THREADED PIPE CONNECTIONS.

USE OF THE PROTECTION VALVE WILLMAINTAIN THE INTEGRITY OF THEORIGINAL PNEUMATIC SYSTEM.

UNDER NO CIRCUMSTANCES SHOULD THEPROTECTION VALVE BE OMITTED FROM THEINSTALLATION.

NOTE: IF A THREADED HOLE IS NOT AVAILABLE ONTHE AIR TANK AND A “TEE” FITTING ISEMPLOYED TO TAP INTO THE ORIGINALPNEUMATIC CONNECTIONS, ENSURE THATTHE ORIGINAL AIR CONNECTIONS ARECORRECTLY RETORQUED.

2. Install the solenoid valve on the chassis rail,using existing predrilled holes. If no suitablelocation is available on the chassis rail, thenmount the solenoid valve to the body sheetmetal. Position the solenoid so that theexhaust port is facing down. Avoid excessiveheat coming from the exhaust system. Thedistance from the solenoid valve to the aircylinder of the E Brake should be within thelength of the supplied hose.

3. Connect the solenoid port marked “1” or “P”to the air tank using the air tubing.

4. Connect port “2” or “A” to the E Brake aircylinder using the air hose as shown in (seeFig. 5).

5. Use the 1/4 - 18 NPT compression fittings forthe tubing connections from the air tank to thesolenoid valve (see Fig. 5).

Page 6: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

6 CUMMINS® E BRAKE FOR ISC,ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL

FIG. 5

Ill. Quan./No. Description Group1 Protection valve 12 Air brake tube 13 Solenoid valve assembly 14 Air brake hose 15 Bushing 16 90° street elbow, 1/4 NPT 17 Compression fit. assy. 1

Ill. Quan./No. Description Group8 45° flared, 45° elbow, 1/8 NPT 19 Hex nipple 110 Compression fit. assy. 111 Hose fitting assembly 212 Pipe tee 113 45° flared elbow, 1/4 NPT 114 Adapter 1

1

24

5

6

7

9

12

11

13

14

3

8

10

11

Page 7: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

CUMMINS® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 7

3. Control Installation

NOTE: IF USING THE AUXILIARY AIR GROUPEMPLOYED ON HYDRAULIC BRAKE-EQUIPPED VEHICLES, THE E BRAKE WIRINGIS SEPARATE AND INDEPENDENT FROM THEAIR COMPRESSOR WIRING.

A. Dash Switch

1. Find a convenient location on the dashboardfor the dash switch, ensuring that it will bewithin easy reach of the driver. Drill a 5/8" holein the dashboard at the selected location andinstall the switch.

DO NOT LOCATE SWITCH IN THE KNEECRASH PANEL OF THE DASHBOARD.

2. Locate Switch ground harness. This harness islabeled “024901” or “3099283” (see Fig. 8). Itis approximately 24" long and contains a greenwire with a spade connector at one end and aring terminal at the other end.

3. Connect the spade terminal on the Switchground harness to one side of the E Brake On/Off switch. Connect the ring terminal on theother end of the harness to a good vehiclechassis ground.

FIG. 6

OEM Access Connector End View

cavity "O"

FIG. 7

B. Wire Harness

Wiring for the E Brake is connected to twoengine input connectors. Figure 6 shows the50-pin OEM connector located on the engineECM. Figure 7 shows the 23-pin OEM accessconnector located on the harness connectedto the engine ECM.

Installation procedures for the E Brake wiringdepend on the vehicle transmission type.

• For vehicles with Allison World (Series MD)automatic transmissions, follow theprocedures in Section B1.

• For vehicles equipped with Allison MT or ATautomatic transmissions, follow theprocedures in Section B2.

• For vehicles equipped with manualtransmissions, follow the procedures inSection B3.

FIG. 8

Harness, 24904 or 3099285

Page 8: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

8 CUMMINS® E BRAKE FOR ISC,ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL

B1. Wiring Vehicles equipped withthe Allison World (MD)Transmission

Refer to Figure 9 for the following procedures.

1. Dash Switch/ECM Connection. Locate ECM/Switch connector subharness, marked“024902” or “3099284” (see Figure 8). Thisharness is approximately 60" long, andconsists of two green wires terminating in aspade connector on one end and Deutschsockets on the other end. Connect theharness as follows:

a. Locate the Engine Control Module (ECM)attached to the side of the engine block.Remove the sealing plugs from the 50 pinOEM connector, grommet locations B34and B27 (see Figure 6). Insert the Deutschconnectors from the ECM/Switchsubharness into locations B34 and B27.

NOTE: IF THERE IS AN EXISTING WIRE INSERTEDINTO GROMMET LOCATION B27, INSULATETHE DEUTSCH CONNECTOR ON THEHARNESS MARKED “024902” OR “3099284”WITH ADHESIVE HEAT SHRINK TUBING.

b. Route the subharness to the Cab, andconnect the spade connector tothe E Brake dash switch.

2. ECM/Ground Connection. Locate the harnessmarked “024931” or “3099286” (Fig. 10).Connect the harness as follows:

a. Locate the OEM Access Connector (seeFigure 7). Remove the sealing plug from

Exhaust Brake Wiring for ISC and ISL Engines - Vehicles with Allison World (MD) Transmissions

FIG. 9

cavity “O” and insert the pink wire with theDeutsch connector into cavity “O”.

b. Connect the ring terminal with the greenwire to a good chassis ground.

c. Connect the white wire to ignition-switchedpower (12 V DC).

d. Connect the Deutsch connector to theE Brake solenoid.

e. Connect the yellow wire to the AllisonElectronic Control Unit (ECU), location A19.

f. Connect the blue wire to the Allison ECUlocation A32.

g. Mount the harness relays to chassis sheetmetal.

Harness, 024931 or 30992

FIG. 10

Cummins ECM Allison

Exhaust Brake ON/OFF Switch

A1

A3

B3

B2

OEM Engine AccessConnector

P/N 3099283

P/N 3099286

Air Solenoid86

8730

85

86

8730

85

12V DC IgnitionSwitched Power

whitegreen

blue

purple

yellow

pin

P/N 3099284

cavity

bn310
NOTE: IF THERE IS AN EXISTING WIRE INSERTED INTO GROMMET LOCATION B27, INSULATE THE DEUTSCH CONNECTOR ON THE HARNESS MARKED “024902” OR “3099284” WITH ADHESIVE HEAT SHRINK TUBING.
bn310
Same comments as other installation document.
bn310
B2 & B3??
bn310
B2
bn310
B3
Page 9: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

CUMMINS® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 9

B2. Wiring Vehicles equipped withthe Allison MT or ATTransmissions

Refer to Figure 11 for the following procedures.

1. Dash Switch/ECM Connection. Locate ECM/Switch connector subharness, marked“024902” or “3099284” (see Fig. 8). Thisharness is approximately 60" long, andconsists of two green wires terminating in aspade connector on one end and Deutschsockets on the other end. Connect theharness as follows:

a. Locate the Engine Control Module (ECM)attached to the side of the engine block.Remove the sealing plugs from the 50 pinOEM connector, grommet locations B34and B27 (see Fig. 6). Insert the Deutschconnectors from the ECM/Switchsubharness into locations B34 and B27.

NOTE: IF THERE IS AN EXISTING WIRE INSERTEDINTO GROMMET LOCATION B27, INSULATETHE DEUTSCH CONNECTOR ON THEHARNESS MARKED “024902” OR “3099284”WITH HEAT SHRINK TUBING.

b. Route the subharness to the Cab, andconnect the spade connector tothe E Brake dash switch.

Exhaust Brake Wiring for ISC and ISL Engines - Vehicles with Allison MT or AT Series Transmissions

FIG. 11

2. ECM/Ground Connection. Locate the harnessmarked “024904” or “3099285” (see Fig. 8).Connect the harness as follows:

a. Locate the OEM Access Connector (seeFigure 7). Remove the sealing plug fromcavity “O” and insert the pink wire with theDeutsch connector into cavity “O”.

b. Connect the ring terminal with the greenwire to a good chassis ground.

c. Connect the Deutsch connector to theE Brake solenoid.

Air Solenoid

Cummins ECM

Exhaust Brake ON/OFF Switch

B3

B2

OEM Engine AccessConnector

P/N 3099284P/N 3099283 P/N 3099285

green

pin

cavity

bn310
NOTE: IF THERE IS AN EXISTING WIRE INSERTED INTO GROMMET LOCATION B27, INSULATE THE DEUTSCH CONNECTOR ON THE HARNESS MARKED “024902” OR “3099284” WITH HEAT SHRINK TUBING.
bn310
B3
bn310
B2
Page 10: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

10 CUMMINS® E BRAKE FOR ISC,ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL

B3. Wiring Vehicles equipped withStandard Transmissions

Refer to Figure 12 for the following procedures.

1. Dash Switch/ECM Connection. Locate ECM/Switch connector subharness, marked“024902” or “3099284” (see Fig. 8). Thisharness is approximately 60" long, andconsists of two green wires terminating in aspade connector on one end and Deutschsockets on the other end. Connect theharness as follows:

a. Locate the Engine Control Module (ECM)attached to the side of the engine block.Remove the sealing plugs from the 50 pinOEM connector, grommet locations B34and B27 (see Fig. 6). Insert the Deutschconnectors from the ECM/Switchsubharness into locations B34 and B27.

NOTE: IF THERE IS AN EXISTING WIRE INSERTEDINTO GROMMET LOCATION B27, INSULATETHE DEUTSCH CONNECTOR ON HARNESS“024902” OR “3099284” WITH HEAT SHRINKTUBING.

b. Route the subharness to the Cab, andconnect the spade connector to theE Brake dash switch.

FIG. 12

Exhaust Brake Wiring for ISC and ISL Engines - Vehicles with Standard Transmissions

2. ECM/Ground Connection. Locate the harnessmarked “024904” or “3099285” (see Figure 8).Connect the harness as follows:

a. Locate the OEM Access Connector (seeFigure 7). Remove the sealing plug fromcavity “O” and insert the pink wire with theDeutsch connector into cavity “O”.

b. Connect the ring terminal with the greenwire to a good chassis ground.

c. Connect the Deutsch connector to theE Brake solenoid.

Air Solenoid

Cummins ECM

Exhaust Brake ON/OFF Switch

B3

B2

OEM Engine AccessConnector

P/N 3099284P/N 3099283 P/N 3099285

Cut wire & insulatewith heat shrink

green

pin

cavity

bn310
INTO GROMMET LOCATION B27, INSULATE THE DEUTSCH CONNECTOR ON HARNESS “024902” OR “3099284” WITH HEAT SHRINK TUBING.
bn310
NOTE: IF THERE IS AN EXISTING WIRE INSERTED
bn310
B3
bn310
B2
Page 11: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

CUMMINS® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 11

Final TestA. Start the engine and run at low idle speed with

the transmission in neutral and the parkingbrake set.

NOTE:NOTE:NOTE:NOTE:NOTE: SOME VEHICLES ARE SET UP SO THE BRAKEWILL NOT TURN ON BELOW 1000 RPM. THISTYPE OF VEHICLE WILL REQUIRE A TESTDRIVE TO VERIFY BRAKE OPERATION.

B. Switch on the dash switch. The E Brakeshould come on within 0.25 seconds. Step onthe accelerator pedal and increase enginespeed. The E Brake must turn off immediately.Take your foot off the pedal and the E Brakeshould turn on again within 0.25 seconds.

C. With the engine at idle, step on the clutchpedal. Again, the E Brake must turn offimmediately. Take your foot off the clutchpedal and the E Brake should turn on again.

D. Check for exhaust gas leakage around the “V”clamps at the turbo outlet and E Brake inlet.Any leakage will significantly reduce theeffectiveness of the E Brake’s retardingperformance.

E. Under normal operating conditions, do not usethe E Brake at idle engine speed.

F. Before returning the vehicle to service, make afinal check of wiring and air tubing/hoserouting to make sure that it does not runagainst hot surfaces or is abraded or kinked.Take the vehicle out for a road test to ensurethat the system is functioning correctly.

bn310
and the transmission in neutral
bn310
Page 12: Installation Manual - parts.jacobsvehiclesystems.com · CUMMINS ® E BRAKE FOR ISC, ISL, ISC03 AND ISL03 ENGINES INSTALLATION MANUAL 3. 1. Installation of the E Brake Assembly. For

025727C

Cummins Engine Company, Inc.Box 3005Columbus, IN 47202-3005U.S.A.

Bulletin 3401713Printed in U.S.A. 10/03©2003 Cummins Engine Company, Inc. andJacobs Vehicle Systems, Inc.

®