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William
William, Fleet Manager
Category: Heavy Equipment
Satisfied Customers: 46
Experience:  OEM trained Allison, Detroit, Cummins, OEM ONAN capability, OEM Carrier AC Dealer, 27 years exp. DOT
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Cummins Isx only get half jake..driving down..throttle

Customer Question

"Cummins" Isx only get half jake ever and while driving down road intermitant throttle. Sometimes jakes don't come on at all. Any Ideas. 565hp with egr 2006.
Submitted: 4 years ago.
Category: Heavy Equipment
Expert:  William replied 4 years ago.

Hi,

 

I would like to take a look at the cummins book for your apllication, can you give me your engine serial number?

 

Also, was the Jake factory installed?

 

Thank you,

 

 

Bud

 

 

Customer: replied 4 years ago.
Jake is integrated into the head - sn 79110875
Expert:  William replied 4 years ago.

Thank you, XXXXX XXXXX get back with you shortly.

 

 

Expert:  William replied 4 years ago.

Attached is the full file for troubleshooting symptoms on your engine. 6

 

CLICK HERE FOR PDF 1

 

CLICK HERE FOR 2

 

CLICH HERE FOR 3

 

I will follow up with a reply to include some additional testing, please let me know if there is something you uncover and need additional information.

 

Thank you,

 

 

 

Bud

Expert:  William replied 4 years ago.

General Information

TOC

NOTE: ICONTM-equipped vehicles use only pins 22 and 31 for engine brake switch inputs. Pin 32 is used for an ICONTM thermostat signal.

The engine brake ON/OFF switch circuit signals the system that the operator is requesting the engine brake system to be activated. The engine brake selector switch determines how many cylinders will be used for engine braking. Three inputs to the ECM from the selector switch are used to communicate the setting to the ECM. Pins 22, 31, and 32 in the OEM connector are used. Various combinations of the three wires are used to represent the six switch positions.



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NOTE: ICONTM-equipped vehicles use only pins 15 and 44 for actuating engines brakes. Pin 25 is used to drive the ICONTM engine autostart alarm.

After the ECM receives the signal from the engine brake ON/OFF switch, the ECM will supply 12 VDC to pins 15, 25, and 44 in the actuator harness, provided the engine speed is above idle and the driver is not in cruise control, or depressing the throttle or clutch pedals. Pins 15, 25, and 44 are connected to the engine brake solenoids in the cylinder head.



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Resistance Check

TOC

If INSITETM is available, monitor the engine brake ON/OFF and selector switches for proper operation. If not, follow the troubleshooting procedures in this section.



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Locate the engine brake ON/OFF switch. Remove the electrical connectors from the switch.

Label the wires with the location on the switch or the wire number. Remove the electrical connectors from the switch.

Adjust the multimeter to measure resistance.

Touch one multimeter probe to one the terminals of the switch. Touch the other multimeter probe to the other terminal of the switch.





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Move the switch to the OFF position. The multimeter must show an open circuit (100k ohms or more). If the circuit is not open, the switch has failed.

Refer to the OEM troubleshooting and repair manual for replacement procedures.





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Place the switch in the ON position. The multimeter must show a closed circuit (10 ohms or less). If the circuit is not closed, the switch has failed.

Refer to the OEM troubleshooting and repair manual for replacement procedures.





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Check for Short Circuit to Ground

TOC

Touch one of the multimeter probes to one of the switch terminals. Touch the other probe to chassis ground. Move the switch to the ON position and measure the resistance. The multimeter must show an open circuit (100k ohms or more). If the circuit is not open, the switch has failed. Refer to the OEM troubleshooting and repair manual for replacement procedures. If the switch passes all of the previous checks, the circuit must be checked for an open circuit, a short circuit to ground, a short circuit from pin to pin, and a short circuit to an external voltage source.





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Expert:  William replied 4 years ago.

Below is the last file I could find.

 

Please let me know if you need anything else,

 

Good Luck,

 

Bud

 

 

 

020-004 Engine Brake Assembly

Table of Contents

Resistance Check
Voltage Check
Initial Check
Engine Brake Solenoid
Engine Brake Rocker Lever
Adjust




Resistance Check

TOC

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Do not connect the engine breakout cable to the engine wiring harness connector. Connecting the engine brake breakout cable to the engine wiring harness will give a false reading when checking the resistance.

Disconnect the engine wiring harness connector from the cylinder head pass-through connector.

Connect one end of the engine brake breakout cable, Part Number 3163150, to the cylinder pass-through connector.

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NOTE: The black test port on the engine brake breakout cable box is the common ground for all three solenoids. The white test ports (1, 2, and 3) are used to test the resistance of the corresponding brake solenoids (1, 2, and 3).

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NOTE: The ignition key must be in the OFF position.

Check the resistance of each solenoid.

    12 volt

  • Cold engine - 8 to 10 ohms
  • Hot engine - 16 to 20 ohms.

    24 volt

  • Cold engine - 32 to 40 ohms
  • Hot engine - 60 to 80 ohms.

NOTE: If not within specification, using the engine brake breakout tool, the engine brake wiring harness and solenoids must be checked separately to identify the faulty component. Refer to Procedure 020-012 (Engine Brake Solenoid Valve) in Section 20. Refer to Procedure 020-015 (Engine Brake Wiring Harness) in Section 20.

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Voltage Check

TOC

Disconnect the engine wiring harness connector from the cylinder head pass-through connector.

Connect one end of the engine brake breakout cable, Part Number 3163150, to the cylinder pass-through connector and the other end to the engine wiring harness connector.

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Connect the red alligator clip of the engine brake breakout cable to battery voltage and the black alligator clip to ground.

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NOTE: The black test port on the engine brake breakout cable box is the common ground for all three solenoids. The white test ports (1, 2, and 3) are used to read the voltage of the corresponding brake solenoids 1, 2, and 3.

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NOTE: The ignition key must be in the ON position.

Check the voltage of each solenoid.

The voltage should be 12-VDC for each solenoid.

NOTE: If not within specification, using the engine brake breakout tool, the engine brake wiring harness and solenoids must be checked separately to identify the faulty component. Refer to Procedure 020-012 (Engine Brake Solenoid Valve) in Section 20. Refer to Procedure 020-015 (Engine Brake Wiring Harness) in Section 20.

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Initial Check

TOC

Engine Brake Solenoid

Disconnect the engine wiring harness connector from the cylinder head pass-through connector.

Connect one end of the engine brake breakout cable, Part Number 3163150, to the cylinder pass-through connector and the other end to the engine wiring harness connector.

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NOTE: The ignition key must be in the OFF position.

  • Button No. 1 actuates solenoid No. 1 and brake Number 1.
  • Button No. 2 actuates solenoid No. 2 and brakes Number 2 and 3.
  • Button No. 3 actuates solenoid No. 3 and brakes Number 4, 5, and 6.

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Press the engine brake breakout cable box button (1, 2, or 3) to activate the corresponding engine brake solenoid (1, 2, or 3).

Listen for a clicking sound when activating the brake solenoid. If no clicking sound can be heard when the button is pressed, the corresponding solenoid valve and the engine brake wiring harness must be checked separately to identify the faulty component. Refer to Procedure 020-012 (Engine Brake Solenoid Valve) in Section 20. Refer to Procedure 020-015 (Engine Brake Wiring Harness) in Section 20.

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Engine Brake Rocker Lever

Remove the rocker lever cover. Refer to Procedure 003-011 (Rocker Lever Cover) in Section 3.

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Install the splash shield , Part Number 3163092, to reduce the amount of oil being thrown by the fuel pump drive gear.

Start the engine.

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Press the engine brake breakout cable box button (1, 2, or 3) to activate the corresponding engine brake solenoid (1, 2, or 3).

Check the corresponding engine brake lever(s) and solenoid for the following:

  • Engine brake piston deployment
  • Leakage from upper seals of solenoid.

Replace parts as needed. Refer to Procedure 020-012 (Engine Brake Solenoid Valve). Refer to Procedure 020-017 (Engine Brake Control Valve). Refer to Procedure 020-019 (Engine Brake Piston) in Section 20.

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Adjust

TOC

All overhead adjustments must be made when the engine is cold (any stabilized coolant temperature at 60°C [140°F] or below).

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Do not use solvent to clean the rocker cover gasket. Solvent can damage the gasket material and cause it to swell.

Remove the rocker lever cover and gasket. Refer to Procedure 003-011 (Rocker Lever Cover) in Section 3.

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NOTE: Early engine vibration dampers are marked with BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine brakes must be set at the appropriate mark on these engines. Newer engine vibration dampers are marked with only A, B, or C, and are adjusted with the valves and injector on the same cylinder.

Locate the valve set marks on the outside of the vibration damper.

The set marks are A, B, and C:

Set to mark A to adjust cylinder 1 or 6.
Set to mark B to adjust cylinder 2 or 5.
Set to mark C to adjust cylinder 3 or 4.

NOTE: Two complete revolutions are required to set all valves, engine brakes, and injectors.

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With Air Compressor:

Remove the oil fill connector from the lower gear case cover.

Insert a 3/4-inch drive ratchet and extension into the air compressor drive.

Rotate the air compressor drive clockwise, as viewed from the front of the engine.

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Do not pull or pry on the fan to manually rotate the engine. To do so can damage the fan blades. Damaged fan blades can cause premature fan failures which can result in serious personal injury or property damage.

The crankshaft rotation is clockwise, as viewed from the front of the engine.

The cylinders are numbered from the front of the engine (1-2-3-4-5-6).

The engine firing order is 1-5-3-6-2-4.

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Without Air Compressor:

Loosen the capscrews and rotate the cover or remove the oil fill tube, if equipped.

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Use a 1 1/2-inch socket, push the barring gear into the gear mesh and bar engine over counterclockwise.

NOTE: Rock the barring device back and forth until it disengages.

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Each cylinder has four rocker levers:

  • The exhaust valve rocker lever (1)
  • The injector rocker lever (2)
  • The intake valve rocker lever (3)
  • The engine brake rocker lever (4).

NOTE: The intake valve rocker lever is always the long lever on the valve rocker lever shaft.

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NOTE: Early engine vibration dampers are marked with BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine brakes must be set at the appropriate mark on these engines. Newer engine vibration dampers are marked with only A, B, or C, and are adjusted with the valves and injector on the same cylinder.

The valves, brakes, and the injectors on the same cylinder are adjusted at the same index mark on the vibration damper.

Signature, ISX and QSX15
Brake Adjustment Sequence
Bar Engine in Direction of RotationPulley PositionBrake
StartA1
Advance toB5
Advance toC3
Advance toA6
Advance toB2
Advance toC4
Firing Order: 1-5-3-6-2-4

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Rotate the compressor drive or barring device in the direction of engine rotation, clockwise. Align the A mark on the vibration damper with the pointer on the gear cover.

NOTE: For illustrative purposes, position A is shown as the first step. It is not necessary to start with position A, as long as the proper sequence is followed.

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Check the valve rocker levers on the given cylinder to see if both intake and exhaust valves are closed.

NOTE: Both sets of valves are closed when the rocker levers and the brake lever are loose. If both sets of valves are not closed, rotate the compressor drive gear one complete revolution, and align the A mark on the front damper with the pointer again.

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To get maximum brake operating efficiency and to prevent engine damage, the brake adjustment instructions must be followed.

For older engines, locate the engine brake set marks on the outside of the vibration damper.

The set marks are BRAKE SET 1-6, and BRAKE SET 2-5, and BRAKE SET 3-4.

BRAKE SET 1-6: Cylinder 1 or 6 adjust

BRAKE SET 2-5: Cylinder 2 or 5 adjust

BRAKE SET 3-4: Cylinder 3 or 4 adjust

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Rotate the compressor drive or barring device in the direction of engine rotation, clockwise. Align the A mark on the vibration damper with the pointer on the gear cover.

NOTE: For illustrative purposes, position A is shown as the first step. It is not necessary to start with position A, as long as the proper sequence is followed.

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Check the valve rocker levers on the given cylinder to see if both intake and exhaust valves are closed.

NOTE: Both sets of valves are closed when the rocker levers and the brake lever are loose. If both sets of valves are not closed, rotate the compressor drive gear one complete revolution, and align the A mark on the front damper with the pointer again.

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Press the engine brake lever down to verify that the camshaft follower is in contact with the camshaft.

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Loosen the locknut on the brake lever adjusting screw, and back out the adjusting screw one turn.

Insert the feeler gauge, Part Number 3163530, between the bottom of the engine brake piston and the top of exhaust valve pin on the exhaust valve crosshead.

Brake Lever Lash Specification
mmin
7.00NOM0.276

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Tighten the adjusting screw until drag on the feeler gauge is felt. Proper drag means that there is no motion of the brake lever camshaft follower against the cam lobe.

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Hold the engine brake lever adjusting screw, and tighten the locknut.

Torque Value: 20 n.m[177 in-lb]

Remove the feeler gauge.

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Engine damage can occur if running clearance is not within specifications.

Check the running clearance:

  1. Rotate the engine brake rocker lever to the detent (neutral) position.
  2. Check the clearance (1) between the engine brake lever actuator piston and the crosshead guide pin.
Engine Brake Lever Running Clearance
mmin
0.635MIN0.025
2.790MAX0.110

If the running clearance does not fall in the given specifications, loosen the rocker lever shaft and rotate the rocker lever shaft, slightly, in the direction required to bring the running clearance within specifications.

Recheck the brake running clearance.

NOTE: The rocker lever shafts must be adjusted so that all three engine brake levers fall within the given running clearance specification.

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Repeat the process to adjust all engine brakes according to the chart shown earlier in this procedure.

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Install the rocker lever cover and gasket. Refer to Procedure 003-011 (Rocker Lever Cover) in Section 3.

If failure resulted in coolant, oil, excessive fuel or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Refer to Procedure 014-013 (Aftertreatment Testing) in Section 14.

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  • Another great insight to what may be the problem. I will have my mechanic take a look at it tomorrow. Thanks again, Frank...you do indeed know your stuff. Jim Castleberry, FL
  • Wonderful service, prompt, efficient, and accurate. Couldn't have asked for more. I cannot thank you enough for your help. Mary C. Freshfield, Liverpool, UK
 
 
 

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    Chris (aka - Moose)

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