Engine Brakes

Installation Manual
Model T765A & T760A Engine Brakes For Detroit Diesel 12.7 L. & 11.1L Series 60 Engines

TecBrake P.O. Box 27822 Houston, Texas 77227

INSTALLATION MANUAL
TECBRAKE T765A AND T760A ENGINE BRAKE FOR DETROIT DIESEL SERIES 60 ENGINES.
The TecBrake T765A engine brake may be installed on popular versions of the Detroit Diesel Series 60 12.7L engines. TecBrake Model T760A engine brake may be installed on Detroit Diesel Series 60 11.1L engines and Detroit Diesel Series 60 12.7 Pre-1991 engines. It should only be installed on engines whose model numbers are included in the Application Chart. All Series 60 engines S/N 06R0004455 and higher are engine brake ready. TecBrake engine brake installation on engines with lower serial number is not approved.

APPLICATION CHART ENGINE CONTROL MODEL TYPE 6067GU40 DDECII 6067WU40 DDECII 6067WU60 DDECII 6067WK60 DDECIII 6067SK60 DDECIII 6067GU28 DDECII 6067GU60 DDECII 6067GU91 DDECII 6067GK28 DDECIII 6067GK60 DDECIII

TECBRAKE MODEL T760A T760A T760A T760A T760A T765A T765A T765A T765A T765A

LASH SETTING 0.020 (0.50mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm)

Special Tools The following special tools are required for installation: 1. 18mm 6/12 point socket 2. Feeler gauge 0.026" / Feeler gauge 0.020" Recommended Torque Values Engine Brake Hold-down bolts Slave Piston Adj. Screw Nuts Valve Cover capscrews Bridge Adjusting screw hex nut-

SECTION 1- INTRODUCTION
NOTICE The TecBrake Engine Brake is designed as a device for slowing a vehicle, not stopping it. It is to be used in conjunction with, but not a substitute for the vehicles service brakes. The service brakes must be in good operating condition and used to bring the vehicle to a complete stop.
Material Required The TecBrake kit includes all of the parts required to make an installation on the most common engine configurations. Prior to installation, determine the engine model to verify that the engine brake being installed is correct for the engine. The engine model number can be found on the option labels located on the valve cover or stamped on the cylinder block below the intake manifold. Also determine whether the engine is a DDECII or DDECIII. Depending on engine control, a different control group is required. Refer to the Application Chart, which list all engine model numbers on which the T765A and T760A engine brake may be installed.

100 lbft (136 N*m) 25 lbft (35 N*m) 9 lbft (12N*m) 35 lbft (47N*m)

SECTION 2- ENGINE PREPARATION

Figure 2-1 1. Thoroughly clean engine before beginning installation. Remove valve cover and gasket. If engine is equipped with an aluminum two-piece valve cover, remove only the upper valve cover for brake installation.

Figure 1-1

Figure 2-2

2. Install the thru head harness prior brake housings installation. Different wire harness is used for DDECII and DDECIII applications.

5. Lay the harness along the side of injector wire harness. Locate the terminals between cylinders 5 and 6.

Figure 2-6 Figure 2-3 3. Remove the mounting flange cover for the electronic injector harness. Flange is located on the rear of the engin head. Remove two plastic plugs from spare holes in the grommet. 6. Insert the wires from the harness in the injector harness conduit on the outside of the head. Replace the harness mounting flange. Use the supplied split conduit to cover the harness wires.

Figure 2-4 Figure 2-7 4. Instert the yellow wire and the white wire from the harness, through the spare holes in the grommet. Insert the wires from outside in. 7. Use the loose connector supplied on engine harness (solenoid harness). Insert the white wire from thru head harness into connector cavity No. 1, also insert the yellow wire in cavity No. 2.

Figure 2-5 Figure 2-8 8. Insert the wedge lock on the connector as shown.

11. Secure the undercover harnesses along the side the injector wire harness. Use supplied plastic ties. SECTION 3- BRAKE HOUSING INSTALLATION

Figure 2-9 9. Connect the engine harness (solenoid harness) to the thru head harness. Verify that the yellow wires from engine harness connect to yellow wire from thru head harness. The wire colors must match each other on both ends of the connector to ensure proper engine brake sequencing.

Figure 3-1 1. Remove and discard the three camshaft bearing cap bolts in locations 2,4 and 6 on the intake manifold side. Locations indicated by arrows.

CAUTION Oil from bolt bores should be removed to prevent cylinder head to crack when tightening the bolts. Blow out the oil from the bolt holes. Cover the holes with towels to reduce oil spilling. Wear eye protection to prevent personal injuries.

Figure 2-10 10. Check injector electrical terminals. On older engines, terminals should be bent 90 upwards to provide clearance for engine brake housings. Newer engine models require no modifications.

Figure 3-2 2. Place the two spacer bars on the exhaust manifold side of the cylinder head. Ensure that "OUT" marking are adjacent to each other, and facing outwards. 3. Position the entire wiring harness to keep it from interference by rocker levers. The brake harness connector should be positioned between cylinder 5 and 6. Use plastic ties to locate it to the side of spacer bar. Make sure that solenoid attaching wires are positioned in direction of the three camshaft bearing cap bolts previously removed in locations 2,4 and 6.
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Figure 2-11

Figure 3-3 Figure 3-6 6. Lubricate each hold-down bolt with clean engine oil before installation. Locate the bolts into brake housings. Three bolts are required for engine brake housing. Use hand tools only.

CAUTION The use of impact or high-speed wrenches may damage the cylinder head.

Figure 3-4 4. Place the three engine brake housings over the rocker shafts with the solenoid valves towards camshaft side of the engine.

NOTICE Be sure engine brake housings do not interfere with wiring harness.
Figure 3-7 7. Before tightening the brake housings hold-down bolts, push the housing from side to side as shown on the above figure. Locate the brake housing in the center position of the movement.

Figure 3-5 5. Install the hardened washers on each of the nine TecBrake hex head hold-down bolts. Figure 3-8

8. Tighten the engine brake housing hold-down bolts using the following tightening sequence: a) Torque the three bolts on the camshaft side of the engine to 40 lbft. (55 N*m). b) Torque the six hold-down bolts on the exhaust manifold side of the engine to 40lbft. (55N*m). c) Repeat the same tightening sequence and re-torque all hold-down bolts to 100 lbft. (136 N*m).

Figure 3-11 2. The exhaust valves on the cylinder to be adjusted must be in the closed position. Determine which cylinders have clearance between exhaust rocker adjusting screws and valve stems (rocker arm loose), indicating that exhaust valves are fully closed. Usually four cylinders show the above condition regardless of the crankshaft position. Figure 3-9 9. Attach the three wires to the solenoids. Make sure of full engagement within the mating terminals. 10. Secure the wiring harness to spacer bars. Make sure harness is free of interference from brake housings and rocker levers. Slave Piston Adjustment The slave piston adjustment procedure must be strictly followed. Adjustment of the slave piston is critical. Proper adjustment is necessary in order to provide peak braking efficiency without over stressing the engine. 3. Refer to the Application Chart to select the correct feeler gauge size.
APPLICATION CHART ENGINE CONTROL MODEL TYPE 6067GU40 DDECII 6067WU40 DDECII 6067WU60 DDECII 6067WK60 DDECIII 6067SK60 DDECIII 6067GU28 DDECII 6067GU60 DDECII 6067GU91 DDECII 6067GK28 DDECIII 6067GK60 DDECIII

Slave piston adjusting screw adjustment must be made with the engine stopped and engine temperature stabilized below 140 F (60C).

TECBRAKE MODEL T760A T760A T760A T760A T760A T765A T765A T765A T765A T765A

LASH SETTING 0.020 (0.50mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm) 0.026 (0.66mm)

4. Place the correct feeler gauge between the solid side of the bridge (the side without the leveling screw) and the exhaust rocker arm adjusting screw.

Figure 3-10 1. Back out the bridge leveling screw until the end of the screw is beneath the surface of the bridge.

Figure 3-12 5. Turn the slave piston adjusting screw clockwise until a slight drag is felt on the feeler gauge.
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1. Start the engine and let it idle for a short time.

Figure 3-13 6. Hold the screw in position and tighten the lock nut to 25lbft. (35 N*m). Verify the clearance by re-inserting the feeler gauge. Repeat if necessary. Figure 3-15 2. Depress and release the top of the solenoid several times to bleed the air from the brake housing. When all of the air has been removed the brake should operate immediately when the solenoid is depressed. 3. Verify the following on all three housings: a) Master piston should be moving up and down onto the roller in the injector rocker arm. b) Slave piston and bridge should be moving up and down onto the exhaust valve rocker arm adjusting screws. c) Bridge leveling screw should be aligned with exhaust rocker arm adjusting screw. d) Verify that wiring harness is not in contact with moving parts. 4. Install the rocker cover. a) For one-piece rocker cover tighten the four bolts, starting with the center bolts and working outwards, to 16 lbft. (22 N*m) torque. b) For two-piece rover cover refer to installation on DDC Service Manual. SECTION 4- ELECTRICAL SYSTEM INSTALLATION A) DDECII Engines Installation of the electrical system involves the mounting of dash switches, a clutch switch, and a relay harness. An optional foot switch may be installed in place of the clutch switch. Wiring harnesses are provided in the kit to complete the installation. Dash Switches Dash switches should be installed in dash where they are visible and convenient to operate. 1. Drill holes in dash to accommodate switches and install switches with proper name plates.

Figure 3-14 7. Place the same feeler gauge between the bridge leveling screw and the exhaust rocker arm adjusting screw. Turn the bridge leveling screw clockwise until a slight drag is felt on the feeler gauge. Hold the screw in position and tighten the hex nut to 35lbft. (47 N*m). Verify the clearance by re-inserting the feeler gauge. Repeat if necessary. 8. Repeat the adjustment procedure on the remaining cylinders with exhaust valves in closed position. Bar the engine over as necessary to set the remaining exhaust valves in closed position for slave piston adjustment. Operational Check Installation of the brake housings is now complete. Functioning of the brakes should be checked before proceeding further.

CAUTION Wear eye protection. When engine is running with valve covers removed, oil splashing will occur. Take precautions to prevent oil contaminating engine and engine compartment.

Clutch Switch It is recommended that the clutch switch be mounted inside the vehicle cab to protect it from road contamination.

2. Mount the relay base in a convenient location on the firewall. Connect the black wire to a chassis ground. 3. Locate or drill a hole on firewall. Run the harness through the firewall, from the engine compartment into the cab. The four wires at the end of harness should now be in the cab. 4. Route the harness to the dash switches close by the clutch switch. Pull a loop of green wire from the split loom. Cut the green wire and install fast-on terminals on both ends. Insert terminals on clutch switch. Use tape around the split loom to keep green wires in place.

Figure 4-1 1. Mount the clutch switch in a convenient location near the clutch pedal so that movement of the clutch pedal will contact the clutch switch actuator arm. See Figure 4-1. 2. Adjust the clutch switch so that the actuator arm is deflected from 1" to 1.5" (25 mm to 38 mm) when the clutch is in the up (clutch engaged) position. 3. Check the switch by depressing the clutch. The switch should click to an open electrical position as soon as the free play in the clutch is taken up. When the clutch is released, the switch should click to a closed electrical position. Relay Harness Figure 4-3 5. The remaining white wire on the relay harness must be connected to wire No. 508 (DDEC cavity A1 upper most closest to the engine).

Figure 4-2 1. Locate the Weather Pack connector from the thru head harness. Locate the Weather Pack connector from the relay harness. Snap together the two mating connectors.

Figure 4-4 6. Cut the wire No. 508 about 4 inches from ECM connector. Attach the wire originating from ECM to white wire from relay harness having a butt connector. Crimp the connector and use a heat shrink tubing to seal the joint. Tape the remaining end of wire No. 508. 7. Connect all wires as shown on Wiring Diagram DDECII.

B) DDECIII Engines Installation of the electrical system involves the mounting of dash switches, and connecting thru head harness to vehicle interface harness. On Series 60 engines equipped with DDECIII, the DDECIII ECM controls the engine brake. The use of relay harness is not required.

NOTICE Some DDECIII engines may not have the ECM programmed for engine brake operation. Verify by using a DDR. If any of ECM input switches K2, K3, S3 or T3 reads NONE, then the vehicle should be taken to a DDC dealer to enable engine braking.
Dash Switches Dash switches should be installed in dash where they are visible and convenient to operate. 1. Drill holes in dash to accommodate switches and install switches with proper name plates. 2. For DDECIII applications, most vehicles already have a vehicle OEM installed clutch switch to use with cruise control. TecBrake clutch switch will only be required if for some reason the vehicle does not have a clutch switch, TecBrake Control Group for DDECIII does not include the clutch switch, if required, must be ordered separately.

Figure 4-6 4. Locate the Metri-Pack connector from the thru-head harness. Snap together the two mating connectors. 5. Identify the color and/or number of wires originating at cavity K2 and K3 from ECM Vehicle Interface Connector.

CAUTION Make sure that only negative ground is input to ECM Vehicle Interface terminals K2 and K3 or damages to ECM may result.
6. These two wires terminate behind the dash and may be grouped with a wire connected to ground. If these wires are not present and optional cab harness for DDECIII must be used. Connect these three wires as shown on Wiring Diagram DDECIII. 7. Connect one terminal of ON-OFF dash switch to green wire No. 953 (battery ground).

NOTICE Engine brake will operate automatically while in cruise control. The brake will come on low when road speed increases a few MPH above the cruise set speed. If speed continues to increase, the ECM will increase the braking power progressively.

Figure 4-5 3. Locate the Metri-Pack connector from the DDCprovided connector. Verify the color and/or number of the two wires coming from ECM engine sensor harness. Label Engine Brake Low Engine Brake Med Wire 562 561 Color Orange Red

SECTION 5- ENGINE BRAKE MAINTENANCE

Figure 5-1 The engine brake is designed to be trouble free and does not require special maintenance. During regularly scheduled maintenance, or if a problem occurs, the procedures described below should be followed. 3. Clean solenoid bore with solvent and wipe dry with paper towel. Be careful not to leave any lint or residue in bore that may contaminate brake hydraulic components.

CAUTION Do not remove any engine brake component while the engine running. This may result in personal injury. Use only approved cleaning solvents.

Solenoid Valve
1. Disconnect the electrical lead from the solenoid and remove solenoid with a spanner or socket wrench. Remove and discard the three rubber seal rings. 2. Clean the filter screen and solenoid with solvent then dry with low air pressure. Figure 5-2

4. Reinstall solenoid valve using three new O -rings. Coat solenoid body with engine lube oil and install upper and center seal rings on solenoid body. Seat lower seal ring in bottom bore of brake. 5. Carefully screw in solenoid valve, using care to assure O-rings remain in position and are not twisted or rolled.

CAUTION Control valve covers are under load from control valve springs. Use care when removing control valve covers to avoid injury.

Figure 5-5 Figure 5-3 6. Tighten solenoid valve to 5 lbft (7 N*M) torque. Control Valve 6. Push on the check valve ball with a small wire through the hole in the bottom of the control valve to make sure that there is spring tension on the ball. The ball should lift freely with a small amount of force and return quickly to the seat when the force is removed. Replace the control valve if it is defective. 7. Dip the control valve in engine lube oil and install in brake housing. Control valve should slide in without any binding. Replace control valve if binding occurs.

Figure 5-4 1. Press down on control valve cover to relieve spring pressure. 2. Remove the hex head cap screw and continue pressing down on valve cover. 3. Slowly remove the cover until spring pressure ceases, then remove the two control valve springs and collar. 4. Remove control valve using needle nose pliers. 5. Wash control valve with solvent.

Figure 5-6

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8. Install both control valve springs and collar in valve bore, install cover and cap screw. Slave Piston Adjusting Screw 1. Loosen slave piston adjusting screw lock nut, and remove adjusting screw from housing. Clean screw with solvent. 2. Inspect slave piston adjusting screw on the bottom area. It should be smooth and free of nicks. Slave Piston Assembly and Torsion Spring.

4. Clean all parts in solvent. Inspect all components for excessive wear or damage. Replace parts if necessary.

Figure 5-9 5. Reinstall all components. Install both bridges with leveling screws toward the center of housing. Install the slave piston torsion spring with ends over the bridge grooves.

Figure 5-7 1. Remove the button head screw and washer that retains the slave piston return spring.

CAUTION Push the torsion spring towards the bridge while tightening the screw. Failure to do so may result in contact between intake valve adjusting screw and torsion spring; Serious engine damage may result.
6. Install the button head screw and washer over the center section of torsion spring. Tighten screw to 15 lbft. (20 N*m). Accumulator Piston

CAUTION When removing slave pistons wear eye protection and use proper tools. Slave piston springs are highly compressed and may cause serious personal injury if not removed with caution.
2. Remove the bridge and slave piston assembly. Loosen leveling screw lock nut from bridge.

Figure 5-10 1. Press down on accumulator valve cover to relieve spring pressure. Figure 5-8 3. Remove slave piston assembly. Inspect slave piston pin for nicks or excessive wear. 2. Remove the hex head cap screw and continue pressing down on cover. 3. Slowly remove the cover until spring pressure ceases, then remove the accumulator spring.

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CAUTION Accumulator cover is under load from inner spring. Use care when removing cover to avoid injury.
4. Remove accumulator piston using a magnet. 5. Wash control valve with solvent. Inspect parts for wear or damage. Replace if necessary. Insert piston in bore. Accumulator piston must slide without binding. Replace if binding occurs.

3. Clean all parts with approved solvent and lubricate with engine oil. 4. Insert piston in bore. Piston must slide in bore without binding. Replace if binding occurs. 5. Reassemble all parts in reverse order from disassembly procedure.

Figure 5-13 Figure 5-11 6. Reassemble all par ts in reverse order from disassembly procedure. Master Piston

6. Make sure spring tabs are aligned with raised surface on end of piston. Torque cap screw to 9 lbft (12 N*m)

Figure 5-12

1. Remove hex head cap screw, washer and flat spring from brake housing. 2. Remove master piston from bore. Check master piston outside diameter ground surface for nicks or burrs. Piston must slide in bore without binding. Replace if binding occurs. Check top surface of piston. Replace piston if there are cracks or pitting.

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Detroit Diesel, Series 60 DDECII and DDECIII are registered trademarks of Detroit Diesel Corporation. TecBrake Inc. P.O. Box 27822 Houston, Texas 77227 1999 TecBrake Bulletin No. TB990175A 04/01/99