Engine Brake Installation Manual

8/3/2019 Engine Brake Installation Manual

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TecBrake

P.O. Box 27822Houston, Texas 77227

Installation

Manual

Model T765A & T760AEngine BrakesFor Detroit Diesel 12.7 L. & 11.1LSeries 60Engines

Engine Brakes


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INSTALLATION MANUAL

TECBRAKE T765A AND T760A ENGINE BRAKEFOR 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 beinstalled on Detroit Diesel Series 60 11.1L engines and

Detroit Diesel Series 60 12.7 Pre-1991 engines. It shouldonly be installed on engines whose model numbers are

included in the Application Chart.

All Series 60 engines S/N 06R0004455 and higher areengine brake ready. TecBrake engine brake installation

on engines with lower serial number is not approved.

SECTION 1- INTRODUCTION

NOTICE

The TecBrake Engine Brake is designed as a devicefor slowing a vehicle, not stopping it. It is to be usedin conjunction with, but not a substitute for the

vehicles service brakes. The service brakes mustbe 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 tomake 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 theengine. 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. Alsodetermine whether the engine is a DDECII or DDECIII.

Depending on engine control, a different control group isrequired. Refer to the Application Chart, which list all engine

model numbers on which the T765A and T760A enginebrake may be installed.

Figure 1-1

APPLICATION CHART

ENGINE CONTROL TECBRAKE LASH

MODEL TYPE MODEL SETTING

6067GU40 DDECII T760A 0.020 (0.50mm)

6067WU40 DDECII T760A 0.026 (0.66mm)6067WU60 DDECII T760A 0.026 (0.66mm)6067WK60 DDECIII T760A 0.026 (0.66mm)6067SK60 DDECIII T760A 0.026 (0.66mm)6067GU28 DDECII T765A 0.026 (0.66mm)6067GU60 DDECII T765A 0.026 (0.66mm)6067GU91 DDECII T765A 0.026 (0.66mm)6067GK28 DDECIII T765A 0.026 (0.66mm)6067GK60 DDECIII T765A 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 - 100 lbft (136 N*m)

Slave Piston Adj. Screw Nuts - 25 lbft (35 N*m)

Valve Cover capscrews - 9 lbft (12N*m)Bridge Adjusting screw hex nut- 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 uppervalve cover for brake installation.

Figure 2-2

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2. Install the thru head harness prior brake housingsinstallation. Different wire harness is used for DDECII

and DDECIII applications.

Figure 2-3

3. Remove the mounting flange cover for the electronicinjector harness. Flange is located on the rear of the engin

head. Remove two plastic plugs from spare holes in the

grommet.

Figure 2-4

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.

Figure 2-5

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

Figure 2-6

6. Insert the wires from the harness in the injector harness

conduit on the outside of the head.Replace the har nessmounting flange. Use the supplied split conduit to cover the

harness wires.

Figure 2-7

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 yellowwire in cavity No. 2.

Figure 2-8

8. Insert the wedge lock on the connector as shown.

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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 headharness. The wire colors must match each other on both

ends of the connector to ensure proper engine brakesequencing.

Figure 2-10

10. Check injector electrical terminals. On older engines,

terminals should be bent 90 upwards to provide clearancefor engine brake housings. Newer engine models require

no modifications.

Figure 2-11

11. Secure the undercover harnesses along the side theinjector wire harness. Use supplied plastic ties.

SECTION 3- BRAKE HOUSING INSTALLATION

Figure 3-1

1. Remove and discard the three camshaft bearing capbolts 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. Blowout the oil from the bolt holes. Cover the holes with

towels to reduce oil spilling. Wear eye protection toprevent personal injuries.

Figure 3-2

2. Place the two spacer bars on the exhaust manifold sideof the cylinder head. Ensure that "OUT" marking are

adjacent to each other, and facing outwards.

3. Position the entire wiring harness to keep it frominterference 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 thatsolenoid attaching wires are positioned in direction of the

three camshaft bearing cap bolts previously removed inlocations 2,4 and 6.

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Figure 3-3

Figure 3-5

5. Install the hardened washers on each of the nine

TecBrake hex head hold-down bolts.

Figure 3-4

4. Place the three engine brake housings over the rockershafts with the solenoid valves towards camshaft side

of the engine.

NOTICEBe sure engine brake housings do not interfere with

wiring harness.

Figure 3-6

6. Lubricate each hold-down bolt with clean engine oilbefore installation. Locate the bolts into brake housings.

Three bolts are required for engine brake housing. Use

hand tools only.

CAUTIONThe use of impact or high-speed wrenches may

damage the cylinder head.

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 3-8

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8. Tighten the engine brake housing hold-down boltsusing the following tightening sequence:

a) Torque the three bolts on the camshaft side of theengine 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 3-9

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 sureharness 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 brakingefficiency without over stressing the engine.

Slave piston adjusting screw adjustment must be

made with the engine stopped and enginetemperature stabilized below 140 F (60C).

Figure 3-10

1. Back out the bridge leveling screw until the end ofthe screw is beneath the surface of the bridge.

Figure 3-11

2. The exhaust valves on the cylinder to be adjusted mustbe in the closed position. Determine which cylinders have

clearance between exhaust rocker adjusting screws and valve

stems (rocker arm loose), indicating that exhaust valves arefully closed. Usually four cylinders show the above condition

regardless of the crankshaft position.

3. Refer to the Application Chart to select the correct feeler

gauge size.

APPLICATION CHART

ENGINE CONTROL TECBRAKE LASH

MODEL TYPE MODEL SETTING

6067GU40 DDECII T760A 0.020 (0.50mm)6067WU40 DDECII T760A 0.026 (0.66mm)6067WU60 DDECII T760A 0.026 (0.66mm)6067WK60 DDECIII T760A 0.026 (0.66mm)6067SK60 DDECIII T760A 0.026 (0.66mm)6067GU28 DDECII T765A 0.026 (0.66mm)6067GU60 DDECII T765A 0.026 (0.66mm)6067GU91 DDECII T765A 0.026 (0.66mm)6067GK28 DDECIII T765A 0.026 (0.66mm)6067GK60 DDECIII T765A 0.026 (0.66mm)

4. Place the correct feeler gauge between the solid side ofthe bridge (the side without the leveling screw) and the

exhaust rocker arm adjusting screw.

Figure 3-12

5. Turn the slave piston adjusting screw clockwise until a

slight dragis felt on the feeler gauge.

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Figure 3-14

7. Place the same feeler gauge between the bridgeleveling screw and the exhaust rocker arm adjusting

screw. Turn the bridge leveling screw clockwise until aslight dragis felt on the feeler gauge. Hold the screw in

position and tighten the hex nut to 35lbft. (47 N*m). Verifythe 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. Barthe 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 beforeproceeding further.

CAUTION

Wear eye protection. When engine is running with

valve covers removed, oil splashing will occur. Takeprecautions to prevent oil contaminating engine and

engine compartment.

1. Start the engine and let it idle for a short time.

Figure 3-15

2. Depress and release the top of the solenoid severaltimes to bleed the air from the brake housing. When allof 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 downonto the exhaust valve rocker arm adjusting screws.

c) Bridge leveling screw should be aligned with exhaustrocker arm adjusting screw.

d) Verify that wiring harness is not in contact with movingparts.

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. Anoptional foot switch may be installed in place of the clutch

switch. Wiring harnesses are provided in the kit to completethe installation.

Dash Switches

Dash switches should be installed in dash where they arevisible and convenient to operate.

1. Drill holes in dash to accommodate switches and install

switches with proper name plates.

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 thefeeler gauge. Repeat if necessary.

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Clutch Switch

It is recommended that the clutch switch be mountedinside the vehicle cab to protect it from road

contamination.

Figure 4-2

1. Locate the Weather Pack connector from the thru head

harness. Locate the Weather Pack connector from therelay harness. Snap together the two mating connectors.

2. Mount the relay base in a convenient location on thefirewall. 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 inthe 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 thegreen 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 4-3

5. The remaining white wire on the relay harness must be

connected to wire No. 508 (DDEC cavity A1 upper mostclosest to the engine).

Figure 4-1

1. Mount the clutch switch in a convenient location near

the clutch pedal so that movement of the clutch pedal willcontact 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 switchshould 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 electricalposition.

Relay Harness

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 remainingend of wire No. 508.

7. Connect all wires as shown on Wiring Diagram DDECII.

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B) DDECIII Engines

Installation of the electrical system involves the mountingof 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 byusing 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 installswitches with proper name plates.

2. For DDECIII applications, most vehicles already have

a vehicle OEM installed clutch switch to use with cruisecontrol. TecBrake clutch switch will only be required if

for some reason the vehicle does not have a clutchswitch, TecBrake Control Group for DDECIII does not

include the clutch switch, if required, must be ordered

separately.

Figure 4-5

3. Locate the Metri-Pack connector from the DDC-provided connector. Verify the color and/or number of the

two wires coming from ECM engine sensor harness.

Label Wire Color

Engine Brake Low 562 OrangeEngine Brake Med 561 Red

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.

CAUTIONMake sure that only negative ground is input to ECMVehicle Interface terminals K2 and K3 or damages to

ECM may result.

6. These two wires terminate behind the dash and may begrouped with a wire connected to ground. If these wires are

not present and optional cab harness for DDECIII must beused. 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).

NOTICEEngine brake will operate automatically while in cruisecontrol. 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 thebraking power progressively.

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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, theprocedures described below should be followed.

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. Removeand discard the three rubber seal rings.

2. Clean the filter screen and solenoid with solvent then

dry with low air pressure.

3. Clean solenoid bore with solvent and wipe dry with papertowel. Be careful not to leave any lint or residue in bore that

may contaminate brake hydraulic components.

Figure 5-2

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4. Reinstall solenoid valve using three new O -rings.Coat solenoid body with engine lube oil and install upper

and center seal r ings on solenoid body. Seat lower sealring in bottom bore of brake.

5. Carefully screw in solenoid valve, using care to assureO-rings remain in position and are not twisted or rolled.

Figure 5-3

6. Tighten solenoid valve to 5 lbft (7 N*M) torque.

Control Valve

Figure 5-4

1. Press down on control valve cover to relieve spring

pressure.

2. Remove the hex head cap screw and continuepressing 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.

CAUTION

Control valve covers are under load from control valve

springs. Use care when removing control valve covers

to avoid injury.

Figure 5-5

6. Push on the check valve ball with a small wire throughthe hole in the bottom of the control valve to make surethat there is spring tension on the ball. The ball should lift

freely with a small amount of force and return quickly tothe 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 5-6

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8. Install both control valve springs and collar in valvebore, install cover and cap screw.

Slave Piston Adjusting Screw

1. Loosen slave piston adjusting screw lock nut, andremove adjusting screw from housing. Clean screw with

solvent.

2. Inspect slave piston adjusting screw on the bottomarea. It should be smooth and free of nicks.

Slave Piston Assembly and Torsion Spring.

Figure 5-7

1. Remove the button head screw and washer that

retains the slave piston return spring.

CAUTION

When removing slave pistons wear eye protectionand use proper tools. Slave piston springs are highly

compressed and may cause serious personal injuryif not removed with caution.

2. Remove the bridge and slave piston assembly.

Loosen leveling screw lock nut from bridge.

Figure 5-8

3. Remove slave piston assembly. Inspect slave piston

pin for nicks or excessive wear.

4. Clean all parts in solvent. Inspect all components forexcessive 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 theslave piston torsion spring with ends over the bridge

grooves.

CAUTION

Push the torsion spring towards the bridge whiletightening the screw. Failure to do so may result in

contact between intake valve adjusting screw andtorsion 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

Figure 5-10

1. Press down on accumulator valve cover to relieve spring

pressure.

2. Remove the hex head cap screw and continue pressingdown 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.

Figure 5-11

6. Reassemble all parts in reverse order from

disassembly procedure.

Master Piston

Figure 5-12

1. Remove hex head cap screw, washer and flat springfrom brake housing.

2. Remove master piston from bore. Check masterpiston outside diameter ground surface for nicks or burrs.

Piston must slide in bore without binding. Replace if bindingoccurs. Check top surface of piston.Replace piston if there

are cracks or pitting.

3. Clean all parts with approved solvent and lubricate withengine 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

6. Make sure spring tabs are aligned with raised

surface on end of piston. Torque cap screw to 9 lbft(12 N*m)

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TecBrake Inc. P.O. Box 27822 Houston, Texas 77227 1999 TecBrake Bulletin No. TB990175A 04/01/99

Detroit Diesel, Series 60 DDECII and DDECIII are registered trademarks of Detroit Diesel Corporation.

Documents

Engine Brake Installation Manual