2008 - Pacbrake
Contents
1. NOTE Use only the ties supplied in the kit which are temperature stabilized and will not deteriorate due to heat 1 BRAKE HOUSING INSTALLATION Place the two spacer bars on the exhaust manifold side of the engine CAUTION Using air pressure blow out the six mounting holes before placing the spacer bars Ensure that the OUT marks are adjacent to each other and facing 2 outwards PACBRAKE 3 Our nylon connector should be positioned between cylinders 5 and 6 Reposition the entire wiring harness to keep it from being chafed 4 by the rocker levers or brake housings If the original Detroit harness is long enough it may be attached to the face but not the corner of the spacer bars NOTE Make certain that the three wires which will be attached to the solenoids are carefully positioned between cylinders 1 2 3 4 and 5 6 Move to the camshaft side of the engine Remove the three D outboard 12 pt flange screws holding the camshaft bearing caps in locations 2 4 and 6 as shown by the arrows CAUTION Using air pressure blow out the three mounting holes f Place a special hardened washer on each of the nine Pacbrake 12 pt flange screws 10 Carefully position the three engine brake housings on the engine Lubricate and loosely install the nine flange screws and washers Run the flange screws down loosely using hand tools only Prior to initial tightening of the flange screws make certain that t2. 34 i AS Application Detroit Diesel Series 60 gt P 61 P 63 P 63A P 63B P 63GC ENGINE BRAKES PACBRAKE EN GIN E BRAKES PACBRAKE 1 BEFORE STARTING Identify the engine model and serial number which may be found on the option labels attached to the valve cover and stamped on the engine block as shown DDEC Ili and DDEC IV Applications Note Two different engine brake activation circuits are available for Series 60 engines The engine ECU has an optional circuit to control the engine brake Use a Prolink diagnostic tool to determine if the circuit is turned on If the circuit is not turned on for engine brake enable it can be reprogrammed by a Detroit Diesel Dealer for a service charge When using this activation circuit if no under cover pado catia uil ONEA wiring exists use Pacbrake Kit P80155 Check the engine serial number and engine build date PRIOR to installing this Pacbrake engine brake An optional ECU bypass system P60154 is available through i plos P 63C model fits engines manufactured before 12 15 99 Pacbrake distrribution This system uses a foot switch and a service P 63C model fits Freightliner engines below 06R566178 brake pressure switch to enable the engine brake the engine ECU P 63C model fits OEM engines below 06R566302 does not need to be reprogrammed for this system P60154 kit P 80 model fits engines manufactured 12 15 99 to 8 10 00 P 80 model fits Freightliner engine
3. he housings are pushed laterally in the direction shown by the arrows as far as each housing will go towards the exhaust manifold side of the engine This action will precisely locate the Pacbrake pistons with their mating engine components Snug down the flange screws NOTE The Pacbrake housings have a machined locating step on the single stud side this aligns with the bearing cap for correct location above the exhaust valve adjusting screws Torque the three flange screws on the camshaft side then the six on the exhaust manifold side to 40 ft Ibs 55 Nm Then repeat in the same sequence to 100 ft Ibs 136 Nm PACBRAKE E BRAK PACBRAKE 11 Attach the three wires to the solenoids NOTE A check should be done at this point if older style injector harness was used in previous step 11 Make certain injector terminals DO NOT contact Pacbrake housing this will cause the engine to misfire 1 SLAVE PISTON ADJUSTMENT Loosen all twelve engine brake adjusting screws and locknuts Determine which cylinders have clearance between exhaust rocker adjusting screws and valve stems indicating that the exhaust valves are fully closed There are usually four cylinders in this condition regardless of the crankshaft position NOTE Both screws on each cylinder having closed valves may be adjusted Slave lash may now be adjusted on all cylinders which have 2 clearance between the exhaust rocker adjusting screw and valve stem
4. ocedure disables cruise control and progressive engine brake feature Metri Pack Connector IV WIRING SCHEMATIC On Off Switch i Battery Ground 30 pin connector Electronic Control Module ECM Under the cover 15 Pacbrake Company toll free 800 663 0096 phone 604 882 0183 fax 604 882 9278 e mail info pacbrake com Internet www pacbrake com Canada 19594 96 Ave Surrey BC VAN 4C3 USA 250 H St Box 1822 Blaine WA 98231 1822 Pacbrake P 61 and P 63A engine brakes are protected by law U S patents 4 655 178 4 898 128 5 036 810 Pacbrake is a registered trademark of Pacbrake Company Other trademarks used herein are property of their respective holders Printed in Canada L2008 0799
5. rear end of the DDEC III or DDEC IV ECM This is the Vehicle Interface Harness MH ex usual NOTE Some DDEC III and IV engines may not have the ECM programmed T CETTE I ae for engine braking This may be verified using a Diagnostic Data Reader If SUN EUG any of the ECM input switches K2 K3 3 or T3 read NONE then the MINE vehicle should be taken to a DDC dealer to have these switches enabled Note the color and or number of the two wires originating at the K2 and K3 terminals of the MH connector They are both on the top row K2 is in the center and K3 is the closest one to the engine These two wires terminate behind the dash and may be grouped with a third wire connected to battery ground Mount the two dash switches and connect the three wires as shown in the DDEC III wiring schematic CAUTION Ensure that ONLY the negative ground side of the electrical system is input to terminals K2 and K3 via the dash switches OR DAMAGES TOTHE ENGINE ECM WILL RESULT PACBRAKE Hi Med Low Switch Jumper wire and terminals 3 supplied To K2 terminal To K3 terminal NOTES One of the features of the DDEC III control system provides a progressive brake feature which is used when the vehicle is in cruise control The level of engine brake low med high selected via the dash switches will be the maximum amount of engine brake the ECM allows Also using the foot brake or clutch during this pr
6. remove fiberglass 4 valve cover NOTE This cover is originally installed with a silicone adhesive on both sides of the camshaft caps Take care not to stretch the gasket when removing the cover PACBRAKE If the engine is equipped with an aluminum valve cover and base both should be removed for easier and faster brake installation NOTE The valve cover base is originally installed with silicone adhesive on both sides of the camshaft caps Take care not to stretch the gasket when removing the valve cover base ENGINE NOT PREWIRED Remove the wiring harness mounting flange from the rear of the cylinder head NOTE Some engines may have engine brake wiring tied to the injector harness If so omit following steps 1 through 13 There are four spare holes through the harness grommet which are sealed with plastic plugs Pulling outward remove any two of these plugs Insert both wires of the Pacbrake through head harness through the grommet from the outside NOTE In trucks with limited access at the rear of the cylinder head it may be easier to slide the grommet out of the head PACIBRAKE E N GINE i a UN QN HE Route the wires alongside the Electronic Unit Injector EUI harness 4 and adjust the length so the terminal ends are between cylinders 5 and 6 ILZU MA Lay the two wires in the convoluted conduit and replace the 5 harness mounting flange 6 DDEC Il applications only Bury the
7. s Turn the Paclash screw clockwise to establish zero exhaust valve lash Once zero lash is determined turn screw an additional 1 4 turn to squeeze out any trapped oil then back screw out to zero lash CAUTION When adjusting the slave lash the adjusting screw has a spring loaded piston exercise caution as the piston in the adjusting screw must be collapsed when final adjustment is performed From this position zero lash turn the Allen wrench counter clockwise exactly 1 2 turn and torque the locknut to 25 ft Ibs 35 N m This method gives the correct slave piston clearance of 025 Repeat this procedure on all cylinders on which the exhaust valves are closed Bar the engine over approximately one revolution and adjust the remaining cylinders which now have clearance between the exhaust rocker adjusting screw and valve stems NOTE Same procedures apply for all models CAUTION Do not overtorque slave adjusting screw locknut Double check all torques and wiring prior to reinstalling the valve cover Use silicone sealant at front and rear bearing caps at valve cover installation Torque valve cover bolts as per DDC service manual PACIBRAKE CONTROL SYSTEM DDEGC Il 1 Locate or drill a 1 2 or larger hole through the firewall From the engine side of the firewall pass the end of the harness with the four wires protruding through the firewall and into the cab Connect these and the power source to the dash switches a
8. s below 06R5661 78 P 80 model fits OEM engines below 06R566302 P 80A model fits engines manufactured 8 10 00 to 9 30 02 P 80A model fits engines with 82 1mm injector lash includes all the necessary components for electrical installation 2 The first letter in the engine model number indicates displacement The second letter indicates the type of electronic control system Sample models 6067 GK 60 12 7 liter model P 63C 11 1 liter model P 61 DDECII DDECIII DDECIV STD 98 1550 ft Ibs torque P 63C PREMIUM 98 1650 ft Ibs torque P 63C DDEC IV PREMIUM 99 P 63C DDEC IV STD 99 P 63C DDEC III IV DDEC III IV DDECIII IV rmuezuudzxczam I 3 DDEC Il equipped engines have the engine brake enable circuit turned on use Pacbrake electrical interface kit P60150 An optional n PI ao oy am eA extension harness P60085 for cab over trucks is available to extend EGA PN WAT ety a the harness supplied in the DDECIII kit P60085 must be ordered INT sir TA ut Wr me i A str m separately Follow the DDEC ll instructions CORONAE 1O ABSTBALIAG DESIGN BHIE 39 DDEC Ill and DDEC IV equipped engines may have the engine brake circuit turned on use Pacbrake electrical interface kit P60155 Engines with the engine brake circuit turned off using kit P60154 follow the under cover wiring installation in this manual and then follow the instructions contained in the P60154 Thoroughly clean the top of the engine and
9. s per the wiring schematic For DDEC Ill and IV proceed to page 14 Install the standard or optional clutch switch and adjust it so the circuit will 2 be broken within the first inch of free travel of the clutch pedal NOTE For vehicles having automatic transmissions please consult the Pacbrake factory Route the harness coming from the dash switches close by the clutch switch Pull a short loop of green wire from the conduit Cut the wire and crimp on the two push on terminals provided Tape the 4 conduit closed where the wires exit and attach to the clutch switch 10 PACIBRAKE Mount the relay receptacle in any convenient position on the firewall using D the special drill point self tapping screw supplied NOTE Ensure that the harness enters the bottom of the receptacle to prevent moisture entering the relay Install the special relay into the receptacle CAUTION Do not substitute with any other relay as the Pacbrake P60045 relay has a built in diode to protect the DDEC system Install on off switch and three position switch in dash conveniently l located for the driver Continue the harness to the rear of the cylinder head and snap the two d mating Weather Pack connectors together L AM cem i I WERARIDREEMEMAM 11 PACIBRAKE This leaves one remaining white wire at the end of the harness which o must be connected to the 508 wire in the vehicle harness This wire originates a
10. t terminal A 1 of the Electronic Control Module ECM cu BAR 2222 The ECM is mounted on the left side of the engine block and 508 wire 10 will be the uppermost one closest to the engine ECM to our white wire with the attached butt connector This should be crimped Then shrunk down using a heat gun or other source to produce a tightly sealed joint 11 Cut the 508 wire where accessible and join the end originating at the NOTE The remaining end of the 508 wire should be taped out of the way as it dead ends in the vehicle harness and will not be used 12 PACBRAKE DDEG iil WIRING SCHEMATIC Hi Med Low Switch On Off Switch Green Fuse Blue L Ignition Yellow Red NOTE Part conduit pull a 6 loop of green Wire from the dash end and apply two terminals then attach to clutch switch Clutch NER Switch ie Relay Receptacle White Weather Pack Connector To 508 wire Under the cover PACBRAKE E N GINE BRAKES Some DDEC III and IV engines have the Pacbrake wiring installed at the factory If not follow the instructions below Installations using kit P60154 follow the electrical instruction provided in the kit CONTROL SYSTEM DDEC III IV Locate the 30 pin connector at the
11. wires within 1 of the Weather Pack connector and tape around the conduit to keep in place NOTE By using this same connector and wire positions the Pacbrake harnesses are completely compatible with the Detroit Diesel engine harness and the VOEMs vehicle harness DDEC IIl and IV applications only With Engine Brake Enable Turned On Only Locate the red 561 and orange 562 wires terminating in the Metri Pack plug This is located in the harness on the drivers side of the engine just below the intake mainfold above the starter PACBRAKE 8 DDEC Ill and IV applications only Remove the black protective cap and connect to Pacbrake harness previously installed in step 3 The through head harness must now be connected to the under 9 cover harness P N P60048 As both halves of the connector are preassembled simply insert the plain white wire into the hole on the same side as the other plain white wire The remaining wires both have black shrink tube markings 10 This connector is polarized and may now be parted and reconnected without losing correct brake sequencing 11 DDEC II Ill and IV applications All injector electrical terminals on older engines should be bent upwards almost 90 as shown to allow clearance for engine brake housings PACBRAKE E N GINE A P QN HE 12 Later type terminals as shown require no modifications Secure the complete Pacbrake harness to the EUI harness with 13 plastic ties
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