L2021 - Pacbrake
Contents
1. _ Connector Frontof E engine 622 621B 621A The Metri Pac connector located above the starter is the same as previous 1999 engines Orange wire is for the LOW position red wire is for the MED position both wires activated for the HIGH position NOTES e One of the features of the DDEC IV control system provides a progressive brake feature which is used when the vehicle is in cruise control e The level of engine brake low med high selected via the dash switches will be the maximum amount of engine brake the ECM allows e Also using the foot brake or clutch during this procedure disables cruise control and progressive engine brake feature INSTALLATION MANUAL L2021 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 V4N 4C3 USA 250 H St Box 1822 Blaine WA 98231 1822 Pacbrake exhaust brakes are protected by law U S patents 5 445 248 Patents pending Pacbrake and Direct Mount are registered trademarks of Pacbrake Company Other trademarks used herein are property of their respective holders Printed in Canada L2021_rev2 03 22 10 BRAKE ENGINE amp EXHAUST BRAKES PAC2. the 30 pin connector at the rear end of the DDEC IV ECM This is the Vehicle Interface Harness VIH NOTE Some DDEC IV engines may not have the ECM programmed for engine braking This may be veri fied using a Diagnostic Data Reader If any of the ECM input switches K2 K3 S3 or T3 read NONE then the vehicle should be taken to a DDC dealer to have these switches enabled 29 Note the color and or number of the two wires originating at the K2 and K3 terminals of the VIH 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 30 Mount the two dash switches and connect the three wires as shown in the DDEC IV 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 DAMAGE TO THE ENGINE ECM WILL RESULT INSTALLATION MANUAL L2021 P 80 and P 80A Engine Brakes PACBRAKE ENGINE amp EXHAUST BRAKES DDEC IV Wiring Schematic P 80 P 80A WITH ENABLE CIRCUIT TURNED ON ONLY On Off Switch Hi Med Low Switch Jumper wire and terminals 3 supplied Battery Ground 953 To K2 terminal ECM P To K3 terminal ECM Electronic Control Module ECM 30 Pin connector Under the cover Metri Pack Decor ccc scree none 2 2 2 2 5 2
3. ACTORY WIRING The through head harness must now be connected to the under cover harness P N P80048 As both halves of the con nector 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 1 4 ALL INSTALLATIONS WITHOUT FACTORY WIRING This connector is polarized and may now be parted and reconnected without losing correct brake sequencing 1 ls ALL INSTALLATIONS Secure the complete Pacbrake harness to the EUI harness with plastic ties Note Use only the ties supplied in the kit which are temperature stabilized and will not deteriorate due to heat INSTALLATION MANUAL L2021 P 80C Engine Brakes PAC ISRAKE ENGINE amp EXHAUST BRAKES Brake Housing Installation 1 7 Evenly remove the three rocker shaft capscrews and nut for each rocker shaft assembly as shown in illustration num bered 1 2 3 and 4 then number 5 6 7 and 8 Discard the Capscrews and save the nuts for reuse later NOTE It is a recommended procedure to check the torque of the Studs at 1 and 8 position Once the nuts are removed torque to 101 116 Nem 75 86 lbs ft as per DDC procedure CAUTION Using air pressure or a suitable suction device remove trapped oil from mounting holes 2 through 7 and 9 through 14 1 8 Place the 6 spacer tubes on the exhaust manifold side of the engine in locations 9 through 14 on previous di
4. AN AIG ACI THIS ENGINE IS CERTIFIED TO OPERATE ON FUEL P 80A model fits engines manufactured 8 10 00 to 9 30 02 LOK SULFUR DIESEL t 18296 UNIT 0680551685 P 80A model fits engines with 82 1mm injector lash These new 2000 model year engines are built starting late December 1999 and differ from the 1999 model year engine by the elimination of the engine brake s dedicated roller on the injector rocker arm The 2000 model year engine has a machined pocket in the injector rocker arm to replace the roller Installing the incorrect engine brake will cause engine and engine brake failure Check the engine s option label on the valve cover for injector setting information Injector settings relate to the engines camshaft The only way to visually confirm which camshaft the engine has is by checking the injector setting on the options label See above Misapplication will cause engine damage If unsure please contact Pacbrake Factory 1 800 663 0096 DDEC Ill 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 wiring exists use Pacbrake Kit P80155 An optional ECU
5. MANUAL PACIBRAKE ENGINE amp EXHAUST BRAKES P SO application Detroit diesel engines 2000 model year 12 7 14 Liter Series 60 P SOA application Detroit diesel engines 2001 2002 model year 12 7 14 Liter Series 60 P 80 and P 80A Engine Brakes PACBRAKE ENGINE amp EXHAUST BRAKES VERY IMPORTANT APPLICATION INFORMATION Please read carefully as incorrect application will cause engine damage 1 Before Starting Use the following information to determine the correct Pacbrake for your application Engine Year Identification Characteristic Pacbrake Model 1999 Roller for master piston on injector rocker arm P 63C 2000 Pocket for master piston on injector rocker arm P 80 81 0 mm injector setting 2001 Pocket for master piston on injector rocker arm P 80A 82 1 mm injector setting Check the engine serial number and engine build date PRIOR to installing this Pacbrake engine brake P 63C model fits engines manufactured before 12 15 99 P 63C model fits Freightliner engines below 06R566178 1 FF P 63C model fits OEM engines below 06R566302 INJ SETTING 81 0 MM ssi SH n P 80 model fits engines manufactured 12 15 99 to 8 10 00 i p ii ay miie P 80 model fits Freightliner engines above 06R5661 78 i rl a ia San Mbt APR A 22 a ONT OGROSSIGRS S9 D 12000 351 P 80 model fits OEM engines above 06R566302 a rT amen wes T i wi 5 DEFINED AT 40 CFE 8 USE IN AN URSAN is iS viel ATION OF FEDERAL I THE CLE
6. agram 1 Q Place the special hardened washers on each of the 12 Pac brake capscrews supplied INSTALLATION MANUAL L5590 P 80 and P 80A Engine Brakes PACBRAKE ENGINE amp EXHAUST BRAKES 1 Locate the 6 longer capscrews these go through the center positions of the housing to secure the housing and rocker shaft Lubricate and install three of these allen head cap screws through the center holes in each housing Carefully position the front engine brake housing over cylinders 1 2 and 3 using the front Detroit stud as a guide Repeat on the rear housing using the rear stud as a guide 20 Install Pacbrake washers on the Detroit rocker studs then loosely install the two rocker hold down nuts removed earlier 21 Loosely install the six shorter allen head capscrews on the turbocharger side of the Pacbrake housing Note Ensure that each master piston link is located over its rocker arm socket 22 Carefully run the capscrews and nuts down evenly in the torque sequence below using hand tools only Do not use an impact wrench as the housings must be tightened down evenly INSTALLATION MANUAL L2021 P 80 and P 80A Engine Brakes PACBRAKE ENGINE amp EXHAUST BRAKES 23 Torque the hold down cap screws and nuts to 55 Nem 40 Ib ft in the sequence shown below Then to 136 Nem 100 Ib ft Double check all bolt torques 24 Attach the three wires to the solenoids Using the plastic ties provid
7. bypass system P60154 is available through Pacbrake distrribution This system uses a foot switch and a service brake pressure switch to enable the engine brake the engine ECU does not need to be reprogrammed for this system P60154 kit includes all the necessary components for electrical installation INSTALLATION MANUAL L2021 P 80 and P 80A Engine Brakes PACBRAKE ENGINE amp EXHAUST BRAKES 2 Before starting check that the kit contains everything shown in this photo CAUTION Care should be taken when handling hous ing Dropping housing could cause leg damage failure which is not covered under warranty Tools Required 3 8 Drive ratchet General use 1 2 Drive ratchet General use Inch pound torque wrench Valve cover bolts 3 8 Torque wrench accurate 25 Ib ft Paclash adjustment 1 2 Torque wrench accurate 100 Ib ft Hold down capscrews Speeder handle Housing capscrews amp nuts 1 2 Breaker bar or flex bar Rocker shaft capscrews removal 36mm Socket Rotate engine 18mm Deep socket 1 2 drive Rocker shaft capscrews lOmm Socket 3 8 drive Valve cover Capscrews lOmm Hex driver Pacbrake housing capscrews Phillips screw driver Solenoid terminal 5 32 4mm Allen wrench Paclash adjustment 3 4 Box End wrench Paclash adjustment 9 16 Box End wrench Paclash adjustment 3 4 Crows foot Torque paclash 3 8 Extension 3 With crows foot 3 8 Extension 6 Valve cover capscrews 3 16 Extension 6 Valv
8. e cover capscrews Flat blade screw driver Breather tube hose clamp Wire cutters Tystraps Compressed air air nozzle or suitable device___ Blowing out bolt holes Threebond liquid gasket PN 1217F Valve cover sealant at bearing caps if required Additional tools for engines which are not factory wired 13 mm Socket Cylinder head wiring connector Needle nose pliers Removal of plugs in connector 3 Stamped on the side of the engine block is the engine serial number and model number Sample 6067MK60 The first letter in the engine model number indicates displacement The second letter indicates the type of electronic control system If unsure attain the engine serial n INSTALLATION MANUAL L2021 P 80 and P 80A Engine Brakes PACBRAKE ENGINE amp EXHAUST BRAKES A Thoroughly clean the top of the engine and remove the valve cover NOTE The valve cover is installed with a silicone adhesive on both sides of the front and rear bear ing caps Take care not to stretch the gasket when removing the cover See page 3 for sealing material if required If your engine is prewired locate the three dedicated wires and omit the following steps 5 through 15 Engine Is Not Prewired 3 Remove the wiring harness mounting flange from the rear of the cylinder head e There are four spare holes through the harness grommet which are sealed with plastic plugs Pulling outward remove any two of these plugs y Insert both wires of t
9. ed secure the harness away from all moving parts Wires may be tied to spacer tubes Use only the ties provided as they are temperature stabilized and will not deteriorate due to heat CAUTION Route wires on front housing as shown by arrow 25 Slave Piston Adjustment Loosen all twelve slave piston adjusting screws and lock nuts Determine which cylinders have clearance between exhaust rocker arm 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 fttit iea D NOTE Both screws on each cylinder having closed valves may be adjusted INSTALLATION MANUAL L2021 P 80 and P 80A Engine Brakes PACBRAKE ENGINE amp EXHAUST BRAKES 26 Slave lash may now be adjusted on all cylinders which have clearance between the exhaust rocker adjusting screw and valve stems Turn the slave adjusting screw clockwise to establish zero exhaust valve lash Once zero lash is deter mined turn screw an additional 1 4 turn to squeeze out any trapped oil then back screw out to zero exhaust valve lash IMPORTANT The term zero lash used in the procedure refers to the clearance between the slave piston and the exhaust valve adjusting screw For P 80 Only USE 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 wh
10. en final adjustment is per formed The P 80A has smaller 3 8 thread solid brake adjust ing screws 27 From this position zero lash turn the Allen wrench counter clockwise exactly 1 2 turn and torque the locknut to 35 Nem 25 Ib ft This method gives the correct slave piston clear ance for P 80 of 025 and 032 for P 80A 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 clear ance between the exhaust rocker adjusting screw and valve stems Double check that slave lash has been adjusted on all 12 Pacbrake adjusting screws P 80 models use a 1 2 NF thread to achieve a Slave Lash of 025 P 80A models use a 3 8 NC thread to achieve a Slave Lash of 032 CAUTION Do not overtorque slave adjusting screw locknut Double check all torques and wiring prior to reinstalling the valve cover Use Threebond sealant at front and rear bearing caps at valve cover installation Torque valve cover bolts as per DDC service manual INSTALLATION MANUAL L2021 P 80 and P 80A Engine Brakes PACBRAKE ENGINE amp EXHAUST BRAKES Engines using P60154 follow the instructions pro vided in the P60154 kit au Control System DDEC IV ENGINES WITH ENABLE CIRCUIT TURNED ON ONLY Some DDEC IV engines have the engine brake wiring in stalled at the factory If not follow the instructions below Locate
11. he 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 INSTALLATION MANUAL L2021 P 80 and P 80A Engine Brakes PACBRAKE ENGINE amp EXHAUST BRAKES Q Route the wires alongside the Electronic Unit Injector EUI harness and adjust the length so the terminal ends are between cylinders 5 and 6 Lay the two wires in the convoluted conduit and replace the harness mounting flange M Bury the wires within 1 of the Weather Pack connector and p tape around the conduit to keep in place NOTE By using this same connector and wire posi tions the Pacbrake harnesses are completely compat ible with the Detroit Diesel engine harness and the VOEMs vehicle harness NOTE If installing a P60154 kit follow the instruc tions provided in the P60154 kit 1 1 ENGINES WITH ENABLE CIRCUIT 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 manifold above the starter 1 y ENGINES WITH ENABLE CIRCUIT TURNED ON ONLY Remove the black protective cap and connect to Pacbrake harness previously installed in step 7 INSTALLATION MANUAL L2021 P 80 and P 80A Engine Brakes PACBRAKE ENGINE amp EXHAUST BRAKES 1 3 ALL INSTALLATIONS WITHOUT F
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