Field Installation Of 3Z-5855 Jake Brake Modification {1119, 1129, 7314} Caterpillar

Articulated Truck:

D25D (S/N: 1HK1-UP)

D30D (S/N: 3AJ1-UP)

Introduction

The following procedure describes field installation of the 3Z-5855 Jake Brake Modification on D25D and D30D Articulated Trucks.

This document also provides system operation, troubleshooting, repair and parts information.

The Jake Brake is a retarding device designed to slow the machine. The Jake Brake is not a machine stopping device. The Jake Brake cannot hold the machine stationary. The service brake system must be used to stop the machine. The parking brake must be used to keep the machine stationary. The Jake Brake supplements the machine service brakes. Using the Jake Brake reduces service brake wear and service brake overheating. On machines equipped with a torque converter mounted retarder, the Jake Brake also reduces transmission oil overheating by reducing the use of the torque converter mounted retarder.

Reference: Operation & Maintenance Manual, SEBU8647-03, "D25D,D30D & D350D Articulated Trucks".

Reference: Specifications, SENR5593-02, "3306B Engine For AVSpare Built Machines".

Reference: System Operations, Testing And Adjusting, SENR5594-03, "3306B Engine For AVSpare Built Machines".

Reference: Disassembly And Assembly, SENR5598-02, "3304B and 3306B Engines For AVSpare Built Machines".

Tools Needed

Refer to the installation portion of this manual for specialty tools. The electrical installation requires only common hand tools.

Parts Needed

In order to install the Jake Brake, refer to Table 1 for the necessary parts.

Table 1

Part Number	Description	Quantity
136-3772*	Brake Kit-Jake	1
168-6887**	Harness As-Cab	1
168-6888**	Harness As-Dashpanel	1
168-6882**	Harness As-Engine	1
168-6880*	Control-Jake Brake	1
1Q-9830	Switch	1
150-1894	Plate-Shield	1
2N-3477	Screw	2
4B-2041	Nut	2
4B-5324	Lockwasher	2
8T-4896	Washer (3/8)	7
6V-8801	Nut (3/8)	3
134-1594	Bracket	1
134-1593	Plate	1
6B-2882	Spacer	2
6V-5782	Bolt (5/16)	2
153-9950*	Plate	1
2U-2589	Screw (2BA)	2
2U-2453	Washer (2BA)	4
2U-2504	Nut (2BA)	4
2U-2591	Screw (2BA)	2
4L-6454	Bolt (3/8)	2
9G-2265	Clip (Red)	1
9G-2264	Clip (Yellow)	2
2U-4497	Strap	25
2U-4556	Sleeving	1
5P-9085	Clip	3
134-1592	Strip	1
8T-4224	Washer	6
9G-9151	Clip	1
170-6369*	Bracket	1
8T-5391	Bolt (5/16)	2
5M-3062	Bolt (3/8)	5
4M-6425	Bolt (5/16)	1
6V-8189	Nut (5/16)	1
Note: An "*" next to a part number indicates this item is no longer serviced through the parts distribution system. Contact Service Engineering for assistance on these items. Note: A "**" next to a part number indicates this item is no longer serviced through the parts distribution system. Assembly information is provided in the Parts section of this document.

Installation Procedures

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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

Cab And Dash Area

1. Prior to performing any modifications to the machine park the machine on a firm, level surface.

2. Engage the parking brake.

3. Turn the battery disconnect switch to the OFF position.

   Reference: Operation & Maintenance Manual, SEBU8647-03, "D25D, D30D & D350D Articulated Trucks", "Disconnect Switch".

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Illustration 1	g00893305

4. Remove the black button head screws attaching 7U-3791 Trim-Dashpanel and remove the Trim-Dashpanel. Retain the spacers and the rubber seals affixed to the upper three fasteners. These are required during reassembly.

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Illustration 2	g00893321
(1) Gauge Gp - Warning (2) 7U-3677 Panel Gp - Switch (Start) (3) 7U-3660 Monitor Gp - Mounting

Note: The machine arrangement will determine the part number for the Warning Gauge Group. The Warning Gauge Group part number could either be 7U-5352 Gage Gp-Warning & , 7U-5353 Gage Gp-Warning & or 7U-5354 Gage Gp-Warning & .

5. Remove the screws that attach Gauge Gp - Warning (1), Panel Group - Switch (Start) (2) and Monitor Gp - Mounting (3) to the Dashpanel Housing Assembly. Protect the surface of each group to insure no scratches and damage occur. Pull each group away from the Dashpanel Housing Assembly .

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Illustration 3	g00893325
(4) Monitor Group - Mounting connector

6. Disconnect Monitor Group - Mounting (3) from connector (4). Remove the Monitor Group to permit access to drill and install the Jake Brake control unit.

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Illustration 4	g00893326

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Illustration 5	g00893328

7. Drill an 18 mm (0.709 inch) diameter hole in the rear wall of the Dashpanel Housing Assembly. Place a metal plate between the Dashpanel Housing Assembly and the windshield to prevent accidental damage to the windshield. Drill two 5 mm (0.197 inch) holes in the rear right side of the top plate of the Dashpanel Housing Assembly. Place a metal plate between the drill and any wires nearby to avoid cutting the wires. Refer to Illustrations 4 and 5.

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Illustration 6	g00896657
(5) 168-6880 Control Unit (6) Screw (7) 2U-2589 Screw (8) 2U-2453 Washer (9) 2U-2504 Nut (10) 153-9950 Plate

8. Remove screws (6) from each side of the cover on Control Unit (5). Remove the cover. Mount the Control Unit to Plate (10) using two Screws (7), two Washers (8) and two Nuts (9). Make certain Washers (8) and Nuts (9) are installed on the inside of Control Unit (5) .

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Illustration 7	g00908332
(5) 168-6880 Engine Brake Control (8) 2U-2453 Washer (9) 2U-2504 Nut (11) 2U-2592 Screw

9. Reinstall the cover onto Control Unit (5). Using two Screws (11), two Washers (8), two Nuts (9) and the 5 mm (0.197 inch) holes drilled in the rear right side of the top plate of the Dashpanel Housing Assembly, install the Control Unit and Plate assembly. Make certain Washers (8) and Nuts (9) are installed on the inside of the dashpanel.

10. Pass two Sure-seal connectors through the 18 mm (0.709 inch) hole drilled in the dashpanel. Install the grommet fitted to the wires for Control Unit (5) into the 18 mm (0.709 inch) hole.

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Illustration 8	g00911500
(12) 168-6888 Harness As-Dashpanel (13) 2U-4497 Strap (14) 9G-2264 Clip (Yellow) (15) 9G-2265 Clip (Red) (16) 168-6887 Harness As-Cab (17) Lock-Up Warning Lamp (18) Retarder Warning Lamp (if Equipped) (A) Dash panel ground stud

11. Install Harness As-Dashpanel (12) to the main dash wiring harness using Straps (13). Follow the main dash wiring routing and secure the Harness As-Dashpanel as indicated in Illustration 8. Route the harness so that the end with terminals is toward the warning lamps and the end with the Sure-seal connectors is toward the Control Unit. Refer to Illustration 8.

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Illustration 9	g00893332

12. Connect the terminal attached to the black wire of the Harness As-Dashpanel onto dash panel ground stud (A). Reference Illustrations 8 and 9.

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Illustration 10	g00896498
(19) Main harness number 130-GN (20) Harness As-Dashpanel wire BR (21) Harness As-Dashpanel wire YL (22) Main harness number 490-GN (23) Harness As-Dashpanel wire OR (24) Main harness number 454-GN

13. Connect the terminals of the Harness As-Dashpanel to the Lock-Up and Retarder (if equipped) warning lamp wires. Make certain the wire color of the Harness As-Dashpanel is connected to the correct wire number of the main dash wire harness. Remove the main dash harness wires one at a time. Verify the wire number and install the correct color wire from the Harness As-Dashpanel onto the terminal from which this wire was removed. Reinstall the original wire to its location by attaching it to the piggyback terminal provided by the Harness As-Dashpanel. If the machine is not equipped with a Retarder warning lamp the wires will still be present. In order to connect the 454-GN and OR wires first remove the sleeving from the 454-GN. Connect the two wires as described previously. Cover the connection with 2U-4556 Sleeve provided. Shrink the sleeving to insulate. Reference Illustrations 8 and 10 and Table 2.
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    Table 2

    Main Harness Wire Number	Harness As-Dashpanel Wire Color
    130-GN	BR
    490-GN	YL
    454-GN	OR

14. Connect the 3-Way and 4-Way Sure-seal connectors of the Harness As-Dashpanel to the Sure-seal connectors of the Control Unit. Install two 9G-2264 Clips (Yellow) (14) to retain the connectors. Reference Illustration 8.

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Illustration 11	g00896768
(25) Grommet

15. Remove spare grommet (25) from the underside of the cab. The grommet is located in the front right side connection box from which the main cab harness exits. The junction box cover does not need to be removed to allow installation of 168-6887 Cab Harness As .

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Illustration 12	g00896770
(26) Hole (27) Slot

16. Prepare the grommet to accept 168-6887 Cab Harness As as shown in Illustration 12.

17. Install 168-6887 Cab Harness As using 2U-4497 Straps (13). Pass the harness through grommet (25) and connect it to the 2-Way Sure-seal connector of 168-6888 Dash Harness As (12). Install 9G-2265 Clip (Red) (15) to secure the connection. Reference Illustration 8.

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Illustration 13	g00893325
(4) Monitor Group - Mounting connector

18. Reconnect the Monitor Group - Mounting to connector (4) .

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Illustration 14	g00896967

19. Reinstall the Gauge Gp - Warning, Panel Group - Switch (Start) and Monitor Gp - Mounting to the Dashpanel Housing Assembly. Reinstall the Dashpanel Trim. The finished installation should appear as in Illustration 14.

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Illustration 15	g00896938
(13) 2U-4497 Strap (16) 168-6887 Harness As-Cab (25) Grommet (28) Connection point

20. Install Harness As-Cab (16) to the main cab wiring harness using Straps (13). Follow the main cab wiring routing and secure the Harness As-Cab as indicated in Illustration 15 to connection point (28) .

Jake Brake Engine Mounted Components Preparation

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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

Note: The information in this section has been reproduced with the permission of the Jacobs Vehicle Equipment Company. Content is the same as that contained in Jacobs manual P/N 014744G except that information not relevant to the D25D and D30D Articulated Truck installation has been omitted.

Note: Information in this section was current at the time the Jacobs manual was printed (12/95) and is subject to change without notice or liability. Jacobs service literature should be consulted for additional applications and updated information.

Note: The following procedure will provide the steps required to install the Jake Brake Model C336 components onto the D25D and D30D Articulated Truck 3306B engine.

Note: The following special instruction is required because some Jacobs supplied spacer housings may need a modification before following the Jake Brake installation procedure.

Illustration 16	g00898309
(A) Area to grind (B) Terminal lead-out holes

Note: Check for clearance between the spacer and the two terminal lead-outs on the inside rear of the housing. Screw the terminal lead-outs into position and check if inserting the terminals from the solenoids causes a short to the spacer. If this is the case then it will be necessary to grind away a section of the spacer to prevent any likelihood of a short circuit. Any grinding should be carried out away from any other Jake Brake parts, or parts of the machine. Wear eye protection and clean all parts of the spacer before the installation procedure is carried out.

Illustration 17	g00898339
(C) Modified 15/16" deep socket (D) 3/8" Flexible socket 1/4" drive

Note: The following tools are essential for successful Jake Brake installation. Socket (D) is a 1/4 inch square drive with a 3/8 inch hex or multi-point flexible head. Socket (C) is a 1/2 inch square drive 12 point 1U-7134 Socket-15/16 in. that has been modified as indicated in Illustration 17.

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Illustration 18	g00898478

1. Each engine brake housing assembly has an identification tag showing model number, part number and installation location marked FRONT and REAR. The serial number is located above the identification tag. Check that both the housing assemblies are marked with the model number C336 (not C336A or anything else).

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Illustration 19	g00898484

2. Inspect the spacer to confirm it is equipped with dual terminal lead-outs. The spacer should have a total of FOUR terminal lead-outs as shown in Illustration 19.

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Illustration 20	g00898495

3. Inspect the two housing assemblies to confirm that the solenoid valves each have TWO terminals. The solenoid valve location is shown in Illustration 20. If the correct number of terminal lead-outs and the correct solenoid valves are present, proceed with the installation. If not, the spacer must be modified and the solenoid valves replaced using the following procedure.

   1. Inspect the Jake Brake kit to confirm that extra terminal lead-outs and/or new solenoid valves are provided. Two extra lead-outs (total of four) and two solenoid valves are needed. There should also be three seal rings for each solenoid valve.

   2. When satisfied that the needed parts are available, mark locations 25 mm (0.984 inch) below (and in line with) the center of the existing lead-out holes.

   3. Drill holes 8.2 mm (0.323 inch) diameter at these locations. Then tap 3/8 inch UNC and remove all burrs.

      Note: If lead-outs are already installed it is recommended they are removed to prevent damage during machining.

   4. Install all lead-outs using a 7/16 inch socket wrench and tighten until seated in the spacer. Be careful not to overtighten.

   5. If necessary, disconnect the wires of each solenoid valve and remove the valves using a 12 point socket.

   6. Discard the three seal rings shown in Illustration 20. If the lower rings stick in the housing, remove with a seal pick.

   7. Smear the new seal rings with engine oil. Assemble the new upper and center rings to the valve body and the new lower ring to the housing bore. Ensure that all rings are properly seated.

   8. Carefully screw the solenoid valve into the housing (be careful not to unseat any of the new seal rings) and tighten by hand. Finally torque the valve to the specification marked on the body.

   9. Turn the battery disconnect switch to the ON position.

      Reference: Operation & Maintenance Manual, SEBU8647-03, "D25D, D30D & D350D Articulated Trucks", "Disconnect Switch".

   10. Reconnect the wires and apply 24 volts DC to confirm correct operation.

   11. Turn the battery disconnect switch to the OFF position.

       Reference: Operation & Maintenance Manual, SEBU8647-03, "D25D, D30D & D350D Articulated Trucks", "Disconnect Switch".

Engine Preparation

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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

1. Remove accessory components and the valve cover. Remove and discard the valve cover gasket.

   Reference: Disassembly and Assembly, SENR5598-02, "(S/N: 1HK) D25D & (S/N: 3AJ) D30D Articulated Trucks", "Valve Mechanism Cover - Remove and Install".

Primary Method To Place Number 1 Piston At Top Dead Center

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Illustration 21	g00898902

1. Remove the plug from the timing hole in the flywheel housing.

   Note: On some applications, the AVSpare engine turning tool can be installed in the flywheel. Reference Illustration 21. When the crankshaft is viewed from the flywheel end, the crankshaft rotates counterclockwise. The number one cylinder of the engine is at the end opposite of the flywheel.

2. Rotate the crankshaft in the direction of rotation until a 3/8"-16 UNC bolt 50.8 mm (2.0 inch) long can be turned into the flywheel through the timing hole in the flywheel housing. Number 1 piston should now be on top center. If number 1 piston is on the compression stroke, the inlet and exhaust valves for number 1 cylinder will be closed (both of the valve rocker arms will be loose and moveable by hand).

3. If number 1 piston is not on the compression stroke, remove the timing bolt and rotate the crankshaft counterclockwise 360 degrees. Install the timing bolt. The number 1 piston is now at top center on the compression stroke.

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Illustration 22	g00899034

4. Remove the timing bolt and replace the plug in the timing hole. Make a mark on the vibration damper and engine as shown in Illustration 22.

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Illustration 23	g00899217

5. Loosen all exhaust and inlet rocker arm adjusting screw locknuts. Remove the rocker shaft capscrews and the rocker shaft assembly.

   Note: The fuel injector lines for cylinders 4, 5 and 6 have been removed for illustration purposes only. It is not necessary to remove fuel lines for engine brake installation.

Alternative Method To Place Number 1 Piston At Top Dead Center

1. Remove timing pin cover from the side of the fuel injection pump housing.

   Note: When the crankshaft is viewed from the flywheel end, the crankshaft rotates counterclockwise. The number one cylinder of the engine is at the end opposite of the flywheel.

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Illustration 24	g00899249

2. Install 6V-4186 Fuel Pump Timing Pin in the fuel injection pump housing as shown in Illustration 24. Slowly rotate the crankshaft counterclockwise until the timing pin goes into the slot in the fuel pump camshaft. The number 1 piston is now at top dead center of the compression stroke.

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Illustration 25	g00899217

3. Loosen all exhaust and inlet rocker arm adjusting screw locknuts. Remove the rocker shaft capscrews and the rocker shaft assembly.

   Note: The fuel injector lines for cylinders 4, 5 and 6 have been removed for illustration purposes only. It is not necessary to remove fuel lines for engine brake installation.

Oil Supply Fitting Installation

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Illustration 26	g00899251

1. Locate the plugged hole in 7C-7011 Shaft Bracket shown in Illustration 26 and remove the plug. If there is no plugged hole in the rocker shaft bracket the bracket must be replaced with a 7C-7011 Shaft Bracket .

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Illustration 27	g00899505

2. Confirm that the pin in the bottom side of the bracket extends by 9.6 mm (0.378 inch) as shown in Illustration 27. Install a new O-ring seal (1) .

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Illustration 28	g00899507

3. Apply a small amount of white pipe sealant onto the threads of the oil supply fitting. Install Jacobs oil supply fitting (2) in the rear bracket as shown in Illustration 28. Turn all the way in until contact is made with the bracket. Back out the fitting until the hole is located vertically with respect to the bracket. Do not install the rocker shaft at this time.

Exhaust Rocker Adjusting Screw Replacement

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Illustration 29	g00899579
(A) AVSpare adjusting screw (B) Jacobs adjusting screw

1. Remove AVSpare exhaust valve adjusting screws (A) and replace them with Jacobs exhaust valve adjusting screws (B). The Jacobs adjusting screws have hex socket heads, whereas the AVSpare adjusting screws have screw driver slots. Turn the screws all the way in from the bottom of the rocker arm.

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Illustration 30	g00899581
(1) Hex head nut (2) Jacobs spherical nut

2. Install Jacobs spherical nut (2) onto each exhaust rocker adjusting screw. Turn the nuts all the way down to contact the rocker arm.

Valve Cap Installation

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Illustration 31	g00899637
(1) Valve cap

1. Apply engine oil inside valve cap (1) and to the valve spring rotor. Install the valve cap on each of the exhaust valves.

Spacer Installation

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Illustration 32	g00899699
(1) Spacer (2) Wrench (3) Terminal lead-out

1. Install terminal lead-out assemblies (3) in spacer (1) using wrench (2). Wrench (2) is a 6 point, 7/16 inch box-end wrench. Tighten the lead-out assemblies until they are seated in the spacer. Be careful not to overtighten the lead-out assemblies.

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Illustration 33	g00899700
(1) Spacer (4) Gasket

2. Install Jacobs gasket (4) to the engine. Install spacer (1) to the engine.

   Note: If interference between the spacer and the injector fuel lines exists, loosen the fittings and support clamps to reposition the fuel lines.

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Illustration 34	g00899701
(1) Spacer (5) Capscrew (6) 3/8" Flexible socket (7) Towel

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Illustration 35	g00899702

3. Place towels (7) around the pushrod holes to prevent capscrews (5) from dropping into the engine. Install spacer (1) capscrews (5) and lightly tighten the capscrews from the center to the ends in the sequence shown in Illustration 35.

4. Torque the capscrews in the sequence shown in Illustration 35 to a torque of 20 N·m (15 lb ft).

Rocker Shaft Installation

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Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.

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Illustration 36	g00899914

1. Use a towel to cover the rocker shaft capscrew holes. Blow out the rocker shaft capscrew holes.

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Illustration 37	g00899918
(1) Rocker shaft assembly (2) Rocker adjusting screw (3) Pushrod

2. Set rocker shaft assembly (1) in place and line up pushrods (3) with adjusting screws (2) .

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Illustration 38	g00899919

3. Install the rocker shaft assembly capscrews and tighten in the sequence shown in Illustration 38. Torque the bolts in the following steps:
   • 155 N·m (115 lb ft)

   • 200 N·m (150 lb ft)

   • 200 N·m (150 lb ft) - final torque check

Intake and Exhaust Valve Adjustments

Note: When the crankshaft is viewed from the flywheel end, the crankshaft rotates counterclockwise. The number one cylinder of the engine is at the end opposite of the flywheel.

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Illustration 39	g00900149
Intake valve adjustment

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Illustration 40	g00900152
Exhaust valve adjustment

1. With number 1 piston at top dead center of the compression stroke (set earlier, refer to ""Primary Method To Place Number 1 Piston At Top Dead Center" " or ""Alternate Method To Place Number 1 Piston At Top Dead Center" ") set the intake and exhaust valves for each cylinder as indicated in Table 3. Set each intake valve clearance to 0.381 mm (0.015 inch). Set each exhaust valve clearance to 0.635 mm (0.025 inch). After setting the valves clearance, hold the adjusting screws and torque the locknuts to 35 N·m (25 lb ft).

   Note: A 3/16 inch hex key wrench is required for turning the exhaust rocker adjusting screw.

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   Table 3

   Engine Setting	Set Exhaust Valve on Cyl.	Set Intake Valve on Cyl.
   Cyl 1 TDC	1, 3, 5	1, 2, 4

2. Rotate the crankshaft 360 degrees in the direction of rotation to place number 6 piston at top dead center of the compression stroke. The alignment mark made previously should be used. Adjust the remaining intake and exhaust valves as indicated in Table 4. Set each intake valve clearance to 0.381 mm (0.015 inch). Set each exhaust valve clearance to 0.635 mm (0.025 inch). After setting the valves clearance, hold the adjusting screws and torque the locknuts to 35 N·m (25 lb ft).
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   Table 4

   Engine Setting	Set Exhaust Valve on Cyl.	Set Intake Valve on Cyl.
   Cyl 6 TDC	2, 4, 6	3, 5, 6

Engine Brake Housing Installation

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NOTICE
To prevent possible cylinder head distortion and/or cylinder head gasket damage, do not remove the cylinder head capscrews until the rocker arm capscrews have been tightened.

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Illustration 41	g00900260
(1) Cylinder head capscrews

1. Remove the four cylinder head capscrews (1) and washers from the positions shown. Leave the center cylinder head capscrew in place.

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Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.

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Illustration 42	g00900261

2. Use a towel to cover the cylinder head capscrew holes. Blow out the oil from the cylinder head capscrew holes.

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Illustration 43	g00900265
(2) Support stud

3. Coat the four support studs (2) threads with moly lube (AVSpare 6V-4876 Lubricant , G-N metal assembly paste or equivalent). Install the AVSpare cylinder head washers onto the support studs and install the studs in the cylinder head. Torque the studs evenly in the following steps:
   • 155 N·m (115 lb ft)

   • 250 N·m (185 lb ft)

   • 250 N·m (185 lb ft) - final torque check

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Illustration 44	g00900273
(3) Jacobs oil supply tube

4. Lubricate the seal rings and install on Jacobs oil supply feed tube (3). Install the feed tube into the hole in the oil supply fitting mounted in the rear rocker shaft support bracket. Reference ""Oil Supply Fitting Installation" ".

   Note: Oil supply tube (3) is shorter than the oil supply jumper tube to be installed later and has no snap ring groove.

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Illustration 45	g00900281
(4) Housing (Typical example)

5. Set the REAR housing (4) in place. Make certain oil supply tube (3) enters the hole in the bottom of the housing.

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Illustration 46	g00900275
(5) Jacobs bolt

6. Install the Jacobs washer onto Jacobs hex head bolt (5). Install the washer and bolt through the housing and into the support stud. Position the housing so that the slave pistons are centered over the exhaust valve caps. Hand tighten the hex head bolts. Do not fully tighten the bolts at this time in order to allow alignments of the housings.

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Illustration 47	g00900279
(6) Oil seal ring (7) Oil supply jumper tube

7. Lubricate and install oil ring seals (6) onto oil supply jumper tube (7). Insert the E-ring into the groove. Insert the tube into the front housing all the way to the E-ring.

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Illustration 48	g00900280
(5) Jacobs bolt (7) Oil supply jumper tube (8) REAR housing (9) FRONT housing

8. Install FRONT housing (9) following the same procedures as for REAR (8) housing installation. Reference 6. Align the FRONT and REAR housings so that jumper tube (7) can be extended from the FRONT housing and inserted into the REAR housing. Torque the bolts of both housings in the following steps:
   • 82 N·m (60 lb ft)

   • 163 N·m (120 lb ft)

   • 200 N·m (150 lb ft)

   • 200 N·m (150 lb ft) - final torque check

Slave Piston Adjustment

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NOTICE
The following adjusting procedure must be strictly adhered to. Any other method of adjusting the slave piston clearance is not authorized by Jacobs and may result in serious engine and/or engine brake damage.

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NOTICE
Slave piston adjustment must be made with the engine stopped and cold. The exhaust valve on the cylinder to be adjusted must be in the closed position. Follow the sequence indicated in the following table.

1. To adjust the slave pistons, follow the sequence in Table 5.
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   Table 5

   Engine Setting	Set Clearance on Cyl. No.
   Cyl 1 TDC Compression	1, 3, 5
   Cyl 6 TDC Compression	2, 4, 6

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Illustration 49	g00900765
(1) Adjusting screw

2. With the exhaust valve closed (rocker arms loose), turn in slave piston adjusting screw (1) until the slave piston contacts the valve stem cap.

   Note: It may be difficult to "feel" the contact with the valve cap. Use a flashlight to visually see the slave piston contact the valve cap.

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Illustration 50	g00900766
(2) Adjusting gauge

3. Place the Jacobs lash adjusting gauge, part number 014767, over adjusting screw (1) and nut so that the A mark is in line with the wrench handle. From this position hold the gauge in place and turn the adjusting screw out (counterclockwise) until the wrench handle lines up with the B mark on the gauge. This will provide a slave cylinder clearance of 0.890 mm (0.035 inch). After adjustment is complete remove the gauge. Hold the adjusting screw with the wrench while tightening the lock nut to a torque of 34 N·m (25 lb ft).

4. Connect the solenoid lead wires to the terminal lead outs in the valve cover spacer. Polarity is not important.

Valve Cover Installation

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Illustration 51	g00899702

1. Place the AVSpare gasket on the spacer and install the valve cover. Tighten the capscrews in the sequence shown in Illustration 35 to a torque of 18 N·m (13 lb ft). Reinstall the accessory components.

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Illustration 52	g00912746

2. Some engines may require the addition of the venting hose extension to permit the breather pipe to clear engine components.

3. Attach the WARNING decal in a convenient location on the dash.

4. Complete and mail the engine brake warranty card.

Engine Area

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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

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Illustration 53	g00897016
(1) 1Q-9830 Switch (2) 134-1594 Bracket (3) 2N-3477 Screw (4) 4B-5324 Washer (5) 4B-2041 Nut

1. Install Throttle Switch (1) to Bracket (2) using two screws (3), two washers (4) and two nuts (5) .

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Illustration 54	g00897084
(2) 134-1594 Bracket (6) 134-1593 Plate (7) 4L-6454 Bolt (8) 8T-4896 Washer (9) 6V-8801 Nut

2. Install the throttle switch and bracket assembly to plate (6) using two bolts (7), two washers (8) and two nuts (9). Do not tighten the nuts at this time as adjustment will be required.

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Illustration 55	g00897110
(10) Dipstick tube (11) 134-1592 Strip

3. Remove the bolt, nut and washer attaching dipstick tube (10) "P"-clip to 9N-1394 Bracket . Do not remove the "P"-clip from the dipstick tube. Remove 9N-1394 Bracket from the engine and retain for later installation. Replace 9N-1394 Bracket with strip (11). Install the strip in the position shown in Illustration 55 using a bolt on the engine that is directly below the mounting position of 9N-1394 Bracket .

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Illustration 56	g00897304
(6) 134-1593 Plate (12) 6V-5782 Bolt (13) 6B-2882 Spacer (14) 8T-4224 Washer

4. Mount the throttle switch and bracket assembly that was attached to plate (6) in Step 2 to the throttle cable bracket. Use two spacers (13), two bolts (12) and two washers (14) to attach the assembly to the throttle cable bracket.

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Illustration 57	g00897474
(1) 1Q-9830 Switch (2) 134-1594 Bracket (6) 134-1593 Plate

5. Adjust bracket (2) and plate (6) so that throttle switch (1) operates when the governor is at rest (the operator's foot is off of the accelerator). A click can be heard when the switch activates. Tighten the bolts after the adjustment of the plate and bracket allows for proper switch operation.

   Note: The throttle switch must open as soon as pressure is applied to the accelerator pedal and close when the pedal is released.

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Illustration 58	g00897552
(15) 150-1894 Plate-Shield (16) 8T-4896 Washer (3/8) (17) 8T-5391 Bolt (5/16)

6. Install Plate-Shield (15) into position using two bolts (17) and two washers (16) .

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Illustration 59	g00897615
(18) 8T-4224 Washer (19) 4M-6425 Bolt (5/16) (20) 170-6369 Bracket (21) 8T-4896 Washer (3/8) (22) 5M-3062 Bolt (3/8)

7. Install bracket (20) onto shield (15) using one bolt (19), two washers (18) and one 6V-8189 Nut . Install the bracket onto the lower hole on the shield. Place one washer (18) on each side of shield (15). Place one washer under the head of bolt (19) and one washer under the nut. Attach the end of the bracket to the underside of the turbocharger using one bolt (22) and one washer (21) .

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Illustration 60	g00898048
(2) 134-1594 Bracket (9) 6V-8801 Nut (14) 8T-4224 Washer (17) 8T-5391 Bolt (5/16) (21) 8T-4896 Washer (3/8) (22) 5M-3062 Bolt (3/8) (23) 5P-9085 "P"-Clip (24) 168-6882 Harness As-Engine (25) 2U-4497 Strap (A) Rear solenoid (B) 9N-1394 Bracket (C) Front solenoid (D) Wire connection

8. Mount Harness As-Engine (24) as shown in Illustration 60. First connect the 2-Way Sure-seal connector to the Harness As-Cab at the connection point on top of the transmission. Refer to Illustration 15. Place a 9G-9151 Metal clip around the connector to secure the connection.

9. Route the Harness As-Engine along the main engine harness using Straps (25) to secure.

10. Connect the black wire (the one with the fork terminal) of the Harness As-Engine to wire 200-BK connection (D). Loosen the screw connecting 200-BK to the shutdown solenoid and slide the fork terminal under the 200-BK ring terminal. Make certain this connection is with the 200-BK wire only.

11. Connect the RD and BK wires with ring terminals to the terminals of the Throttle Switch mounted onto Bracket (2). Polarity is not important.

12. Install bracket (B) that was removed from the dipstick tube in Step 3 onto the location shown in Illustration 60 using one bolt (22) and one washer (21) .

13. Route the braided section of the Harness As-Engine as shown in Illustration 60. Secure the harness to bracket (B) using "P"-clip (23), bolt (22), washer (21) and nut (9) .

14. Connect the harness wires to rear solenoid (A). Polarity is not important.

15. Route the braided section across the top of the rocker cover and connect the harness wires to front solenoid (C). Secure this section of the harness using two "P"-clips (23), two bolts (17) and two washers (14). Polarity is not important.

System Operation

Control Unit Operation

Illustration 61	g00900988
(1) Jake Brake Control switch (2) Jake Brake Stage 1 indicator (Yellow LED) (3) Jake Brake Stage 2 indicator (Red LED) (4) Lock-up indicator (Green LED) (5) Retarder indicator (Red LED)

Whenever lock-up is engaged, Lock-up indicator (Green LED) (4) will be illuminated. This will allow the Jake Brake to operate if the accelerator is released. Jake Brake switch (1) is a three position switch. If the switch is in the center position then the Jake Brake will not operate when the Lock-up indicator is lit and the accelerator is released. If the top of the switch is pushed Stage 1 is selected and Stage 1 indicator (Yellow LED) (2) will be illuminated. The switch in this position allows the Jake Brake to operate at 50% capacity.

If the bottom of the switch is pushed Stage 2 is selected and both Stage 1 indicator (Yellow LED) (2) and Stage 2 indicator (Red LED) (3) will be illuminated. The switch in this position allows the Jake Brake to operate at 100% capacity, with both the first and second stages in operation. Depressing the accelerator pedal and/or the transmission reverting to convertor drive will disengage the Jake Brake.

If the machine is equipped with a retarder and the retarder is switched off then the Jake Brake operates as described above. If the retarder is operating and the top of the Jake Brake switch is pushed then Stage 1 is activated and both Stage 1 of the Jake Brake and the retarder will operate. If the retarder is operating and the bottom of the Jake Brake switch is pushed then Stage 2 is activated, however, only the retarder will operate the Jake Brake will not. As long as Retarder indicator (Red LED) (5) is illuminated the Jake Brake Stage 2 indicator (Red LED) will not illuminate nor will the Jake Brake operate.

Theory of Operation

Illustration 62	g00900819
(1) Solenoid valve (2) Oil passage (3) Control valve (4) Adjusting screw (5) Oil passage (6) Master piston (7) Lead-out (8) Engine oil port (9) Ball check valve (10) Oil passage (11) Slave piston (12) Exhaust valve (13) Exhaust rocker arm (14) Pushrod

Energizing the engine brake effectively converts a power producing diesel engine into a power absorbing air compressor. This is accomplished by opening cylinder exhaust valves (12) near the top of the normal compression stroke, releasing the compressed cylinder charge to the exhaust.

The blow down of compressed air to atmosphere prevents the return of energy to the engine piston on the expansion stroke. The effect is a net energy loss, since the work done in compressing the cylinder charge is not returned during the expansion process.

Exhaust blow down of the braking cylinder is accomplished by utilizing the exhaust cam motion of another cylinder.

Pushing the control switch in the cab sends electrical current through lead-out (7) to solenoid valve (1). Energizing the solenoid valve permits engine oil flowing into port (8) to flow through passage (2) on to control valve (3) into passage (10). Then the oil flows to both slave piston (11) and master piston (6) .

Engine oil pressure causes the master piston to move down, coming to rest on the corresponding exhaust rocker arm (13). Pushrod (14) causes the exhaust rocker arm to move up (as in normal exhaust cycle), forcing the master piston upward and creating a high pressure flow through passage (5) to slave piston (4) of the braking cylinder. The oil flows through passage (10) back to control valve (3). Ball check valve (9) in the control valve traps high pressure oil in passages (10) and (5) and the master and slave pistons.

Reacting to the high pressure oil flow, the slave piston moves down, momentarily opening exhaust valve (12) at a predetermined amount of slave stroke. The exhaust valve is forced open prior to top dead center position, releasing the compressed cylinder air to the exhaust manifold. Compressed air escapes into the atmosphere (usually through the turbocharger), completing a compression braking cycle.

Maintenance

Solenoid Valve

Illustration 63	g00911872
(1) Solenoid valve (2) Housing (3) Adjustment screw (4) Locknut (5) Control valve cover (6) Retaining ring (7) Control valve (8) Seal rings (9) Retaining ring (10) Slave piston (11) Master piston (12) Master piston spring (13) Bolt

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NOTICE
Do not disassemble or tamper with the solenoid valve. Engine damage could result.

1. Disconnect the solenoid harness. Using a 7/8 inch socket and extension on early solenoids, or a 3/4 inch socket and extension on later solenoids, unscrew solenoid valve (1).

2. Remove and discard three rubber seal rings (8). If the lower ring stays in the bottom of housing (2) solenoid bore, remove it with a seal pick.

3. Clean out the solenoid valve bore in the housing. Use clean paper towels. Never use rags, as they may leave lint and residue which can plug the oil passageways.

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Illustration 64	g00901588
(1) Solenoid valve (8) Seal rings

4. Wash out solenoid valve (1) with an approved cleaning solvent. Use a brush to clean the oil screen. Clean and dry the valve with compressed air. Replace the oil screen if necessary.

5. Reinstall the solenoid using new seal rings (8). Seat the lower seal ring in the base of the solenoid valve housing bore. Wipe clean lube oil into and around the bore. Place the upper and center seal rings on the solenoid valve body. Be sure the seals are seated properly.

6. Carefully screw the solenoid valve into the housing without unseating the seals. Tighten the valve to a torque of 14 N·m (10 lb ft) for the earlier-style solenoids, or a torque of 20 N·m (15 lb ft) for later-style solenoids. Be careful not to twist the seals while installing.

Control Valve

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Sudden release of spring force can cause injury. To prevent the possibility of injury, follow the procedure to relieve the spring pressure.

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

Illustration 65	g00911872
(1) Solenoid valve (2) Housing (3) Adjustment screw (4) Locknut (5) Control valve cover (6) Retaining ring (7) Control valve (8) Seal rings (9) Retaining ring (10) Slave piston (11) Master piston (12) Master piston spring (13) Bolt

Illustration 66	g00901589
(5) Cap (6) Retaining ring (7) Control valve

1. Apply pressure on control valve cover (5) and remove retaining ring (6) using retaining ring pliers.

2. Slowly remove the cover until spring pressure ceases, then remove the two control valve springs and control valve shim.

3. Using needle nose pliers, remove control valve (7) .

1. Wash the control valve bore in housing (2) using clean paper towels.

2. Wash the control valve with approved cleaning solvent. Push a wire through the hole in the base of the valve to make sure that the ball check is free. The ball should lift with light pressure on the wire. If the ball is stuck or there is no spring pressure, replace the control valve. Dry the valve with compressed air, and wipe clean with a paper towel.

3. Dip the control valve in clean lube oil. Drop the valve into its bore. If binding occurs, the control valve should be replaced.

4. Reassemble the parts reversing the removal procedure. Rotate the retaining ring ears 90 degrees from the housing drain slot after installation.

Slave Piston

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Remove slave pistons carefully. The slave pistons are under spring pressure. Remove with care to avoid personal injury.

Table 6

Jake Brake Tool Name	Jake Brake Part Number
Slave piston removal tool	017397

Illustration 67	g00911872
(1) Solenoid valve (2) Housing (3) Adjustment screw (4) Locknut (5) Control valve cover (6) Retaining ring (7) Control valve (8) Seal rings (9) Retaining ring (10) Slave piston (11) Master piston (12) Master piston spring (13) Bolt

1. Remove locknut (4) from slave piston (10) adjustment screw (3). Back out the adjustment screw until the slave piston is fully retracted (screw is loose).

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Illustration 68	g00901592
(14) Removal tool

2. Use removal tool (14) (Jacobs part number 017397) and the following procedure to remove and replace the slave piston.

3. Place the hole in the removal tool over the slave piston adjustment screw. Replace the locknut. Snug tighten to hold the tool securely.

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Illustration 69	g00901591
(9) Retaining ring (10) Slave piston (15) Retainer

4. While holding the tool in position, screw the tool down over the slave piston until retainer (15) is contacted.

5. Turn the handle slowly until the retainer is depressed about 1.02 mm (0.040 inch), relieving pressure against retaining ring (9) .

6. Remove the retaining ring using retaining ring pliers.

7. Back out the removal tool until the springs are loose and remove the tool.

8. Remove all components. Check that there is no binding or burrs. Clean in an approved cleaning solvent or replace as necessary.

9. Use the removal tool to install the piston and springs. Be sure retaining ring (9) is place on retainer (15) before screwing the tool down over the slave piston.

10. Compress the slave piston springs until the retainer is about 1.02 mm (0.040 inch) below the retaining ring groove. Reinstall the retaining ring. Be sure the retaining ring is fully seated in the groove.

11. Rotate the retaining ring about 90 degrees in either direction.

12. Remove the tool slowly to ensure proper seating of the retaining ring.

Master Piston

Illustration 70	g00911872
(1) Solenoid valve (2) Housing (3) Adjustment screw (4) Locknut (5) Control valve cover (6) Retaining ring (7) Control valve (8) Seal rings (9) Retaining ring (10) Slave piston (11) Master piston (12) Master piston spring (13) Bolt

Illustration 71	g00901593
(11) Master piston (12) Master piston spring (13) Bolt

Note: If the master piston hard facing is damaged, inspect the corresponding rocker arm adjusting screw spherical nut for excessive wear or pitting. Replace if damaged.

1. Remove bolt (13), the washer and master piston spring (12) from the bottom of housing (2) .

2. Remove master piston (11) from its bore using needle nose pliers. If binding occurs, check for burrs or contaminants in lube oil. Clean in approved solvent. Inspect the hard face surface. Pitted, chipped, cracked or galled pistons should be replaced.

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Illustration 72	g00901594
(11) Master piston (12) Master piston spring (13) Bolt

3. Reassemble the parts reversing the removal procedure.

   Note: The spring tabs (arrows) should be equally spaced from the raised piston area.

Exhaust Valve Stem Cap

Illustration 73	g00901893
(16) Exhaust valve stem cap prior to 1October 1992 (17) Exhaust valve stem cap after to 1October 1992

The exhaust valve stem cap assembly consists of two parts. It is not necessary to disassemble the parts. Inspect the assembly for excessive wear at various contact surfaces. Replace the valve cap assembly if excessive wear is apparent. When installed, the valve stem cap should fit snugly around the exhaust valve spring retainer.

Exhaust valve stem cap (17) may be used in place of earlier design exhaust valve stem cap (16). Both parts are interchangeable.

Electrical Troubleshooting

Illustration 74	g00904354

(1) Lock-up indicator light

(2) Retarder indicator light

(3) Retarder switch

(4) Control unit

(5) Lock-up switch

(6) Jake brake Stage 1 solenoid

(7) Jake brake Stage 2 solenoid

(8) Throttle switch

Refer to Illustration 74 for the individual components and the identification of their respective circuits.

Illustration 75	g00904451

Illustration 76	g00904456

Illustration 77	g00904457

Illustration 78	g00904458

Illustration 79	g00913068

Note: The system is protected against external shorting. If the subsystem shorts the box lights will operate but there will be no input signal.

Illustration 80	g00904462

Illustration 81	g00904463

Supplemental AVSpare Parts Information

Note: Parts in this section are those items not included in Parts Book, SEBP2537-00, "D25D & D30D Articulated Trucks".

AVSpare Basic Engine

Illustration 82	g00902911

Table 7

136-3772 BRAKE GP.
NOTE	REF NO	PART NUMBER	QTY	PART NAME	NOTE	REF NO	PART NUMBER	QTY	PART NAME
	1	1D-4586	4	BOLT		9	2S-0736	4	WASHER
	2	7E-4172	4	O-RING SEAL		10	148-7435	1	SPACER
	3	7E-4170	1	TUBE		11	170-6273	4	TERMINAL LEADOUT
	4	7E-4171	1	E-RING		12	136-4193	15	BOLT
	5	5P-8247	4	WASHER		13	7E-4182	1	GASKET
Y	6	148-7432	1	HOUSING GP- FRONT		14	104-4805	6	NUT
Y	6	148-7433	1	HOUSING GP- REAR		15	7E-4179	6	SCREW
	7	7E-4169	1	TUBE		16	102-8820	6	CAP
	8	4P-0859	4	STUD		17	7E-4176	1	FITTING
Y - SEPARATE ILLUSTRATION

Housing Group

Illustration 83	g00902913

Table 8

148-7432 HOUSING GP. - FRONT AND 148-7433 HOUSING GP. - REAR
NOTE	REF NO	PART NUMBER	QTY	PART NAME	NOTE	REF NO	PART NUMBER	QTY	PART NAME
	1	143-6665	2	HARNESS		12	2U-1492	1	SEAL
	2	143-2534	3	RING		13	2U-1493	1	SEAL
	3	143-2597	3	COVER		14	143-6469	3	SPRING
	4	143-6489	3	SHIM		15	143-6472	3	PISTON
	5	148-7437	1	SOLENOID		16	143-6497	3	PISTON
	6	1B-4430	3	NUT		17	143-2594	3	RETAINER
	7	143-2590	3	SPRING		18	143-6470	3	SPRING
	8	143-2596	3	SPRING		19	143-2559	3	RING
	9	143-6482	3	SCREW		20	143-6471	3	SPRING
	10	102-8780	3	VALVE		21	5P-0537	3	WASHER
	11	143-6642	1	SEAL		22	0S-1613	3	BOLT

Special Tools

Illustration 84	g00903113

Table 9

SPECIAL TOOLS
NOTE	REF NO	PART NUMBER	QTY	PART NAME	NOTE	REF NO	PART NUMBER	QTY	PART NAME
	1	149-0114	1	GAUGE		2	149-6106	1	TOOL BOX

AVSpare Wire Harnesses

The following wire harnesses are no longer serviced by the AVSpare Parts Distribution system. The following illustrations and parts list will allow the technician to replicate these wiring harnesses if required.

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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

168-6882 Harness As.-Engine

Illustration 85	g00905169
(1) 7N-7780 Connector Pin (2) 7N-7779 Connector Socket (3) 7N-9737 Plug Housing (4) 2U-4556 Sleeve (5) 2U-4559 Sleeve (6) 2U-4702 Terminal-blue spade (7) Terigraine braiding Ø6 (8) 2U-4649 Terminal-red fork (9) 6V-2690 Heat Shrink Tube (10) 2U-4487 Sleeving (11) 2U-4469 Terminal (A) Connector to chassis harness (B) Connector to Jake Brake stage 2 (C) Connector to shutdown solenoid (D) Splice RD (B) (E) Connector to throttle switch (F) Connector to Jake Brake stage 2

Chassis connector (A) circuit consists of two wires, BK "A" and "B" and BK "C" and ""D". Circuit BK "A" and "B" is constructed by using 3940 mm (155 inch) of 504/05 silicon black wire and cutting it to a length of 1370 mm (54 inch) as shown in Illustration 85. Do not install 7N-9737 Housing (3) and 7N-7779 Socket nor 2U-4702 Terminal-blue spade (6) until 2U-4556 Heatshrink (4) and 2U-4559 Sleeving (5) has been installed.

Circuit BK "C" and "D" is constructed by using the remainder of the 3940 mm (155 inch) of 504/05 silicon black wire and cutting it to a length of 2020 mm (79.5 inch). Install 2U-4556 Heatshrink (4), 2U-4559 Sleeving (5) onto both wires to braiding (7). Install both wires into 7N-9737 Housing (3) and install 7N-7780 Pin and 7N-7779 Socket as shown in Illustration 85. Do not install 2U-4702 Terminal-blue spade (6) until 2U-4556 Heatshrink (4), 2U-4559 Sleeving (5) and braiding (7) has been installed.

The throttle switch circuit consists of two wires, RD "A" and "B" and BK "E" and "F". Circuit BK "E" and "F" runs from the throttle switch to the shutdown solenoid. Circuit BK "E" and "F" is constructed by using the remainder of the 3940 mm (155 inch) of 504/05 silicon black wire and cutting it to a length of 550 mm (21.7 inch) as shown in Illustration 85. Do not install 2U-4649 Terminal-red fork (8), 2U-4469 Terminal (11), until 2U-4487 Sleeving (10), 6V-2690 Heatshrink (9), 2U-4556 Heatshrink (4) and 2U-4559 Sleeving (5) has been installed.

Circuit RD "A" and "B" runs from the throttle switch to splice (D). Circuit RD "A" and "B" is constructed by using 2240 mm (88 inch) of 504/05 silicon red wire and cutting it to a length of 1050 mm (41 inch). Install 2U-4487 Sleeving (10) as shown in Illustration 85.

Install 2U-4556 Heatshrink (4) and 2U-4559 Sleeving (5) onto wire RD "A" and "B" and wire BK "E" and "F" as shown in Illustration 85. Install one 2U-4469 Terminal (11) to each wire.

Install 2U-4487 Sleeving (10), 6V-2690 Heatshrink (9) and 2U-4649 Terminal-red fork (8) onto wire BK "E" and "F" as shown in Illustration 85.

Circuit RD "C" and "B" runs from the Jake Brake stage 2 solenoid to splice (D). Circuit RD "C" and "B" is constructed by using the remainder of the 2240 mm (88 inch) of 504/05 silicon red wire and cutting it to a length of 270 mm (10.6 inch).

Circuit RD "D" and "B" runs from the Jake Brake stage 1 solenoid to splice (D). Circuit RD "D" and "B" is constructed by using the remainder of the 2240 mm (88 inch) of 504/05 silicon red wire and cutting it to a length of 920 mm (36 inch).

Splice circuits RD "A" and "B", RD "C" and "B" and RD "D" and "B" together at splice (D) as shown in Illustration 85.

Install braiding (7), 2U-4556 Heatshrink (4) and one 2U-4702 Terminal-blue spade (6) to each wire as shown in Illustration 85.

168-6888 Harness As.-Dashpanel

Illustration 86	g00905171
(1) 7N-7779 Connector Socket (2) 7N-7780 Connector Pin (3) 2U-4466 Terminal (4) 2U-4489 Sleeve (5) 2U-4559 Sleeve (6) 7N-8204 Receptacle Housing (7) 7N-9738 Receptacle Housing (8) 7N-9737 Plug Housing (9) 2U-4469 Terminal (A) Connector to control unit (B) Connector to retarder lamp (C) Connector to lock-up lamp (D) Connector to dash ground (E) Connector to Jake Brake solenoids

The dash ground circuit runs from the control unit to the terminal on the dash frame. This circuit consists of one wire. Ground circuit BK "A" and "B", is constructed by using 1 m (3.3 ft) of 2U-4483 Wire-14/030 BK and cutting it to a length of 350 mm (13.8 inch). Install 7N-8204 Housing (6), 2U-4469 Terminal (9), and 7N-7779 Socket (1) as shown in Illustration 86.

The lock-up lamp circuit runs from the control unit to the lock-up lamps. This circuit consists of two wires, circuit BR "A" and "B", and circuit YL "A" and "B". Circuit BR "A" and "B" is constructed by using 2 m (6.6 ft) of 2U-4448 Wire-14/030 BR and cutting it to a length of 1350 mm (53.1 inch). Install this wire into 7N-8204 Housing (6) and 7N-7779 Socket (1) as shown in Illustration 86. Do not install 2U-4466 Terminals (3) until 2U-4559 Sleeving (5) has been installed.

Circuit YL "A" and "B" is constructed by using 2 m (6.6 ft) of 2U-4474 Wire-14/030 YL and cutting it to a length of 1350 mm (53.1 inch). Install 7N-9738 Housing (7) and 7N-7779 Socket (1) as shown in Illustration 86. Do not install 2U-4466 Terminal (3) until 2U-4559 Sleeving (5) has been installed.

The retarder lamp circuit runs from the control unit to the retarder lamp. This circuit consists of one wire. Circuit OR "A" and "B" is constructed by using 2 m (6.6 ft) of 2U-4663 Wire-14/030 OR and cutting it to a length of 1420 mm (56 inch). Install this wire into 7N-9738 Housing (7) and 7N-7780 Pin (2) as shown in Illustration 86. Do not install 2U-4466 Terminal (3) until 2U-4589 Sleeving (4) and 2U-4559 Sleeving (5) has been installed.

The Jake Brake solenoids circuit runs from the control unit to the Jake Brake solenoids. This circuit consists of two wires, circuit BU "A" and "B", and circuit GN "A" and "B". Circuit GN "A" and "B", to solenoid 1, is constructed by using 1 m (3.3 ft) of 2U-4835 Wire-14/030 LT GN and cutting it to a length of 400 mm (15.75 inch). Install this wire into 7N-8204 Housing (6) and 7N-7780 Pin (2). Install 7N-9737 Housing (8) and 7N-7780 Pin (2) as shown in Illustration 86.

Circuit BU "A" and "B", to solenoid 2, is constructed by using 1 m (3.3 ft) of 2U-4642 Wire-14/030 BU and cutting it to a length of 400 mm (15.75 inch). Install this wire into 7N-8204 Housing (6) and 7N-7780 Pin (2). Install 7N-9737 Housing (8) and 7N-7779 Socket (1) as shown in Illustration 86.

Install 2U-4589 Sleeving (4) and 2U-4559 Sleeving (5). Install 2U-4466 Terminals (3) to the retarder and lock-up wires. Connect the retarder terminal (3) to original machine circuit 454-GN. Connect the lock-up YL terminal (3) to original machine circuit 490-GN. Connect the lock-up BRterminal (3) to original machine circuit 130-GN.

168-6887 Harness As.-Cab

Illustration 87	g00905170
(1) 7N-7780 Connector Pin (2) 7N-7779 Connector Socket (3) 7N-9737 Plug Housing (4) 2U-4487 Sleeving (5) 7N-9738 Receptacle Housing (A) Connector to engine (B) Connector to cab

Circuit "A", going to solenoid 1, is constructed by using 3 m (9.8 ft) of 2U-4835 Wire-14/030 LT GN and cutting to a length of 2600 mm (102.4 inch). Circuit "B", going to solenoid 2, is constructed by using 3 m (9.8 ft) of 2U-4642 Wire-14/030 BU and cutting to a length of 2600 mm (102.4 inch). Install 2U-4487 Sleeving (4), 7N-9737 Housing (3), 7N-9738 Housing (5), 7N-7780 Pins (1) and 7N-7779 Sockets (2) as shown in Illustration 87.

Supplemental Jake Brake Parts Information

Note: Parts in this section are those items that may be acquired through an authorized Jacobs distributor. A list of authorized Jacobs distributors is at the end of this section.

Attaching Parts Group

Illustration 88	g00902911

Table 10

014760 Hsg. Aug. Parts Group
NOTE	REF NO	PART NUMBER	QTY	PART NAME	NOTE	REF NO	PART NUMBER	QTY	PART NAME
A	1	017440	4	Bolt	B	9		4	Washer
	2	014439	4	O-ring		10	025959	1	Spacer
	3	013427	1	Lumper oil supply tube		11	025663	4	Terminal leadout
	4	014540	1	E-ring		12	017077	15	Hex screw
A	5	017441	4	Washer		13	014750	1	Gasket
Y	6	018949	1	Front housing assy., 24 VDC		14	018993	6	Spherical nut
Y	6	018950	1	Rear housing assy., 24 VDC		15	014632	6	Adjusting screw
	7	014276	1	Feed oil supply tube		16	018882	6	Valve cap guide assy.
	8	017156	4	Stud		17	013120	1	Oil supply fitting
"A" - Sold as a set "B" - AVSpare supplied part "Y" - Separate illustration

Housing Assemblies

Illustration 89	g00902913

Table 11

018949 Front housing assy., 24 VDC and 018950 Rear housing assy., 24 VDC
REF NO	PART NUMBER	QTY	PART NAME	REF NO	PART NUMBER	QTY	PART NAME
1	020820	2	Solenoid harness	12	001082	1	Center seal ring
2	011284	3	Retaining ring	13	001083	1	Lower seal ring
3	011252	3	Control valve cover	14	013417	3	Slave piston inner spring
4	014431	3	Control valve shim	15	013430	3	Slave piston
5	020235	1	Solenoid Valve, 24 VDC	16	014679	3	Master piston
6	009353	3	Hex nut	17	008895	3	Slave piston retainer
7	007500	3	Control valve inner spring	18	013418	3	Slave piston outer spring
8	010843	3	Control valve outer spring	19	001023	3	Slave piston retaining ring
9	014351	3	Adjusting screw	20	013428	3	Master piston flat spring
10	011930	3	Control valve	21	001030	3	Washer
11	020229	1	Upper seal ring	22	001492	3	Hex capscrew

Service Tools

Illustration 90	g00903962

Table 12

Service Tools and Parts
NOTE	REF NO	PART NUMBER	PART NAME	NOTE	REF NO	PART NUMBER	PART NAME
	1	014767	Feeler gage, .035 inch		5	016895	Mounting bolt
	2	017397	Slave piston removal tool		6	012804	Support
	3	001283	Solenoid screen retainer		7	017465	Tool box
	4	001282	Solenoid screen		8	018280	Oil pressure test group
Not shown		019469	Tune-up kit

Authorized Jacobs Distributors

Table 13

North America
Finning Ltd 555 Great Northern Way Vancouver, BC V5T 1 E2	Cummins Americas 3450 Executive Way Miramar, FL 33025 ph. 305-431-5511 fax 305-433-5797
Medland, Inc. 608 Paseo de Alteza Calexico, CA 92231 ph. 619-357-3559 fax 619-357-5794	Chazen Industrial Corp. 280 Midland Avenue Saddle Brook, NJ 07662 ph. 201-794-1330 fax 201-794-1663
RDC International 6119 E. Sandra Square Scottsdale, AZ 85267 ph. 602-483-1487 fax 602-483-1754
South America
Distributor Medland S.A. de C.V. Calzada Camarones No. 517A Col. Sta. Ma. Maninalco 02050 Mexico, D.F., Mexico ph. 52-5-352-0546 fax 52-5-352-9599	Navitrans International Diagonal 50 No. 10 Sur 143 Medelin, Columbia ph. 57-4-285-9797 fax 57-4-285-9385
Distecnicas Ltda. C.C. Automotoriz L. 152 CI. 23 No. 43A-145 Medelin, Columbia ph. 57-4-262-6708 fax 57-4-262-6708	Comercial Kaufmann S.A. Av. Ramon Freire 5830 Santiago, Chile ph. 56-2-776-7650 fax 56-2-776-4109
Dismerint Eloy Alfaro 2091 y 6 de Diciembre, Quito, Equador ph. 59-32-462-901 fax 59-32-465-418	Divemotor S.A. Av Canada 1160 La Victoria Lima, Peru ph. 511-224-0525 fax 511-224-0266
Australia
Retarding Systems Australasia 117 Eldridge Road Condell Park New South Wales, Australia 2200 ph. 612-708-2122 fax 612-708-2912
Asia
Cummins Diesel Sales Corp. 8 Tanjong Penjuru Jurong Industrial Estate, Singapore 2260 ph. 65-265-0155 fax 65-264-0664	Scott & English Ltd. 2 Sixth Lok Yang Rd Singapore 2262 ph. 65-264-4922 fax 65-268-2985
Inchcape Industrial Group Inc Pac Parts Distribution 11 Second Chin Bee Road, Singapore 2261 ph. 65-268-8318 fax 65-268-8812	Scott & English Sdn Bhd Kuala Lumpur Malaysia ph. 603-221-1033 fax 602-652-985
South Africa
Cummins Diesel Sales Corp. Post Bag X7 13 Eastern Service Road Kelvinview, Wendywood, South Africa 2144 ph. 2-711-444-3225 fax 2-711-444-1899