Models
680A/B
The Model 680A Jake Brake® engine retarder is designed and approved for use on Mack® E6
engines with four-valve cylinder head configuration. The Model 680B is designed and approved
for use on Mack E7 engines. Information in this manual was current at the time of printing and is
subject to change without notice or liability.
Jacobs Service Letters should be consulted for additional applications and updated information.
Table of Contents Safety Precautions
Section 1: Introduction ........................................................ 3 The following symbols in this manual signal potentially
dangerous conditions to the mechanic or equipment. Read
Housing Identification ............................................................. 3
this manual carefully. Know when these conditions can
Tools Needed ............................................................................ 3 exist. Then, take necessary steps to protect personnel as
well as equipment.
Torque Values ............................................................................ 3
Section 2: Engine Preparation ...................................... 4 - 6
Exhaust Rocker Arm Adjusting Screw .................................. 4
Exhaust Valve Yoke Replacement ........................................ 5 THIS SYMBOL WARNS OF POSSIBLE PER-
SONAL INJURY.
Exhaust Valve Yoke Adjustment ........................................... 5
Section 3: Brake Housing Installation ..................... 7 - 10
Slave Piston Adjustment ......................................................... 8
THIS SYMBOL REFERS TO POSSIBLE EQUIP-
Inlet and Exhaust Valve Adjustment .................................... 9 MENT DAMAGE.
Brake Housing Spacer Installation ....................................... 9 NOTE:
Replacement of Valve Covers and Accessories ............. 10 INDICATES AN OPERATION, PROCEDURE OR
Section 4: Electrical System Installation ............... 10 - 13 INSTRUCTION THAT IS IMPORTANT FOR
CORRECT SERVICE.
Dash Switch ............................................................................ 11
Fuels, electrical equipment, exhaust gases and moving
Clutch Switch .......................................................................... 11 engine parts present potential hazards that could result in
Fuel Pump Switch ................................................................. 11 personal injury. Take care when installing an engine brake.
Always use correct tools and proper procedures as outlined
Control Systems ..................................................................... 13 in this manual.
Section 5: Engine Brake Operation Check .................... 14
MH Air Cleaner Adapter Kit ................................................. 14
Section 6: Engine Brake Maintenance ................... 15 - 19
SEE JACOBS DRIVER’S MANUAL FOR PROPER
Theory of Operation .............................................................. 15 ENGINE BRAKE DRIVER TECHNIQUES.
Solenoid Valve ........................................................................ 16 THE JAKE BRAKE RETARDER IS A VEHICLE
SLOWING DEVICE, NOT A VEHICLE STOPPING
Control Valve .......................................................................... 16
DEVICE. IT IS NOT A SUBSTITUTE FOR THE
Master Piston .......................................................................... 17 SERVICE BRAKING SYSTEM. THE VEHICLE’S
SERVICE BRAKES MUST BE USED TO BRING
Slave Piston ............................................................................. 18
THE VEHICLE TO A COMPLETE STOP.
FIG. 2
JACOBS MACK
Remove the rocker bracket bolts and washers and then
remove the rocker arm shaft assemblies (see Fig. 3).
FIG. 4
Pick up existing photo from Jacobs USE ONLY JACOBS EXHAUST ROCKER ARM
680A/B Installation Manual, P/N 018061 ADJUSTING SCREWS FOR ENGINE BRAKE
Page 4, Fig. 3 INSTALLATION. THE USE OF MACK OR ANY
OTHER TYPE OF SCREW WILL RESULT IN
SEVERE SCREW WEAR AND ENGINE DAMAGE.
FIG. 5
FIG. 6
NOTE:
FIG. 8
THE EXHAUST VALVE YOKES IN THE E6
ENGINE HAVE SAE THREADS. THE JACOBS Turn adjusting screw an additional 1/6 turn (60° clockwise)
EXHAUST VALVE YOKES HAVE METRIC (see insert in Fig. 9).
THREADS. JACOBS ADJUSTING SCREWS AND
LOCKNUTS ARE INCLUDED IN THE 680A
ENGINE BRAKE KITS. THE YOKES IN THE E7
ENGINE HAVE METRIC THREADS AND THE
MACK ADJUSTING SCREWS AND LOCKNUTS HOLD THE ADJUSTING SCREW IN THIS
SHOULD BE REUSED FOR 680B INSTALLA- POSITION AND TORQUE THE LOCKNUT TO 33
TIONS WITH JACOBS YOKES. LB.-FT. (44 N•M). TO CHECK THE YOKE
ADJUSTMENT, INSERT A 0.010” THICKNESS
For Model 680A installation, use the Jacobs adjusting screw GAGE BETWEEN THE YOKE AND VALVE STEM
and locknut provided in the kit. AT BOTH THE INBOARD AND OUTBOARD
For Model 680B installation, remove the Mack adjusting LOCATIONS. EXERT A MODERATE FORCE BY
screw and locknut from the Mack exhaust yoke and install PRESSING ON THE TOP OF THE YOKE. AN
in the Jacobs yoke. EQUAL “DRAG” SHOULD BE FELT ON BOTH
THICKNESS GAGES. IF THE “DRAG” IS
Apply engine oil to the yoke guide pin, guide pin bore and UNEQUAL, READJUST THE YOKE ADJUSTING
top pallet of yoke (see Fig. 7). Install the Jacobs yokes in the SCREW.
engine with the adjusting screw outboard (toward the
intake manifold side of the engine).
FIG. 9
FIG. 7
NOTE:
FIG. 11
680A (E6) 55 lb.-ft. (75 N•m) Lubricate and install “O” rings in the groove in the Jacobs oil
680B (E7) 40 lb.-ft. (54 N•m) supply screws. Install the screws into the rocker brackets
and tighten to 5 lb.-ft. (7 N•m). Apply clean engine oil to the
Remove the two hex head screws and lock washers located “O” rings (see Fig. 14).
on the rocker brackets which lock the rocker shafts (see
Fig. 12). There are six (6) rocker shaft brackets. The two
screws that lock the shafts are on the first and fourth shaft
brackets (from the front of the engine).
Pick up existing photo from Jacobs
680A/B Installation Manual, P/N 018061
Page 6, Fig. 16
FIG. 14
Pick up existing photo from Jacobs DO NOT ROTATE THE ENGINE CRANKSHAFT
680A/B Installation Manual, P/N 018061 BACKWARDS WHEN USING THE HUB-
Page 7, Fig. 17 DAMPER BOLT, SINCE THIS MIGHT CHANGE
THE BOLT TORQUE.
FIG. 17
IMPORTANT!
FIG. 16
For 1991 and later engines
with manual transmissions,
refer to Mack’s E7 Engine Manual.
40 lb.-ft. (55 N•m). After tightening the nut, recheck the lash
setting. If it has changed, repeat the entire procedure.
FIG. 20
FIG. 21
FUEL PUMP
SWITCH
(C)
THREE-POSITION
DASH SWITCH
(A)
FIG. 22
NOTE:
FIG. 24
1.5” (38 mm)
1.0” (25 mm) For Model 680A (E6 Engine with UTD Fuel
CLUTCH
MEMBER Pump)
When used on a Mack engine outfitted with a UTD fuel
pump, modify P/N 020605 as shown in the engine control
group assembly instructions (P/N 020624). Then, install as
follows:
1. Refer to Fig. 25 and remove the two governor screws
from the rear of the fuel pump assembly. Install the
Jacobs fuel pump switch using the two governor
screws. Torque to 100 lb.-in. (11 N•m).
FIG. 23
FIG. 25
CONTROL
MODULE
FIG. 29
FIG. 30
FIG. 31
FIG. 32
Energizing the engine brake effectively converts a power- The Injector Rocker Arm moves up (as in normal injector
producing diesel engine into a power-absorbing air cycle), forcing the Master Piston upward and creating a
compressor. This is accomplished by opening the cylinder High Pressure Oil Flow (J) to the Slave Piston of the braking
Exhaust Valves (A) near the top of the normal compression cylinder. The Ball Check Valve (K) in the Control Valve traps
stroke, releasing the compressed cylinder charge to exhaust. high pressure oil in the Master/Slave Piston system.
The blow-down of compressed air to atmosphere prevents Under the influence of the high pressure oil flow, the Slave
the return of energy to the engine piston on the expansion Piston moves down, momentarily opening the Exhaust
stroke. The effect is a net energy loss, since the work done Valves at a pre-determined amount of slave stroke. The
in compressing the cylinder charge is not returned during Adjusting Screw (L) uncovers a passageway in the Slave
the expansion process. Piston, thus allowing oil to flow back to the underside of
the Control Valve, where it is stored for the next cycle. Prior
Exhaust blow-down of the braking cylinder is accomplished to top dead center position, the Exhaust Valve is forced
by utilizing the Injector Rocker Arm (B) motion of that open, releasing the compressed cylinder air to the exhaust
cylinder. manifold.
Energizing the Solenoid Valve (C) permits Engine Lube Oil Compressed air escapes into the atmosphere, completing a
to Flow Under Pressure (D, E) through the Control Valve (F) compression braking cycle.
to both the Master Piston (G) and Slave Piston (H).
SOLENOID
VALVE
(C)
OIL IN LOW CONTROL SLAVE
(D) PRESSURE VALVE PISTON
OIL (F) (H)
(E) BALL
CHECK
VALVE
(K)
DIODE
INJECTOR ROCKER
ARM (B)
THREE- FUEL CLUTCH
POSITION PUMP SWITCH
DASH SWITCH
SWITCH CIRCUIT
BREAKER
EXHAUST VALVES (A)
MASTER SLAVE
PISTON PISTON
FIG. 33
Control Valve
DO NOT DISASSEMBLE OR TAMPER WITH THE
SOLENOID VALVE. ENGINE DAMAGE COULD
RESULT. THE SOLENOID VALVE IS NOT FIELD
SERVICEABLE.
REMOVE CONTROL VALVE COVERS CARE-
1. Disconnect solenoid harness. Using a 12-point 7/8” FULLY TO AVOID PERSONAL INJURY.
socket and extension, unscrew solenoid valve. CONTROL VALVE COVERS ARE UNDER LOAD
FROM THE CONTROL VALVE SPRINGS.
2. Remove and discard the three rubber seal rings. If the
lower ring stays in the bottom of the housing solenoid 1. Apply pressure on the control valve cover and remove
bore, remove with a seal pick. the hex head capscrew.
FIG. 35
FIG. 38
THE SLAVE PISTON IS RETAINED BY SPRINGS Pick up existing photo from Jacobs
THAT ARE UNDER HEAVY COMPRESSION. IF 680A/B Installation Manual, P/N 018061
THE FOLLOWING INSTRUCTIONS ARE NOT Page 17, Fig. 45
FOLLOWED AND PROPER TOOLS NOT USED,
THE SPRINGS WILL BE DISCHARGED WITH
ENOUGH FORCE TO CAUSE PERSONAL
INJURY.
FIG. 41
FIG. 39
NOTES:
3. While holding the fixture in position, screw the holder
down over the slave piston until the spring retainer is BE SURE COMPONENTS ARE REASSEMBLED
contacted. IN PROPER ORDER.
4. Turn the handle slowly until the retainer is depressed THE RETAINER MUST BE INSTALLED WITH THE
to about 1/32” (1 mm), relieving pressure against the KEY THROUGH THE SLOT IN THE SLAVE
retaining ring. PISTON. INSTALL THE SLAVE PISTON WITH
THE OPEN AREA TOWARD THE CENTER OF
THE HOUSING. THE OPEN AREA OF THE
SLAVE PISTON IS FOR ROCKER ARM CLEAR-
ANCE (SEE FIG. 42).
90°
A
FIG. 42
P/N 018061C ©1995 Jacobs Vehicle Equipment Company Printed in USA 8/95