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Jacobs Engine Brake™ U
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790/795/797 Series M
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Table of Contents

Page
Section 1: Introduction 4-5
Housing Identication 4
Engine Identication 4
Special Tools 5
Recommended Torue Values 5
Engine Covers 5

Section 2: Engine Preparation 6-7

Series 60 Engines with DDEC IV & V
Undercover Wire Harness Installation (Retrot) 6

Section 3: Brake Housing Installation 8-10

Slave Piston Adjustment 10

Section 4: Engine Brake Controls 11

Section 5: Engine Brake Operational Check 12

RockerCoverInstallation

Section 6: Engine Brake Maintenance 13-19

Theor o Operation 13
Exhaust Blowdown 13
Part Identication 14
Control Valve 15
Slave Piston Adjusting Screw 16
Solid Screw 16
Solenoid Valve 16
Master Piston 17-18
Slave Piston 19

 INSTALLL
INSTALLLA
ATION
TIONINST
INSTRUCT
RUCTIONS
IONSFOR
FOR790/7
790/795/79
95/797SER
7SERIESJ
IESJACOB
ACOBSEN
SENGINE
GINEBRAK
BRAKES™
ES™
General Information
Theseinstructionsdescribetheinstallationothe
Model790/795/797SeriesJacobsEngineBrake™,
designedortheDetroitDieselSeries60®engine.
Forspecicapplicationinormationandslavepiston
clearancesettings,reertotheJacobsEngineBrake
orDetroitDieselEnginesApplicationGuide,P/N
4770,whichcanbeoundonwww.jakebrake.com.
Foradditionalinormationonthe790/795/797Series
enginebrakes,reertotheSeries60EngineService
Manual,P/N6SE483.
UseOSHA-approvedcleaningsolventorcleaning
parts.Originalpartstobereusedshouldbeinspected
orwearandreplacedasreuired.Besuretocoat
partswithcleanengineoilwhenreinstallingthem.
ThestandardJacobsVehicleSstemsWarrant
appliestotheinstallationoaJakeBrake ®Kit.The
warrantisadministeredbDetroitDieselCorporation.
ForspecicwarrantcoveragespleasecontactDetroit
Diesel.
INSTALLATION INSTRUCTIONS FOR 790/795/797 SERIES JACOBS ENGINE BRAKES™
Safety Precautions
Theollowingsmbolsinthismanualsignalconditions
potentialldangeroustothemechanicoreuipment.
Readthismanualcareull.Knowwhenthese
conditionscanexist.Thentakenecessarstepsto
protectpersonnelaswellaseuipment.
THISSyMBOLWARNSOFPOSSIBLE
PERSONALINJURy.
THISSyMBOLREFERSTOPOSSIBLE
EqUIPMENTDAMAGE.
NOTE: INDICATESANOPERATION,PROCEDURE
ORINSTRUCTIONTHATISIMPORTANTFOR
CORRECTSERVICE.
Fuels,electricaleuipment,exhaustgasesand
movingenginepartspresentpotentialhazards
thatcouldresultinpersonalinjur.Takecarewhen
installingeuipmentorparts.Alwaswearsaet
glasses.Alwasusecorrecttoolsandollowproper
proceduresasoutlinedinthismanual.
NOTE: THEJACOBSENGINEBRAKEISAVEHICLE
SLOWINGDEVICE,NOTAVEHICLESTOP-
 PINGDEVICE.ITISNOTASUBSTITUTEFOR
THESERVICEBRAKINGSySTEM.THEVEHI-
CLE'SSERVICEBRAKESMUSTBEUSEDTO
BRINGTHEVEHICLETOACOMPLETESTOP.

NOTE: NEVERREMOVEORADJUSTANyENGINE
BRAKEORCOMPONENTWITHTHEENGINE
RUNNING.
3
Section 1: Introduction

HousingIdentifcation
Themodel,partnumber,serialnumber,andadjust-
mentinormationarelocatedonthenameplateatthe
topoeachhousing.(SeeFig.1andFig.)
EngineIdentifcation
Enginemodelidentication,serialnumberandmodel
number,areonthenametaglocatedonthesideo
thevalvecoverandstampedontheclinderblock
beneaththeintakemaniold.(SeeFig.3)

Fig1

Fig3

Fig

4 INSTALLLATIONINSTRUCTIONSFOR790/795/797SERIESJACOBSENGINEBRAKES™
SpeciaToos
EngineCovers
Genera Theenginebrakehasbeendesignedtotonthe
18mm-1pointSocket
Series60enginewithnoadditionalvalvecovers.On
10mm-1pointSocket
engineseuippedwithatwo-piecealuminumvalve
6"Extension
cover,itisNOTnecessartoremovethelowervalve
13mmWrench
covertoinstalltheenginebrake.However,onestle
RetainingRingPliers(.047"diameter,45˚)
uppervalvecovermareuiremodicationatthe
DiagonalWireCutter
breatherhousinglocation(inside)orenginebrake
clearance.
KentMoore
Rocker ShatLitingTool P/NJ-35966A
Stud Torue Socket P/N J-44706A
MasterPistonAssemblTool P/NJ-45976
(Model797Onl)

DetroitDiese
Series60EngineServiceManual

Jacobs
Feeler Gage, 0.00" (0.508 mm) P/N 01778
Feeler Gage, 0.06" (0.660 mm) P/N 017671
Feeler Gage, 0.03" (0.813 mm) P/N 030504 Fig4
ControlValveCoverRemovalTool P/N016978

RecommendedTorque NOTE: IFINTERFERENCEEXISTSBETWEENTHE

FRONTENGINEBRAKEHOUSINGANDTHE
Vaues ROCKERCOVERCAPATTHEBREATHER
HOUSINGLOCATION,GRINDTHEUPPER
COVERTOPROVIDECLEARANCE.CLEAN
COVERTHOROUGHLyAFTERGRINDING.
HousingHold-down
Cap Screws 80 lb.-t. ( 108 N-m)
(lubricatedwithengineoil)

RockerShatHold-downStud 100lb.-t.(136N-m)

SlavePistonAdjusting
Screw Locknut 336 lb.-in. (38 N-m)

Solenoid Valve 110 lb.-in. (1.4 N-m)

SlavePistonSpring
Shoulder Bolt 00 lb.-in. (3 N-m)

INSTALLATION INSTRUCTIONS FOR 790/795/797 SERIES JACOBS ENGINE BRAKES™ 5

Section 2: Engine Preparation
Series 60 Engines with DDEC IV & V
AccessEngineOverhead
c.Disconnect10pinwiresocketlocatedon
1. DisconnectBatter intakesideoclinderblockbelownumber
six(6)intakeport.(SeeFig.6)
FAILURETODISCONNECTBATTERyMAy
CAUSEECMDAMAGE.

. Thoroughlcleanengine

3. Removevalvecoverandgasket.

NOTE: IFTHEENGINEHASATWO-PIECECOVER,
THELOWERVALVECOVERBASEDOESNOT
HAVETOBEREMOVED.

ExchangeWireHarness

Fig6
1. Removeexistinginjectorharness&mounting
clipsromclinderhead.
d.Removeharnessbmanipulatingharness
a.Separatewireharnessromclinderhead throughclinderheadpassthroughatrear
retainingclips. ohead.

b.Removeharnessmountingboltsromrear e.Removeharnessretainingclipsrom
oclinderheadatheadpassthroughholes. threadedholesinheadanddiscardclips.
(SeeFig.5) (SeeFig.7)




Fig5
Fig7

 NOTE: REMOVEENTIRECLIPS,HOLESWILL

BERE-USEDFORJACOBSSUPPLIED
HOUSINGHOLDDOWNBOLTS
NOTE: FORADDITIONALACCESSTOREAR
CyLINDERHEADPASSTHROUGH,THE
ROCKERSHAFTSMAyBEREMOVED
USINGKENTMOORETOOL#J35996A

6 INSTALLLATIONINSTRUCTIONSFOR790/795/797SERIESJACOBSENGINEBRAKES™
 . InstallnewharnessP/N3536019oron-
highwaapplicationsorP/N353444or
o-highwaapplications
a.Manipulateharnessthroughrearheadpass
through.Routeharnessconsistentto
previousharness.
b.Connectnewharnesstoinjectors.
c.Connect10pinwiringsockettomainengine
harnessandsecureharnesswithplastic
wiretiesasnecessartobrakespacer
tubes(reerenceFig11inSection3or
image).

d.Secureharnessatrearheadpassthrough
withmountingbolts.

HARNESS IS NOW READY FOR JAKE BRAKE INSTALLATION

Fig8

TAKECARENOTTODAMAGEWIRINGORCONNECTORS

INSTALLATION INSTRUCTIONS FOR 790/795/797 SERIES JACOBS ENGINE BRAKES™ 7

Section 3: Brake Housing Installation

InstaEngineBrakeHousings
3.Setront&rearJakeBrakehousingson
rockershatslocatingonretoruedstuds.
1. RemoveRockerShatAssembliesusing18mm Ensurethatmasterpistonpushrodswillengage
SocketandKentmoore#J-35996A withpocketlocatedontopoinjectorrocker
arm(seeFig.10).
NOTE: REMOVINGTHEOILFROMTHEBOLTHOLES
PREVENTSTHECyLINDERHEADFROM
CRACKINGWHENBOLTSARETIGHTENED.
ATTACHALENGTHOFTUBINGTOANAIRGUN

NOZZLEANDBLOWOUTTHEOILFROMTHE
ROCKERSHAFTHOLD-DOWNBOLTHOLES.
COVERTHEHOLESWITHHANDTOWELSTO
MINIMIZEOILSPRAy

WEARSAFETyGLASSESWHILE
BLOWINGTHEOILFROMTHEBOLT
HOLES.
Fig10
a.Removerockerarmholddownbolts
M1x100mmlong(6).
4.PositionJakeBrakemountingspacertubes
b.Removerockerarmnutsatrontandrearo
underouterhousingmountinglegs.(SeeFig.
head().
11)
c.Retoruerockershatstudslocatedatront
NOTE: TOPREVENTDAMAGETOWIREHARNESS,RUN
andrearoclinderheadat100lb.-t.(136 WIRESINBOARDOFSPACERTUBESAND
N-m)withKentmooretool#J-44706A.(See SECURETOTUBESUSINGPLASTICWIRETIES.
Fig.9)



Fig11
Fig9

.SetRockerShatAssembliesbackoncam
caps.

8 INSTALLLATIONINSTRUCTIONSFOR790/795/797SERIESJACOBSENGINEBRAKES™
 6. Toruedownbrakehousingperseuence
5. InstallJacobssuppliedmountingbolts, inFig.14at80lb.-t.(108N-m).
twolengths,andoriginalDDCstudhexnuts
removedearlier.(SeeFig.1)

B
Fig1 Fig14

A-M1x140mm-usedontheexhaustsideothe
engine
B-M1x170mm-usedonintakeside(solenoid
side)oengine
7.Veriexhaustandintakevalvelashisstillwithin
DDCspecicationsorengine.Ivalvelash
isoutotolerance,reertoDDCmanualor
resettingprocedure.
8.Attachsolenoidwirestosolenoidandengage
wiresinwireretainerclip.(SeeFig.15)

 BEFORETORqUINGENSURETHAT
WIREHARNESSISINBOARDSOASTO
 NOTE:
NOTINTERFEREWITHVALVECOVER

BEFORETIGHTENINGHOLDDOWN
BOLTS,MOVETHEHOUSINGFROM
NOTE:
SIDETOSIDEANDTHENLOCATE
HOUSINGINCENTEROFTRAVEL.(SEE
FIG.13)

Fig15

NOTE:

797BAPPLICATIONSUTILIZEADDC
WIREHARNESSTRAyWHICHISAT-
TACHEDONTOTHEREARBRAKE
HOUSING.

REFERENCETHEDDCSERIES60
ENGINESERVICEMANUALP/N6SE483
FORPROPERTRAyTORqUINGPRO-
CEDURE

Fig13

INSTALLATION INSTRUCTIONS FOR 790/795/797 SERIES JACOBS ENGINE BRAKES™ 9

 Adjust Slave Piston Clearance
4. Rechecklashsettings.Ilashsettingis
incorrect,repeatsteps(1)through(3)above

FAILURETOFOLLOWADJUSTMENT
PROCEDURESCANRESULTINENGINE
ORENGINEBRAKEDAMAGE.
NOTE: MAKESLAVEPISTONADJUSTMENTWITH
THEENGINESTOPPEDANDCOLD.ADJUST
EACHCyLINDERWITHTHEEXHAUST
VALVESINTHECLOSEDPOSITION.
 NOTE:
ONCETHEENGINEBRAKEHASBEENRUN
yOUWILLNOTBEABLETOCHECKTHEEN-
GINEBRAKEADJUSTMENT.THISISBECAUSE
OFOILRETAINEDINTHEJ-LASHADJUSTING
SCREW.IFUNSUREOFTHEADJUSTMENT,
yOUMUSTREPEATSTEPS(1)THROUGH(4)
ABOVE.

NOTE: REFERENCEJACOBSAPPLICATIONGUIDE
P/N4770FORPROPERENGINEAND
MODEL 795/797 SERIES
BRAKESPECIFICLASHSETTINGS.
1. Backouttheadjustingscrewsontheslave
pistonsuntiltheslavepistonsdonottouchthe
exhaustrockerarmadjustingscrews.
MODEL 790 SERIES
. Insertthepropereelergage(correctadjustment
1.Backouttheadjustingscrewsontheslave
isonhousingdatatag)betweentheslave
pistonsuntiltheslavepistondoesnottouchthe
pistonandtheexhaustrockeradjustingscrew.
rockerarmadjustingscrew.
Usinga3/16"(inch)hexwrenchturninthe
adjustingscrewuntiltheslavepistoncontacts
. Insertthepropereelergage(correctadjustment
theexhaustrockeradjustingscrewthroughthe
isonhousingdatatag)betweentheslave
eelergage,andadragiseltonthegage.
pistonandtheexhaustrockeradjustingscrew.
Usinga3/16"(inch)hexwrench,turninthe
adjustingscrewuntiltheslavepistoncontacts
theexhaustrockeradjustingscrewthroughthe
eelergage.Continueturningintheadjusting
screwuntilthevalvespringsbegintocompress,
thenturninone(1)additionalturn.Waitatleast
30secondsoroiltobepurgedromtheJ-Lash
adjustingscrew.

NOTE: ALLOILMUSTBEPURGEDFROM
THEJ-LASHADJUSTINGSCREW.IFOILIS
BELOW60°F,16°C,WAITATLEASTTWO
MINUTESFOROILTOBEPURGEDFROM
THEJ-LASHADJUSTINGSCREW.

SERIOUSENGINEDAMAGEMAyOCCUR
FROMIMPROPERLASHSETTING.

3. Aterthetimeintervalspeciedinstep(),back Fig16

outtheadjustingscrewONLyuntilalightdrag
iseltontheeelergage.Donotretractmore
than required to obtain a light drag on the
feeler gage. Hold the J-Lash adjusting screw
inplaceandtoruethelocknutto38N•m(336
lb-in).
3. Holdtheadjustingscrewinplaceandtorue
thelocknutto38N•m(336lb-in).Recheck
lashsettings.Ilashsettingisincorrect,repeat
steps(1)through(3)above.

NOTE: IFTHEJ-LASHADJUSTINGSCREWIS
BACKEDOUTUNTILITNOLONGER
COMPRESSESTHESLAVEPISTONSPRING,
OILWILLENTERTHESCREWANDTHE
ADJUSTMENTWILLBEINCORRECT.IFTHIS
OCCURS,REPEATSTEPS(1)AND().

OVERTORqUEOFLOCKNUTWILL
PROHIBITPROPERJ-LASHOPERATION

10 INSTALLLATIONINSTRUCTIONSFOR790/795/797SERIESJACOBSENGINEBRAKES™
Section 4: Engine Brake Controls
Series 60 Engines with DDEC IV & DDEC V
Jacobs Dash Switch (optional)

(mauseinplaceoVOEMswitch)

1. Locateanareaonthedashorthedashswitch
group,JacobsP/N00035,anddrilla"hole.
 

. PasstheloosewiresothevehicleOEMwire
ONSERIES60ENGINESEqUIPPEDWITH
harnessthroughthe"holeromthebackto
DDECIVORV,THEENGINEBRAKEIS
theront
CONTROLLEDByTHEDDECECM.USEOF
AJACOBS'SUPPLIEDCONTROLMODULE
3. Attachthewireharnesstotheswitchterminals
ISNOTREqUIRED.
ontheswitchgroupp/n00035.
CONTACTyOURVEHICLEOEMWITHyOUR
VEHICLESERIALNUMBERFORBILLOF 4. Installtheswitchassemblwiththebracket,
MATERIALSNEEDEDFORINSTALLATION. lockwashersandwingnuts(seeFig.18).

Fig17

DONOTOVERTIGHTENNUTS.SWITCH
FAILURECOULDRESULT!

NOTE: CONTACTVEHICLEOEMFORINSTALLATION
DETAILSANDWIRINGDIAGRAMOFTHE
WIRINGHARNESSANDINTERFACEWITH
DASHCONTROLSWITCH.

INSTALLATION INSTRUCTIONS FOR 790/795/797 SERIES JACOBS ENGINE BRAKES™ 11

Section 5: Engine Brake Operational Check

Bleed the engine brake housings Two-piece Rocker Cover Installation

1. Besurewiresareawarommovingparts. 1. Makesurethesealisinplaceintherocker

coverbaseandsetthecoverinplaceonthe
. Starttheengineandallowtorunoraew coverbase.
minutes.

3. Manuallactivatethesolenoidvalveseveral
timestoallowthehousingtobelledwithoil.

NOTE: THESOLENOIDVALVEISMANUALLy
ACTIVATEDByDEPRESSINGTHE
ARMATUREPINLOCATEDINTHECENTER
ONTOPOFTHESOLENOID.
SERIES60ROCKERCOVER
Fig18
Check for proper operation.

1. Manuallactivatethesolenoidvalveandwatch . Installtheboltwithafatwasher,isolatorand

themasterpistonstobesurethearemoving
downintothepocketintheinjectorrockerarm.
. Watchtheslavepistons.Theshouldmove
downtocontacttheexhaustvalverockerarm
adjustingscrews.
limitingsleeveintothecoverholes.
3. Tightentheboltsto14N•m(10lb-t)inthe
seuenceshowninFig.1.
4. Toruetheboltsto7N•m(0lb-t).

3. Checkeachhousingtobesureitisunctioning.

4. Shutdownengine. Road Test the Vehicle.

1. Roadtestthevehicle.Theenginebrakeshould
comeonwhentheswitchisintheONposition,
Rocker Cover Installation theclutchisengagedandnothrottleisbeing
applied.
One-piece Rocker Cover Installation

1. Installthesealintothegrooveinthecoverand
setthecoverinplaceontheclinderhead.

. Installtheourretainingboltswithisolatorsand
washers.

3. Startingwiththecenterboltsandworking
outward,tightentheboltstoN•m(16lb-t).

4. Presstheprotectiveplugsintothetwocenter
holes.

1 INSTALLLATIONINSTRUCTIONSFOR790/795/797SERIESJACOBSENGINEBRAKES™
Section 6: Engine Brake Maintenance

TheoryoOperation
Energizingtheenginebrakeeectivelconverts
apower-producingdieselengineintoapower-
absorbingaircompressor.Thisisaccomplished
throughmotiontranserusingamaster-slavepiston
arrangementwhichopensclinderexhaustvalves
nearthetopothenormalcompressionstroke,
releasingthecompressedclinderchargetoexhaust.
Theblowdownocompressedairtoatmospheric
pressurepreventsthereturnoenergtotheengine
pistonontheexpansionstroke.Theeectothis
actionisanetenergloss,sincetheworkdonein
compressingtheclinderchargeisnotreturned
duringtheexpansionprocess.
3. Theinjectorrockerarmbeginsitstravelasin
thenormalinjectionccle,movingthemaster
pistonupwardanddirectinghighpressureoil
totheslavepiston.Theballcheckvalveinthe
controlvalveimprisionshighpressureoilinthe
master-slavepistonsstem.
4. Highpressureoilcausestheslavepistonsto
movedown,momentarilopeningtheexhaust
valves(F),whiletheenginepistonisnearitstop
deadcenterposition,releasingcompressedair
totheexhaustmaniold.
5. Compressedairescapestotheatmosphere,
completingacompressionbrakingccle.

ExhaustBowdown
Reerringtotheschematicdrawingbelow,exhaust
blowdownoccursasollows:

1. Theenergizedsolenoidvalve(A)permitsengine
lubeoil(B)tofowunderpressurethroughthe
controlvalve(C)toboththemasterpiston(D)
andtheslavepistons(E).

. Oilpressurecausesthemasterpistontomove
down,comingtorestintheinjectorrockerarm
recess(pocket).

A
C
B
ENGINE OIL IN

ENGINE OIL OUT

E E
D

F F

Fig19

INSTALLATION INSTRUCTIONS FOR 790/795/797 SERIES JACOBS ENGINE BRAKES™ 13

 Fig0
PARTS LISTING
NEVERREMOVEANyENGINEBRAKE
COMPONENTWITHENGINERUNNING.
1SolenoidValve
PERSONALINJURyMAyRESULT
Seal,SolenoidUpper
3Seal,SolenoidCenter
5MasterPiston
6MasterPistonPushrod
7MasterPistonSpring
TheJacobsEngineBrakeistpicallatrouble-ree 8MasterPistonRetainer
device.However,inspectionsarenecessarand 9SpiroloxRing(797)
somemaintenanceisreuired.Usetheollowing 9SnapRing(790/795)
procedurestokeeptheenginebrakeintopcondition. 10AdjustingScrewLockNut
11SolidScrew(795/797)
Thissectioncovershowtoproperlremove,clean 11J-Lash(790)
andreinstallenginebrakecomponents.Usean 1SlavePiston
OSHA-approvedcleaningsolventwhenwashing 13SlavePistonSpringGroup
parts.Besuretocoatpartswithcleanengineoil 17RetainingRing
whenreinstallingthem. 18Washer
19InnerControlValveSpring
0OuterControlValveSpring
1ControlValve
PipePlug
3DriveScrew
4WireHarnessClip
5CapScrew
6CapScrew
7SpacerTube
Fig1
14 INSTALLLATIONINSTRUCTIONSFOR790/795/797SERIESJACOBSENGINEBRAKES™
 ControVave
5. Washthecontrolvalveswithapprovedcleaning
solventPushawirethroughtheholeinthe
bottomothevalvetoinsurethattheballcheck
isree(seeFig.).Theballshouldlitwithlight
pressureonthewire.Itheballisstuckinthe
REMOVECONTROLVALVECOVERS
CAREFULLy.CONTROLVALVECOVERSARE
valve,thecontrolvalveshouldbereplaced.Dr
UNDERLOADFROMTHECONTROLVALVE thevalvewithcompressedairandwipeclean
SPRINGS.REMOVEWITHCARETOAVOID withapapertowel.
PERSONALINJURy.

1. Pressdownoncontrolvalvewasherusingthe
controlvalvecoverremovaltool,Jacobsp/n
16978torelievespringpressure(SeeFig.1)

Fig

6. Thoroughlcleanthecontrolvalveboreinthe
housingusingcleanpapertowels.
Fig1
7. Dipthecontrolvalvesincleanlubeoil.Holding
thevalvebthestem,guideitintotheborethen
. Removeretainingringusingretainingringpliers allowthevalvetodecendtothebottomothe
(SeeFig.1). borebitsownweight.Ibindingoccurs,the
controlvalveshouldbereplaced.Reassemble
3. Slowlremovecoveruntilpressureceases,then partsreversingtheremovalprocedure.Besure
removethetwocontrolvalvesprings. retainingringearsarerotated90º(degrees)ater
installationtoensureullengagement.
4. Usingneedle-nosepliers,reachintothebore
andgraspthestemothecontrolvalve.
Removethecontrolvalve.

8
INSTALLATION INSTRUCTIONS FOR 790/795/797 SERIES JACOBS ENGINE BRAKES™ 15
SavePistonAdjustingScrew
MODEl790SERIES
1. Loosentheslavepistonadjustingscrewlocknut
andremovetheJ-Lashadjustingscrewrom
thehousing.Cleaninapprovedcleaning
solvent.
. InspecttheJ-Lashassembltoassurethe
plungerisretainedinthescrewbod,bpulling
ontheplungerwithngers.Theplungershould
retractsmoothlandcompletelunderpressure
inotreplaceentireassembl.
NOTE:AMODERATETOHEAVySPRINGFORCE
WILLBEPRESENTBEHINDTHEPLUNGERIF
OILISSTILLTRAPPEDINTHEASSEMBLy.
3. PlacetheJ-Lashassemblintotheslavepiston
adjustingscrewboreandreplaceadjusting
screwlocknut.
NOTE:DONOTEXCEEDLOCKNUTTORqUE.THIS
WILLHINDERPLUNGERMOVEMENTAND
CAUSEENGINEBRAKEPERFORMANCE
PROBLEMS.
Fig3
SoidScrew
MODEl795/797SERIES
1. Removethesolidscrews.
.Cleanthesolidscrewsinapprovedcleaning
solvent.Inspectorexcessivewearordamage.
Replaceinecessar.
16 INSTALLLATIONINSTRUCTIONSFOR790/795/797SERIESJACOBSENGINEBRAKES™
SoenoidVave
 DONOTDISASSEMBLEORTAMPERWITH
THESOLENOIDVALVE.ENGINEDAMAGE
COULDRESULT.
1. Disconnectsolenoidvalveharness.Using3/4"
socketandextension,unscrewsolenoidvalve.
. Removeanddiscardthetworubbersealrings.
Itheringsstainthehousingbore,remove
withapieceowire.
3. Washoutthesolenoidvalvewithapproved
cleaningsolvent.Useabrushtocleantheoil
screen.Risethesolenoidvalveincleaning
solvent.
4. Cleanoutthesolenoidvalveboreinthe
housing.Usecleanpapertowels.Neveruse
rags,asthemaleavelintandresiduewhich
canplugtheoilpassagewas.
5.Coatnewsolenoidvalvesealringswithclean
lubeoil.Installthesealringsontothesolenoid
valvebod.Becareulnottotwisttheseal
whileinstalling.
Fig4
6.Besurethesealsareseatedproperl.Careull
screwthesolenoidvalveintothehousing
withoutunseatingtheseals.Toruethevalveto
110lb.-in.(1.4N-m).
MasterPiston
MODEl797SERIES
MODEl790/795SERIES

1. Compressmasterpistonretainerandremove 1. Usemechanic'spicktowedgescrewdriver

snapringusingretainingringpliers(.047" bladebeneathspiroloxring(SeeFig.6).
diameter,45˚).(SeeFig.5)

REMOVESNAPRINGCAREFULLy.MASTER
PISTONISUNDERLOADFROMTHE
SPRING.REMOVEWITHCARETOAVOID
PERSONALINJURy.

Fig6

.Rotatescrewdriverarounddiametertounwind
spirolox.Removeanddiscardspiroloxring-it
cannotbereused(SeeFig.7).

REMOVESNAPRINGCAREFULLy.MASTER
PISTONISUNDERLOADFROMTHE
Fig5 SPRING.REMOVEWITHCARETOAVOID
PERSONALINJURy.

. Removemasterpistonpushrod,retainer,spring
andmasterpiston.

3. Cleanthemasterpistoninapprovedcleaning
solvent.Inspectorexcessivewearordamage.
Replaceinecessar.Inspectthemasterpiston
bore.Somewearmarksarepermissible.Appl
cleanlubeoiltothepistonandinsertintobore.
Masterpistonshouldmoveinandoutreel
withnobinding.Ibindingoccurs,replace
masterpistonand/orhousing.
Fig7
5. Reassemblethemasterpiston,pushrod,spring,
andretainerinhousing.Besuretorotatesnap
ring90º(degrees)aterinstallation.
3.Removemasterpistonpushrod,retainer,spring
 andmasterpiston.
NOTE:THESPRINGSHOULDHOLDTHEMASTER
PISTONCOMPLETELyINTHEHOUSING.IF
4. Cleanthemasterpistoninapprovedcleaning
NOT,THESPRINGHASRELAXEDANDMUST solvent.Inspectorexcessivewearordamage.
BEREPLACED. Replaceinecessar.Inspectthemasterpiston
bore.Somewearmarksarepermissible.Appl
NOTE:THESMALLERDIAMETERENDOFTHE cleanlubeoiltothepistonandinsertintobore.
SPRINGENGAGESTOTHEMASTERPISTON
Masterpistonshouldmoveinandoutreel
PUSHRODBALLEND.SPRINGMUSTNOT
EXPANDOVERBALLEND. withnobinding.Ibindingoccurs,replace
masterpistonand/orhousing.

INSTALLATION INSTRUCTIONS FOR 790/795/797 SERIES JACOBS ENGINE BRAKES™ 17

 5.Reassemblemasterpiston,pushrod,spring,
retainer,andspiroloxringinhousingusing b.Engagemasterpistonassembltoolintobore.
masterpistonassembltoolJ-45976.(SeeFig. Ridgewillengagewithborechamer.
8)
c.Pushdownonspiroloxuntilitsnapsintoplace.
NOTE:WHENPLACINGRETAINERINTOBORE (SeeFig.31)
-PARTNUMBERSHOULDBEVISIBLE.

Fig8
Fig31

a.Loadspiroloxintotapperedring.(SeeFig.9)

NOTE:THESPRINGSHOULDHOLDTHEMASTER
PISTONCOMPLETELyINTHEHOUSING.IF
NOT,THESPRINGHASRELAXEDANDMUST
BEREPLACED.

NOTE:THESMALLERDIAMETERENDOFTHE
SPRINGENGAGESTOTHEMASTERPISTON
PUSHRODBALLEND.SPRINGMUSTNOT
EXPANDOVERBALLEND.

Fig9

Fig30

18 INSTALLLATIONINSTRUCTIONSFOR790/795/797SERIESJACOBSENGINEBRAKES™
SavePistons

1. Removeslavepistonshoulderbolts.

NOTE:SPRINGPRESSUREWILLBERELEASEDAS
BOLTISREMOVED.THEREWILLBENO
SPRINGPRESSUREREMAININGPRIORTO
BOLTBEINGCOMPLETELyDISENGAGED.

Fig30

. Removesprings,bridge,andslavepistons.

3. Cleantheslavepistonsinapprovedcleaning
solvent.Inspectorexcessivewearordamage.
Replaceinecessar.

4.Ensureslavepistonborehasnoburrsorridges,
isoremovewithamachinistdeburringtool.
Donothonetheslavepistonbore.Removal
otoomuchmaterialwillreducebraking
perormance.

5. Reassemblecomponents.Torueshoulderbolt
00lb.-in.(3N-m).

OVERTORqUEWILLFRACTUREBOLT.

INSTALLATION INSTRUCTIONS FOR 790/795/797 SERIES JACOBS ENGINE BRAKES™ 19

JacobsVehicleSstems VisitusontheInternet:
EastDudleTownRoad www.JAKEBRAKE.COM
Bloomeld,CT0600
P/N 9901 Rev. B ©004 Jacobs Vehicle Sstems, Inc. Printed in U.S.A. Rev. 1/06