Installation/Maintenance Manual for Model 122 Engine Brake ‘The Model 122 Jako Brake® Engine Retarder is designed for use on Volvo 12 iter diesel engines TD 120, TD 121 and TD 122. Reer to Jacobs Service Letters and instructional Iterature for specific application information. Information contained in this manual was ‘current atthe time of printing and is subject to change without notice ‘or lability ‘See Jacobs Driver's Manual ‘or proper engine bake This rot i covred by US. Patt No, 425% 051 Cher US. an rin pte iSoedorpote, te Jae rate agate ol dace Vion Calpnart Corea ‘poiatiae hep ntonca Power aston ener! heats Ven ee “Tee Joke Bro Retardorle avotisia stow SAKE AEBRAKE nea. ay boused te bring he vanisie oa eomplate Sacobs® orice ‘Equipment Company 22 East Dudley Town Road Bloomfield, CT 06002 U.S.A 203-243-1441 (©1002 Jacob Voile EqupmantCompary PrtedinUSA 02Ue (caution Nore: ‘TABLE OF CONTENTS: ‘SECTION + INTRODUCTOON..... = a4 ENGINE PREPARATION, 8 seCTION® ENGINE BRAKE INSTALLATION 7 SECTIONS ELECTRICAL SYSTEM INSTALLATION oon SECTIONS. SECTIONS MAINTENANCE/SPECIFICATIONS ons 1S47 SECTION? {TROUBLESHOOTING 1021 ‘SAFETY PRECAUTIONS. ‘The following symbols in this manual signal potentially dangerous conditions tothe mechanic or equipment. Read this manual care fully Know when these conltions can exist. Thon ake necessary ‘eps to protect personnel as well as equipment. ‘This symbol warns of possible personal Injury. ‘Thia symbol rters to possbie equipment damage, n operation, procedure or Instruction thet Is Important for Fuels, electrical equipment, exhaust gases and moving engine pans resent potnial hazards hat could result in persona injury. Take ‘ae when installing an engine rake. Always wear eye protection, Always use correct tools and proper procedures as outlined in this ‘manual ‘SECTION 1 INTRODUCTION ScHEMATC DIAGRAMOF ENGINE BRAKE OPERATION. A MODEL 122 voLvO antes NASTER-SLAVE CIRCUTTRELATIONSHIP LOCATIONOFMASTER _LOCATIONOF SLAVE RETATES No.1 pusHTUBE 'NO.9 EXHUAST VALVE. No.8 PUSHTUBE NNO. EXHAUST VALVE. No.3 PUSHTUBE NNO. EXHAUST VALVE. No.2 PUSHTUBE NO. EXHAUST VALVE. NO. 4 PUSHTUBE NO. EXHAUST VALVE. THEORY OF OPERATION - Simply stated, energizing the Engre Brake effectively conversa power producing sel engine into a power absorbing air compressor. ‘Tas is accomplished, when desired, by hoton wanster through a master-slave piston arrangement which opens the cylinder exhaust valve near the top of te normal compression stroke, releasing the compressed eylinder ‘charge to exhaust ‘The Blowdown of compressed air atmospheric pressure prevents the retum of energy to the engine piston on the expansion suoke, the effect being u net ence loss since the work done in compressing the cylinder charge is not retumed during the expansion proces. Exhaust blowdown of the braking eyliner is accomplished by utilizing the pushtube motion of fm exhaust valve of ancter eyinder during its normal exhaust eycle a follows 1. Energizing te solenoid valve pemmits engine Tube ot flow, under pressure, through the ‘contro valve o both the master piston and he slave piston 2 Oil pressure causes the mate piston to move down, coming to rest on te corresponding exhaust rocker arm ajsting screw. (Soe Table No. I for master-slave operating reltonsti. 3, The Exhaust rocker pushtube egin upward travel (asin noma exhaust eyee) forcing the ‘master piston upward and creating & high ‘pressure ol flow to the slave piston braking tylinder. The ball check valve inthe contol ‘valve tps high pressure olin the master- slave piston circuit 4 The slave piston under the infuence of the high pressure ol low moves down, momentarily ‘opening the exhaust valve while the engine piston is near its top dead cxner position, releasing compressed cylinder arto the exhaust manifold 5, Compressed sirescapes to atomspher, completeing& compression raking cyele‘METHOD OF DRIVING VEHICLE EQUIPPED WITH A JACOBS ENGINE BRAKE 11s easy to Ieam the proper method of driving 8 vehicle thats equipped witha Jacobs Engine Brake. Since the engine brake is most effective at higher engine speeds, gear selection is very important. Gearing down the vehicle ‘within the limits of recommeded engine speed makes the engine brake a more effective retarder. Maximum retarding ‘occurs wih the solecton of the lowest gear that prevents exceeding the maximum allowable engine speed. “The Engine Brake kits contain a progressive switch that provides three-orsix-eyiner operation for greater flexibility in selecting tbe amount of retarding needed for various road conditions. For more information on diving withthe Jake Brake, consult your owners Driver's Manual. To get a detailed presentation on diving withthe Jacobs Engine Brake, consult your Jacobs Distributor, SECTION 1 INTRODUCTION (CONTINUED) ‘Torque Specifications Part Name Torque ‘Sus Nat 01H 40 em) Bula Aseptor sane. 09m Evotial Cnmetor Youd (la teny ‘SpacerCapacows 148A (1010) Brake Hold-down Nuts 3006 (ON) Bate Pesionng Sorewe ‘Spin. (08 Nem) Bate Pestonng Screw Nuts 2st (958m) Benj-ting Seems ‘aie. (19m) Hoce Nut 148A 190m) ‘Gover Bot 4b 13m) ‘Special Tools Needed Feel gauge 0.059. (1.50 mm) ‘16 Hox wrench Volvo Maintenance Manual ‘Slave Piston Lash Adjustment ‘Volvo 12 Liter Engines Englne Brake Model Slave Paton Lash Adlustment 0120, T0 124, T0122 we (0.080 (150mm) ‘SECTION 2 ENGINE PREPARATION NOTE: No. 1 mastr pion feeds No. 3 slave Plsionin ront brake assembly. No, Sas {or piston feods No, 4 slave piston in rear broke assombly. JAKE BRAKE MODEL 122 - a, IN: iow | STALLATION 1. Removeengine front lifing bracket and irfilter. Bend freeendof| air filter support bracket 90 degres toward rea of engine. Re- ‘mount air flker and modified brakes with first intake manifold 2. Using a tube cutter, cut fusl pump aneroid tube at horizontal section above the cylinder heads between heads No. t and [No.2 leaving about 3. (76 mm) onthe horizontal. Discantend ‘contected toairintake manifold. Bend fev end90 degrees toward ‘rot of engine. See Fig. 1. 3. Disconnect extiaust brake airhose and tbe at support bracket on intake manifold, 4, Remove six Volvo valve covers, saving capserews. Discard the ‘washers gaskets. Removeoil filleapand install on frontJacobs ‘5. Loosen all rocker adjusting serew nus and back off crews unit loowe. secTion2 FiatWak ospine see rT / Ei Fig? Fo.9 66. Remove pedestal capscrews and discard, Take pedestals trom the engine and pace inorder, by cylinder, ona workbench, 7. Remove exhaust rocker adjusting serew nuts and replace with Jacobs adjusting serews. Reuse Volvo nuts. 8. Replace six exhaust valve caps with Jacobs valve caps (Fig. 2). ‘Spacer installation 1, Install balkhesd adaptor and sel into each spacer frm the ‘otto leave loose. 2, Install electical connector ito each space fom the baton; torque to 10 182, (14 Nem). Install dee ew gaskets into each space. ‘4, Mount spacers onto engine. Use Volvo cover eapserews and Jacobs washers; torque to 14 bt (19 Nem)- Make Sure spacer is ‘entered overheads and that there is no interference with valve springs. Podesta! Installation 1, Clean drt and ol from the pedestal mounting holes in heads. 2, Place each pedestal ont its original eylinder head poston. 3, Insall amounting shim into slot in each pedestal. See Fig. 3. ‘One endof shim is notched to clear the dowel pin inthe rocker shaft. Visually locate dowel pin i slot before installation, Make ‘site that shims do not touch the intake or exhaust rocket levers. 4, nial studs with ston threaded end down; band ghten, ‘5. Center each rocker shalt in pedestal. Check that each rocker lever can move fealy, 6, Install mut onto the stud on uncloted side of pedestal only. SECTION? SECTION 3 BRAKE INSTALLATION Intake/Exhaust Valve and Slave Piston Adjustment a1 4 5. AUTON ‘Won instaing or removing thls engine bra al tube nuts must be Ugh. Loosen ‘only stbeloretighoning holdout (G20 Section 3 Brake ination} Engine ‘rake damage can eau. ‘Torque 30 Ib (40 Nem) ‘Loosen slave piston adjusting sorews (safety sorew assemblies.) Referto Fig 1 and place brake assemblies over studs. Make sure that Jake Brake slave pistons centr onthe valve caps. ‘Loosen all ube fiting nis on brake assemblies. Install hold-down nus. Torque 10 30 Ib. (40 Nem). ‘Loosen nits on ant-tcking set screws. Set anl-rocking set screws 1o touch heads of spacer capscrews. Use 3/16 (S mim) hex wrench and torgue to 5 Ibn. (0.6 Nem), Torque nit 25 Ibi. GA Nem). ‘Attach ine ol suppy tbe from each spacer to supply housing (Fg. 1). Tighten banjo-iting serews into supply housings. ‘Torque to 14 Ibh. (19 Nem) Tighten tube mats 16 tm past hand tight (1 hex fla. Move high pressure tubes as required 10 make connection. ‘Retghten all tube nuts 1/6 tum past hand tight (1 ex fat). ‘Connect solenoid wires from each solenoid to terminal nthe spacer Nore: [As necossary, oats engine crankshaft to Deaton whore exhaust valve le closed Set intake valve lash and exhaust valve lash por Volvo specif- before making these settings, ‘ation, Torgue adjusting serew nuts to 30 Ibe (40 Ne), “After exhaust valve ajusimen, the slave piston adjustment can ‘be made. With the exhaust valves in the closed position (rocker ‘arm loose), st slave piston lash using 8 0.059 in (1.50 mm) feeler gauge. Tore locknuts 0 18.5 Ibf. 23 Nex), ‘Supply Installation Remove existing adaptors and connettng hardware from sccesibe ol gallery ports) on engine. Install suitable Jacobs adaptors. Reatlach Volvo connecting hardware. Connect one ol supply hose (elbow end) to the bulkhead adaptor on each spacer. Then torque the bulkhead adaptors 10 14 foh. 19 Nem), ‘Connect one hose to gallery fom bulkhead adaptor on front spacer. Torque each hose nu to 14 bt. (19 Nem). ‘Connect one hose wo gallery from bulkhead adaptor on rear spacer. Torgue each hose ut to 14 Tb. (19 Ne). Install clamps on hoses (Fg. 1) or as required, sections 7Installation of Covers, 1. Install new Jacobs valve cover gasket nto tbe groove in each cover, Ovelap the gasket about 1.0 in. (254mm) and cut ‘ppropsate length. Be sure thee isa gap at each end of gasket See Fig. 4 2, Place covers over brake assemblies, Install bolts and washers ‘Tongue to 14 bf. (19 Nem). Anerold Tube Installation Connect sneroid tbe extension fre intake manifold to cutolf end ofthe original Volvo aneroid tube, Use te tube union wo connect the free ends, Cut Jacobs aneroid tbe to length, as required Connect 10 the intake manifold using the loose ferrule ad we nut Tighten as, follows: 1 Oil he ferrule, cone and threads 2, Place nut and ferrule oato tub. ‘3. With the end ofthe tube firmly seated in the mating coupling tbody, ighten the nut 13/4 tums pest hand tight, For reuse, tighten 1/6 tn (1 ex fa, 4, Referto Fig. 1 Install clamp on tbe. (n engines without intercooler, install sence spacer between snake manifold and turbocharger to raise eross-over pipe Remove exhaust brake air hose bracket from mount. manifold Reinstall with Jacobs spacer tube, washes Reconnect exhaust brake air hose and ube intake secTions SECTION 4 ELECTRICAL SYSTEM INSTALLATION Keaurion ‘Botore porting any work, daconnect postive Datlary ied and insulate. Fallre to flow thls precautlon could led te equlpment damoge, Dash Switch Install dhe dash switch ina convenient location in the cab, Use available switch mount location (Fig, 5), Bend abs on dash mount ing plate as required. Carefully measure and ext all hamesses to proper length. Install eceptates and connect at locations shown in| wiring diagram (Fig. 8) Cluteh Switeh 1. Mount the clutch switch i the most convenient or aeessible Tocation possible. Locations may include in eab under dash, ‘nde dor wheel well oF in area of the bel housing. 2. Install switch with the switch actuator arm in contac with the clutch pedal arm or osereluch member. 3. Adjust dhe switch by moving the switch along the mounting bracket The actuator au should be defied 1.015 (25-38 mm), measured atthe tip ofthe actuator, when the cutch peat is in the up (luc engaged) position. 4. Check installation by moving the elutch pedal. The switch sould click in the freeplay modion of te clutch pedal before ‘ctu elutch disengagement ake plac. 5. Cutwires to proper length and secure them with tes, Connect the wires as shown in the wiring diagram (Fig. 8) Low Engine Speed Retarder Cut-Off System ‘The low engine speed retarder cut-off system sa fully automatic engine bake contol system that Senses engine speed (RPM) and electrically deactivates the engine brake at speeds below approxi ‘mately 900 RPM. The Iv speed cut-off feature ensures uelng will rot take place while braking a ow engine speeds, I provides a diver convenience in frequent stop/tart operations and is useful for ‘operations whore several drivers may operate one vehicle. “The kit consists ofa low speed rtader cut-off module (Fig), relay and wiring hamesses, The module can be mounted in the engine ‘compartment on the firewall or other convenient location Installs ton instructions, P/N T8391, are included inthe Kt and on page 8 of this mana ‘secon 4 Excoouing in. detection ofthescutator ‘amma cause och damage ‘gine bake maltuntion.Electical System installation for Model 122 nore: Sogo lead wire systems require a diode ‘8 the fuel swheh for switch protection ‘See Fig. 8. There no diode required for ‘wo wie systems. [Acaurion DO NOT connect battery voltage rectly tothe ESSD ori willbe destroyed. 0 Low Speed Switch Instructions 1. Mount the ESSD and Relay Block Assembly inside the vehicle ‘ab withthe main vehicle electrical connections 22, Connect the BROWN wire from the Relay Block to Number "#" ‘erminal onthe ESSD. 3, Connect the GREY wire from the Relay Block to the main fed ofthe engine brake circuit, 44 Connect the GREEN wire fom the Relay Block tothe vehicle's positive ignition feed via a circuit beaker or fase (10 Amp). 5. Connect the PURPLE wire from the Relay Block to the ve- icle's positive ignition feed. 6. Cone:t one end ofthe BLACK wire to teminals Number" and "3" on the ESSD; connect the ctr end toa negative vehicle ground. Connect one end ofthe Signal Cable 0 Number “Irena on the ESSD,; connect the other end tothe signal source (vehicle allemaior AC ouput. 8, Check that ll connections are secure. SECTION s Fuel Switch Referto wiring diagram on page 10 and (Fig. 9). reo 1 Mtl evich nat se de pkg inure wc cen eg Se cco ttn cet le Tolono 2. Cisco ie ed Ase. VON yg es specifications. 3. Loosen the two mounting screws on the fuel switch. Position the switch actuator arm 10 touch the trotle lever by moving the ‘switch along the mounting bracket, Carefully bend the actuator arm on the switch to make a fina adjustment, if necessary. ‘Move the switch into te trode lever una llc is heard. ‘Then move the switch in an aditional 0.125 in (3 mm, ‘Tighten the site mounting crews, "‘SECTIONS OPERATION CHECK (Check Solenoid - With engine shot down and the electrical system ‘tumed on (key switch on and clutch engaged), turn the engine brake ‘ash switch on, The solenoid valve armatures (discs) should move own, Bleed Brake Assemblies and Check Operation - Star engine and allow to tun 5 1 10 minutes. With the engine brake sich of, 1} soceerate engine o approximately 1800 RPM Release throtle and cleaticaly advate of manually depress cach solenoid valve die i Repeat his procedure five of sx imes to permit engine oi oil te brake housings. Engine oil pressure must be atleast 20 pl to operate the engine Take See Char in Maintenance/Specifications Section ‘Check Low Speed Control - With brake switched off, increase ‘engine RPM slowly and verity thatthe low speed relay activates at ‘approximately 900 RPM, Failure to Activate - If solenoid valve fais to activate or any of| ‘he master pistons or save pistons do not move when solenoid valves ae activated, shut down te engine and check: 1. Solenoid Valve Ifa solenoid valve doesnot activate, use a ‘volv/ampfohm mcterto check the voltage to the solenoid valve. Refer tothe solenoid valve specifications char in Maintenance) Specifications Section + there is pot proper voltage othe solenid valves, check all ‘wiring and connections. Repair as require. + Ifthere i proper vliage to the solenoid valve and it des not ‘etivate, disconnect the wire wo the solenoid valve. Check Use {ground strapon the sie ofthe solenoid valve. fit is broken or loose, replace the solenoid valve I + Ihe solenoid valve doesnot mee specifications, replace it 1 (Check de solenoid valve spetifcations chart in Msintenance/ ‘Specifications Section 2. Hany ofthe pistons fal to activate, check master piston, con valve and slave piston according tothe Maintenance/Specitcs tions Section. SECTIONS SECTION 6 ENGINE BRAKE MAINTENANCE/SPECIFICATIONS Fa10 “The Jacobs Engine Brake is typically wouble-ree. However, pesi- ‘dic inspoctons are recommended and Some maintenance may be ‘required. Jacobs recommends the following maintenance atthe ime of engine overhaul Never remove any engine brake compo rent with engine running, Personal nry rey raul ‘This section covers how to property remove, clean and reinstall engine brake components. Use cleaning solvent to clean pats. Be Sure wo coat parts with clean engine oll when reinstalling them, Brake assemblies must be removed frm the engine to perform maintenance operations forte save piston and master piston. Ee Gieurox ] When Instaling oF removing this engine 0 ight. Loosen tnlyjutbetoretghteingholsaownests. See Section 9 Brake instalation. Engine brake damage can rut. secrions.Control valve Remove control valve covers caretily Control valve covers are under load rom the contol valve springs. Remove with ‘cate to avold personal injury 1. Press down on contol valve cover to relieve spring pressure and remove screw. See Fig. II 2, Slowly remove the cover unt spring pressure is reieved. Remove the two springs and use needie-nose piers to remove the control valve Fig. 10) ‘Wash the control valves with leaning solvent and inspect as follows: Push a wire through the ole inthe base ofthe contol valve to ensure tat the check balls fe, The ball should it wi ight pressure onthe wire. If the balls stuck or there is no spring pressure, replace the control valve with anew one ‘Thoroughly clan the control valve bore in the housing, using clean paper towels Dip the contol valves in clean lube of and replace the valve int ts bore. If there is any binding, replace ‘the contol valve with anew one. 6, Reinstall the springs, cover and serew, Torque the screw 10 9 bt (12 Nem). Slave Piston AXwarwinc. ‘Wosr safety lasses ae 1 Remove the locknut fom the safety screw assembly, Back out the safety serew assembly unl the save piston is Fully retracted (sere is loos), 2. Place th hole in the Jacob slave piston tool, PIN 17397, lover the safety screw assembly. Remove save piston carefully. The slave pistons retainedby opringsth heavy compression. th srenottolonedandpropertecisnotused, thosprngeouldbedachorgedlhencugh fe. Toree te eause porsona Injury. 3, Tumihe handle slowly until the retainer is depressed about 1 1mm, relieving pressure agaist the retaining ring Fig. 12 “ secTions 4, Remove the retaining ring with retaining ring piers, Back ou the halder util the springs ate loose. Remove the tol 5, Remove ll components, checking that there is no binding oF burrs. Clean in a leaning solvent or replace as necessary 6. Chek the top surface ofthe slave piston, If the contact area ‘wih the adjuring sorew has a dep larger Dhan 0,002 in {205 mm), replace the slave piston and adjusting sexew. Run a sll wire through the hole, Replace the piston if the ‘outside diameter is sraiched or scored, note: ‘Be sure components ao reassembled In proper order (Fg 10) 7. Use clamp fixture to reinsall piston and springs. Be sue eain- ng ring is placed on the retainer before screwing the clamp holder down over the slave piston, 8, Compress the slave piston springs un the retainers about 1 sm below the aig ring groove. Reinstall the eaining ring. Be sure the retaining rng is fully seated in the groove. 9, Remove the clamp fixture slowly to propery seat retaining sng 10, Assemble safety screw assembly and nut; do not tighten Sately Screw Assembly Reaurion De not disassemble or tamper withthe ‘ajusting sere Engine aamage could result 1. Loosen the safety screw assembly locknut and remove from baising. Se Fig. 10. Inspect the sore. The plunger should protrude from the bottom, ofthe serew 0.1765 +/-0.0085 in. (4.48 /-0.22 mm) and should reset itself quickly from a fully depressed condition, 3. Clean with cleaning solvent before reusing or replace, if nec essary, The safety serew assembly is not to be serviced.Hold pring whoo ‘Tho taba shouldbe equally spaced from Nore: tha raised piston ares (ig. 13). De not dasssemble of tamper with the solneld valve. Engine damage could re AcauTion Fa 13 Fig. 14 Master Piston 1 Remove the screw, washer and master piston sping from the bottom of housing, 2. Remove master piston fom its bore (Fig, 10) using needle nose pliers 1 binding occurs, check for burs or excessive wear on fs outer surface, Inspec the hard face surface, Pte, chipped, cracked or galled pistons sould be replaced unard facing camage,inpecthe cor responding rocker arm adjusting screws {or excessive wear or piling, Replace, i eae 3. Check master piston bore for wear If damaged, replace the housing. 4, Reasemble in reverse onder, When tightening the capserew, make certain the two spring tabs are centered on and do not interfere with the sides of the master piston center raised por tion. Torque the cpscrew to 9 Ibn. (12 Nem, Solenoid Valve 1 Discoanect wire) fom the solenoid valves. Using 278i. (22mm), 12 point socket and extension, unscrew solenoid valves. 2, Remove and discard the tree rubber sel sings ftom each solenoid valve (Fig. 14). Ifthe lower sing says inte botom of the housing solenold valve bore, remove witha seal pick, 3, Wash out the solenoid valve with approved cleaning solvent ‘Use a brush to clean the oil seen and rinse in solvent 4, Clean out the solenoid valve bore in the housing. Use clean Duper towels. Never use regs as they may leave lit and residue Which can plug the oil passageways, 5. Using new solenoid valve seal rings, coat dhe with clean Tube ‘il. natal the upper and center sel rng on the solenaid valve body and te lower sel ring into the bottom ofthe solenoid valve bore in the Bousing 6, Be sure the seal rings are seated properly and carefully serew tte solenoid valve into housing without unseating the sal “Torque to 5 Il (7 Nem) Be Careful not wo vist the seals while isting Solenoid Valve Specifications ‘The solenoid valve cannot be overhauled o repaired inthe fed. IF caher than a seal rng failures occurs, the solenoid valve must be re- Placed, The any way to determin a propery operating solenoid Valve cols wih 2 voluamp/ohim meter. If your reaings do not compare withthe specifications in Chart 1, the solenoid valve must be replaced, Chart 1 Reslatance Check (Ohms) 24 voc r2voe (rust be check a the slots va) aid 70 aap. 0.09.6) 215285 a7s1075 Het (0-109 og.) 45513 tea current raw with 26 VOC applied (Amps) ald 70 deg F 20 cn C) "082.069 sates Het (0-100 op.) 4705s Oiaaoe Pullin Vetage (min) (Vas OC) Cold 70 ag F (20 dap. 6) "7 7s Het'176:212dep. (80-100 cag.c) 21 as ll Pressure Specitications Proper operation ofthe engine brake can only occur when the engine ‘il pressure supplied tothe engine brake housing is within the ‘operating range ofthe contol valvespring combination. See Chart 2 (il pressure below minimum will ease erati brake operation. Oil pressure above maximum cause the engine brake to sip Functioning ently. Chart 2 Control. ContrelVaWve Mla, Operating Maximus ValeePN “Springs Pat" Prossure” Prossure 11800 t¥e2a/10049 opel topPossible Cause Correction = = Problem SECTION? TROUBLE SHOOTING gine be sow to opente orveseinetes Problem Possible Cause Correction Fag ow 1. Saesod vale “om, ——~—=1, Tome camer ff w engine bcs, 2. Solid valve sustin“ant 2, Relic solid ae. Engine bake wilree 1. Blown fs openleaial 1, Bele eplcing an (Wamp) oo fer ow tea Sisto in ing, Rel any re, bets orcad wires Cok slen ‘ale emia fori of shoring place ‘oad ave itctemy 2. Dashswieh,ichsvich, 2, Use a yolvohm meer make cern hat rote sichout fades Dereielcnal ue aalie tn mentor defective tein teach swe. Read needed croc vag wl pass rough sc syetem energised 2 Incase power 3, Powersupply mist be within pcia- ne fone shown noi valve spon tn, car 2 Recomended power Suis tom hy with Peston, Check a ower ot asa froma sou id an atonal tt sh ii sch 4. Lowergne i pessir—temin oi presi at Jake rae See har oro prea eqns in alnerancetspestsioe Secon rol presi elo pita, Coyne shout aed in acrcance sath aru proses Engine brake activates with 1+ Engine brakeimproperly |, Check witing in accordance with engine ‘switches open (off), wired. brake wiring diagrams, 2 Camerseal sing orscenid 2. Retove slid, Replace al seal ns SECTION. Lube oil cold and thick 2, Improper stave piston adjust rent or slave piston binding indore 3. Upperorlower solenoid seal ring damaged, allowing oil to eit housing. 4, Solenoid sereen clogged, re- Stlcting supply of ofl o Jake Brake 5. Master piston not moving in bor. 6. Control valves binding in housing bor, 7. Contol valve defective 8, Switch operation uggs: check! * Dashswiteh + Clutchswiten + Throttle switch 1. Allow engine to warm before operating brakes 2. Readjust in accordance with Jacobs proce: dures for this brake model. Check that the ‘lave piston responds smoothly 1 the adjusting crew by loosening jam nut and ‘screwing the serew through is fll travel, ‘Make sue slave piston travels full ange ‘without binding o ticking, Remove slave piston carefully when disassembly is necessary. Use slave piston removal tool, tavailabe, oran BSrbor press of c-clamp, Slave piston springs are under heavy compression. 3, Remove solenoid valve and replace all sel rings. 4. Remove solenoid valve and clean the ‘5. Inspect master piston and bore for scoring ‘or bus any present, clean surface with ‘crocus cloth, Irbinding contines, replace ‘master piston or housing. 6. Remove contol valve, lean housing and control valve. I'binding continues, replace control valve andr housing as required 7. Remove contol valve, Make sure check bali eating in bre and can be moved of seat. Make sure there is spring pressure ‘against ball. Fish in cleaning solve. Replace if necessary 8. Readjust or replace switch. Check throtde ‘orelutch rtm springs fr proper opers-Problem Possible Cause Correction Problem Weak solenoid valve, 9. Check solenoid valve using electical specifications explained in this manual, Do not touch electrical connection ‘whon eystom is energized, gine brake slow 10 9 operate or weak in effect. (Contd) One or more eylinders fll 10 stop braking or engine stalls Slow brake turnoff (Check plugs for signs of leaks. leaks are ‘resent, remove plug, clean threads and reinstall 10, Engine brake housing plugs 10. leaking 11, Outer control valve spring 11 broken. [spring is broken, replace 12, Engine oil pressure ex 2, tremely high. Se Chart 1 in ‘Maintenance/Specifcations ‘Consult appropriate engine epair manual for causes of high lube ail pressure, Possible Cause 1. Control valve inner spring broken. 2. One or more conirol valves stuck in “on” oF up position, 3. Solenoid valve sticking in “on” position. 4. Solenoid valve exhaust plugged. 5. Clutch switch or trom switch stuck ia “on” positon oroat of adjustment, Correction 1. Replace inner sping 2. Check cont valves for binding. Remove and clean or replace if necessary. Inspect Tube ol for contaminants, 3. solenoid valve cap remains down with no electric cuent being supplied, replace selenoid valve 4. Remove any restrictions at exhaust (bt tom) of solenoid valve. 5. Check for proper operation. Reads or replace as needed. Section 13, Oil pressure dropping below 13, See 13a through 13 bel tal pee pressure dropping below ee 13 through 13 below. # ‘minimum requted for Jake 13a, Check for aeration ofthe oil Activate then 13a, Acration of lubricating i. ‘deactivate Jake Brate, Watch oi coming 1 Slave piston lash (clearance) fut of adjustment. 2. Improper engine vale(s) clesranoe. 1. Readjst slave piston lash (clearance) 2. Check according tothe engine manual From contol valve cover. 1 i has bubbles ‘ot appears foamy, sis presen in systom, ‘Aeration can be caused by an overfilled or ‘Sudden drop in engine lube “ndrfiled crankcase, crackin ol pickup oil pressure. tube or leaks in oi suction tube or hose. Correct in accordance wth engine man facturr's procedures 13b.Lubreating oi being diluted 13b,Have anol analysis of lube oll dane wo do- by fel oi vemine if felis present. Comect per ‘engine manufacturer's procedures 13s. Low engine ol level, 13e, Consult engine manual for specifications, ‘Add ol as required. 134.Wom engine rckerlever_13d.Replace bushings in accordance with bushings ‘engine manufacturer's procedures 13e.Resrctons inthe oll pas: 13e. Inspect al tbe passageways; remove any sages leading o Jake Brake items restricting oil ow. SECTION ‘SECTIONT 0 1 Upper solenoid valve seal ring damaged. 2, Solenoid lose. 1, Remove solenoid valve and replace ll sal rings. 2. Check seal ings and retighten pe spec.