1 page

INDEX1
Models J08C-TP and J08C-TR EXHAUST BRAKE 15-1

15-180E-03

CHAPTER 15
EXHAUST BRAKE
Models: J08C-TP and J08C-TR

TROUBLESHOOTING ...............................................................15 - 2

EXHAUST BRAKE SYSTEM ....................................................15 - 3

BRAKE CYLINDER ...................................................................15 - 4

CONTROL CYLINDER ..............................................................15 - 10

CONTROL PARTS.....................................................................15 - 15 15
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15-2 EXHAUST BRAKE Models J08C-TP and J08C-TR

TROUBLESHOOTING

Symptom Possible cause Remedy/Prevention

Switch does not work Defective contacts .............................................. Check and correct
Open circuit in harness ...................................... Check and correct
Valve does not close Valve clogged with carbon ................................. Remove carbon
Burnt shaft .......................................................... Check and correct
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Models J08C-TP and J08C-TR EXHAUST BRAKE 15-3

EXHAUST BRAKE SYSTEM

1
10 4
9

7
6

1. Exhaust brake switch 6. Magnetic valve

2. Exhaust brake indicator lamp 7. Control cylinder
3. Clutch switch 8. Brake cylinder
4. Accelerator switch 9. Clutch pedal
5. Air tank 10. Accelerator pedal

NOTE: Refer to Electrical Wiring Diagram in CHAPTER W and Brake Piping Diagram in
CHAPTER 13, SERVICE BRAKE for Details in Chassis Manual.
SM15-286
Fig. 1
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15-4 EXHAUST BRAKE Models J08C-TP and J08C-TR

BRAKE CYLINDER

1
2
3

4
7

5
8
6

9
5
10

SM15-281

1. Lever 6. Shaft
2. Adjusting screw bracket 7. Butterfly valve
3. Adjusting screw 8. Brake cylinder
4. Seal ring 9. Stud bolt
5. Bushing 10. Plate

Fig. 2
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Models J08C-TP and J08C-TR EXHAUST BRAKE 15-5

REMOVAL
1. REMOVE THE BRAKE CYLINDER.
1. Disconnect the air hose from the control cylinder.
2. Remove the exhaust brake cylinder from the exhaust
pipes.

WARNING
Do not work on exhaust brake cylinder while it is
SM15-299 still hot. This can result in personal injury.
Fig. 3

DISASSEMBLY
1. DISASSEMBLE THE BRAKE CYLINDER.
1. Remove the control cylinder.
a. Remove the elbow.

ASM15-300
Fig. 4
b. Remove the clevis pin, use screw driver to push pis-
ton.
c. Remove the control cylinder.

ASM15-301
Fig. 5
2. Remove the lever.
3. Remove the adjusting screw bracket.

SM15-302
Fig. 6
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15-6 EXHAUST BRAKE Models J08C-TP and J08C-TR

4. Remove the butterfly valve.

SM15-303
Fig. 7
5. Remove the shaft.

SM15-304
Fig. 8
6. Remove the seal rings and bushing by hand.

SM15-305
Fig. 9
7. Remove the plate.
8. Remove the bushing.

SM15-306
Fig. 10
9. Disassembled parts of the brake cylinder.

SM15-307
Fig. 11
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Models J08C-TP and J08C-TR EXHAUST BRAKE 15-7

INSPECTION
1. INSPECT THE CYLINDER WITH VALVE, BUSHINGS
AND SEAL RINGS FOR WEAR AND ANY OTHER
DAMAGE. IF THERE IS ANY DAMAGE, REPLACE
THE PARTS.

SM15-308
Fig. 12

ASSEMBLY
1. ASSEMBLE THE BRAKE CYLINDER.
1. Install the bushing at the plate side.
2. Install the plate.
Tighten the lock bolts with a specified tightening
torque.
Tightening Torque: 160 - 220 kg·cm (12 - 15 lb·ft)
SM15-309
Fig. 13
3. Install the bushing and the seal rings at the adjust-
ing screw bracket side.

SM15-304
Fig. 14
SEAL RINGS NOTE: The small seal rings and large seal rings must be
installed alternately.

BUSHING

VALVE
SM15-082A
Fig. 15
4. Install the butterfly valve.
Apply lithium base disulfide molybdenum grease to
the lock bolts.
Tighten the lock bolts with a specified tightening
torque.
Tightening Torque: 1st 100 kg·cm (8 lb·ft)
2nd 60˚+30˚
–0 turn

SM15-310
Fig. 16
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15-8 EXHAUST BRAKE Models J08C-TP and J08C-TR

5. Install the adjusting screw bracket.

Tighten the lock bolts with a specified tightening
torque.
Tightening Torque: 160 - 220 kg·cm (12 - 15 lb·ft)

SM15-311
Fig. 17
6. Install the lever.
Tighten the lock nut with a specified tightening torque.
Tightening Torque: 100 - 160 kg·cm (8 - 11 lb·ft)

SM15-302
Fig. 18
2. ADJUSTMENT
C1
1. Closed position
a. Set the lever to close. Then adjust the adjusting
screw so that the average gap between cylinder and

( )
butterfly valve C1 + C2 will be Assembly Standard.
2

Assembly Standard: 0.4 - 0.55 mm (0.016 - 0.021 in.)

C2
SM15-025
Fig. 19

LOCK NUT b. Lock the adjusting screw with a lock nut.

ADJUSTING
SCREW
Tightening Torque: 100 - 160 kg·cm (8 - 11 lb·ft)

SM15-312
Fig. 20
2. Open position.
90˚ a. Set the lever to open. Then adjust the adjusting screw
so that the butterfly valve will be right angle (90˚) to
the flange of the brake cylinder.

SM15-026
Fig. 21
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Models J08C-TP and J08C-TR EXHAUST BRAKE 15-9

b. Lock the adjusting screw with a lock nut.

ADJUSTING
SCREW Tightening Torque: 100 - 160 kg·cm (8 - 11 lb·ft)

LOCK NUT

SM15-313
Fig. 22
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15-10 EXHAUST BRAKE Models J08C-TP and J08C-TR

CONTROL CYLINDER

5 7

12
13
12
11

4
14
3
14
2
1
10

15

16

1. Cap 9. Control cylinder sub assembly

2. Gasket 10. Retainer ring
3. O-ring 11. Boot
4. Piston 12. Clevis pin
5. Rod sub assembly 13. Clevis
6. Compression spring 14. Pin
7. Spring seat 15. Clip
8. Air filter 16. Pipe

ASM15-285
Fig. 23
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Models J08C-TP and J08C-TR EXHAUST BRAKE 15-11

DISASSEMBLY
1. DISASSEMBLE THE CONTROL CYLINDER.
1. Remove the boot.
2. Remove the retainer ring.

SM15-314 SM15-315
Fig. 24
3. Remove the cap.

SM15-316
Fig. 25
4. Remove the piston with rod.

ASM15-317
Fig. 26
5. Disassemble the piston and rod.

SM15-318
Fig. 27

INSPECTION
1. INSPECT FOR WEAR AND ANY OTHER DAMAGE.
IF THERE IS ANY DAMAGE, REPLACE THE PARTS.

ASM15-319
Fig. 28
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15-12 EXHAUST BRAKE Models J08C-TP and J08C-TR

ASSEMBLY
3
1. ASSEMBLE THE CONTROL CYLINDER.
NOTE: ● When assembling the control cylinder,
replace the gasket and O-ring with new
ones.
● When assembling the control cylinder,
1 apply silicone grease to each sliding sur-
2
face of the assembling parts.
SM15-011
1. Push rod and End plug
Fig. 29
2. Piston and cylinder
3. O-ring

1. Assemble the piston and push rod.

Tightening Torque: 60 - 80 kg·cm (4.4 - 5.7 lb·ft)

SM15-320
Fig. 30
2. Assemble the control cylinder.

ASM15-321
Fig. 31
3. Install the cap.

Tightening Torque: 450 - 550 kg·cm (33 - 39 lb·ft)

SM15-316
Fig. 32
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Models J08C-TP and J08C-TR EXHAUST BRAKE 15-13

4. Install the retainer ring.

5. Install the boot.

SM15-322 SM15-314
Fig. 33
INSPECTION
1. CHECK THE CONTROL CYLINDER FOR FUNCTION
AND AIR LEAKAGE.
8.5 kg/cm2 1. Apply 8.5 kg/cm2 (121 PSI) of compressed air to the
inlet port.
AIR 2. Check the control cylinder for function.
PRESSURE 3. Check the joints and push rod side for air leakage
GAUGE
AIR TANK by applying soapy water with a brush.
SM15-049 4. Any leakage noted in the soapy water test means
Fig. 34 that the O-ring is defective and needs replacement.
ASSEMBLY
1. INSTALL THE CONTROL CYLINDER TO THE BRACKET
AND CONNECT THE CLEVIS WITH THE LEVER.
1. Install the control cylinder to the bracket.
Tightening Torque: 300 - 350 kg·cm (22 - 25 lb·ft)
2. Install the clevis pin, use screw driver to push pis-
ton.

ASM15-300
Fig. 35
3. Install the elbow.

Tightening Torque: 500 - 600 kg·cm (37 - 43 lb·ft)

SM15-323
Fig. 36
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15-14 EXHAUST BRAKE Models J08C-TP and J08C-TR

INSTALLATION
1. MOUNT THE BRAKE CYLINDER.
1. Install the exhaust brake cylinder on the exhaust
pipes.
NOTE: To prevent gas leak, replace the brake cylin-
der gaskets whenever the brake cylinder is
dismounted.

SM15-299
Tightening Torque: 650 - 750 kg·cm (47 - 54 lb·ft)
Fig. 37

2. Connect the air hose to the control cylinder.

Tightening Torque: 200 - 230 kg·cm (15 - 16 lb·ft)

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Models J08C-TP and J08C-TR EXHAUST BRAKE 15-15

CONTROL PARTS

ADJUSTMENT
1. ADJUST THE EXHAUST BRAKE ACTING ENGINE
∞ 0 SPEED.
1. Adjust the engine idling speed by turning the throttle
control knob.
Engine Idling Speed: 700 - 750 r.p.m.
2. Adjust the exhaust brake acting engine speed by
moving the accelerator switch body.
SM15-115 SM15-042
Acting Engine Speed: 800 - 850 r.p.m.
Fig. 38
A B INSPECTION
EXHAUST
BRAKE SWITCH 1. USING AN OHMMETER, CHECK THE SWITCHES AND
MAKE SURE THAT THEY WORK PROPERLY, AS IL-
ON
LUSTRATED.
1. Exhaust brake switch.
A : OFF – Insulation
B : ON – Continuity

SM15-039 SM15-040
Fig. 39
A B 2. Clutch switch.
A : OFF – Insulation
B : ON – Continuity

SM15-041
Fig. 40
A B 3. Accelerator switch.
A : OFF – Insulation
∞ 0 ∞ 0
B : ON – Continuity

SM15-042 SM15-043
Fig. 41
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15-16 EXHAUST BRAKE Models J08C-TP and J08C-TR

A B 4. Magnetic valve.
A : Normal – Continuity
B : Defect – Insulation

SM15-098
Fig. 42
2. INSPECT THE CONTROL CYLINDER, MAGNETIC
VALVE AND OTHER JOINT PARTS FOR AIR LEAKAGE
BY APPLYING SOAPY WATER WITH A BRUSH.

SM15-016
Fig. 43