1 INDEX

Model J05C-TD (Vacuum air control) EXHAUST BRAKE 15-1

15-181E-04

CHAPTER 15
EXHAUST BRAKE
Model: J05C-TD (Vacuum air control)
1 Model: J05C-TD (Compressed air control)

EXHAUST BRAKE SYSTEM ....................................................15 - 2

BRAKE CYLINDER AND VACUUM CYLINDER ......................15 - 3

15
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15-2 EXHAUST BRAKE Model J05C-TD (Vacuum air control)

EXHAUST BRAKE SYSTEM

3
2

D 4

13

8
11
12
9 14
10
10

:A
1. Battery 12. Air cleaner :B
2. Accelerator switch 13. Vacuum cylinder :C
3. Accelerator pedal 14. Brake cylinder
SM15-100B
4. Clutch switch A. Electric line
5. Exhaust brake switch B. Air line
6. Exhaust brake indicator lamp C. Accelerator cable
7. Vacuum pump D. To injection pump
8. Vacuum switch
9. Vacuum tank NOTE: Refer to Electrical Wiring Diagram in
10. Check valve CHAPTER W and Brake Piping Diagram
11. Magnetic valve in CHAPTER 13, SERVICE BRAKE for
details.

Fig. 1
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Model J05C-TD (Vacuum air control) EXHAUST BRAKE 15-3

BRAKE CYLINDER AND VACUUM CYLINDER

23 39 40

24
25

22 37
38
15 26
21 27
14 20 28
12 13 18
19 29 30
11 17
16 31
10
9
8 32
7
5
4 6
33 34

35
3
2 36
1
SM15-287

1. Protector 16. Bearing 31. Brake cylinder

2. Hose connector 17. Heat insulator 32. Stud
3. Connector 18. Nut 33. Shaft
4. Vacuum cylinder 19. Clevis 34. Bolt
5. Label 20. Cotter pin 35. Valve
6. Guide 21. Washer 36. Bushing
7. Spring 22. Clevis pin 37. Nut
8. Push rod 23. Lock nut 38. Adjusting bolt
9. Piston washer 24. Lever 39. Dust cover
10. O-ring 25. Bolt 40. Screw
11. Plate 26. Bracket
12. Diaphragm 27. Cover
13. Retainer 28. Bushing
14. Nut 29. Seal ring (large)
15. Vacuum cylinder 30. Seal ring (small)

Fig. 2
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15-4 EXHAUST BRAKE Model J05C-TD (Vacuum air control)

REMOVAL
1. REMOVE THE EXHAUST BRAKE ASSEMBLY.
1. Disconnect the vacuum hose from the vacuum cyl-
inder.
2. Disconnect the exhaust muffler from the exhaust
brake cylinder.
3. Remove the exhaust brake cylinder from the exhaust
pipe.
SM15-325
Fig. 3 WARNING
Do not work on the exhaust brake cylinder while it
is still hot. This can result in personal injury.

DISASSEMBLY
1. DISASSEMBLE THE EXHAUST BRAKE ASSEMBLY.
1. Remove the dust cover from the bracket.
2. Remove the clevis pin to disconnect the lever and
clevis.

SM15-290 SM15-291
Fig. 4
3. Remove the vacuum cylinder from the bracket.
4. Remove the clevis from the vacuum cylinder.
a. Loosen the lock nut.
BEARING HEAT
b. Remove the clevis, lock nut, heat insulator and bear-
INSULA-
TOR ing.
LOCK
NUT
CLEVIS
SM15-293 SM15-294
Fig. 5
5. Remove the lever and adjusting bolts.

SM15-292 SM15-295
Fig. 6
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Model J05C-TD (Vacuum air control) EXHAUST BRAKE 15-5

BRAKE CYLINDER BRACKET 6. Remove the bracket, seal rings and bushing from the
brake cylinder.
NOTE: Before removing the bracket, place the match
marks “A” on the brake cylinder and bracket.

7. Clean the parts.

BUSH-
A
ING
SEAL RINGS
SM15-289
Fig. 7

BRAKE CYLINDER INSPECTION

1. INSPECT FOR WEAR AND DAMAGE. REPLACE ANY
DAMAGED OR WORN PARTS IN THE FOLLOWING.
Brake cylinder with valve, bushing, seal rings and vacuum
VACUUM cylinder bearing.
CYLIN-
DER
VALVE BEARING
SEAL RINGS
BUSHING SM15-288
Fig. 8
2. CHECK THE VACUUM CYLINDER FOR AIR TIGHT-
NESS.
Connect the vacuum cylinder as shown in Fig. 9 then
apply Vacuum Pressure of 500 mmHg (19.69 inHg) and
check that the decreasing vacuum pressure is less than
25 mmHg (0.98 inHg) in 15 Seconds.

SM15-111
Fig. 9
BRAKE CYLINDER BRACKET ASSEMBLY
1. ASSEMBLE THE EXHAUST BRAKE ASSEMBLY.
Assemble the exhaust brake assembly
1. Install the bushing, seal rings and bracket on
the brake cylinder.
NOTE: ● The small seal rings “B” and large seal
B
A rings “C” must be installed alternately.
C
BUSHING
● Align the match marks “A” of the
SM15-289
brake cylinder and bracket.
Fig. 10
Tightening Torque: 100 - 160 kg·cm (8 - 11 lb·ft)

2. Install the adjusting bolts loosely.

3. Install the lever on the shaft.

SM15-295 SM15-292
Fig. 11
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15-6 EXHAUST BRAKE Model J05C-TD (Vacuum air control)

4. Install the heat insulator, bearing, lock nut and clevis

on the vacuum cylinder.
5. Set the clevis setting length and lock it with a lock
BEARING HEAT nut.
INSULA-
TOR

LOCK Setting Length (L): More than 84.5 mm (3.327 in.)

NUT
CLEVIS
Tightening Torque: 100 - 160 kg·cm (8 - 11 lb·ft)
SM15-294A SM15-297
NOTE: This setting must be provided to prevent
Fig. 12
malfunction of the exhaust brake caused by
looseness of linkage.

6. Install the vacuum cylinder on the bracket.

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

SM15-293 SM15-298
Fig. 13
7. Connect the lever and the clevis with the pin then
lock it with the cotter pin.
8. After valve adjustment, install the dust cover on the
bracket.

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

SM15-291 SM15-290
Fig. 14
2. ADJUSTMENT
C1 1. Closed side
a. Apply 650 - 700 mmHg (25.60 - 27.55 inHg) of
vacuum to the vacuum cylinder and set the butterfly
valve to the closed position.
C2
b. Adjust the gaps between the brake cylinder and the
A butterfly valve C1 and C2 with the adjusting bolt “A”.
Gap: C1, C2 = 0.25 - 0.4 mm (0.010 - 0.015 in.)
SM15-025 SM15-296
c. Lock the adjusting bolt “A” with a lock nut.
Fig. 15
Tightening Torque: 50 - 70 kg·cm (3.7 - 5.0 lb·ft)
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Model J05C-TD (Vacuum air control) EXHAUST BRAKE 15-7

2. Opened side
a. Set the lever to the opened position.
b. Adjust the butterfly valve to be at right angle (90˚) to
90˚ the flange of the brake cylinder with the adjusting
bolt “B”.
c. Lock the adjusting bolt “B” with a lock nut.

B Tightening Torque: 50 - 70 kg·cm (3.7 - 5.0 lb·ft)

SM15-026 SM15-293A
Fig. 16

INSTALLATION
1. MOUNT THE BRAKE CYLINDER.
1. Install the exhaust brake cylinder on the exhaust pipe.
2. Connect the exhaust muffler to the exhaust brake
cylinder.

NOTE: To prevent gas leak, replace the brake cylin-

der gaskets whenever the brake cylinder is
SM15-325
dismounted.
Fig. 17

Tightening Torque: 650 - 750 kg·cm (47 - 54 lb·ft)

3. Connect the vacuum hose to the control cylinder, and

fix it securely with clamp.

ADJUSTMENT
1. ADJUST THE EXHAUST BRAKE ACTING ENGINE
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.
SM15-324 SM15-042
Acting Engine Speed: 750 - 850 r.p.m.
Fig. 18
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15-8 EXHAUST BRAKE Model J05C-TD (Vacuum air control)

A B
INSPECTION
EXHAUST 1. USING AN OHMMETER, CHECK THE SWITCHES AND
BRAKE SWITCH
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. 19
A B 2. Clutch switch.
A : OFF – Insulation
B : ON – Continuity

SM15-041
Fig. 20
A B 3. Accelerator switch.
A : OFF – Insulation
B : ON – Continuity

SM15-042 SM15-043
Fig. 21
A B 4. Magnetic valve.
A : Normal – Continuity
B : Defect – Insulation

SM15-116 SM15-117
Fig. 22
2. AIR CLEANER
CAP The function of the air cleaner is to clean the air which is
taken into the vacuum booster. The air cleaner is installed
on the magnetic valve.
FILTER At every 12,000 miles, remove the cap of the air cleaner,
BODY
take out the filter and clean it. Be sure to return the cap to
its original state after cleaning.
TO VACUUM BOOSTER
SM13-172
Fig. 23