Jacobs Engine Brake manual
Contents
1. intervals 100 000 miles 300 000 miles 500 000 miles Part 3 000 hours 9 000hours 15 000 hours Wiring Terminal Connections Clutch Throttle Buffer Screw A A R A R Lash Adjusting Screw A I A I A R Solenoid Valves R Crosshead Bridges Valve Stem Caps Injector Exhaust Rocker Arms Screws Master Piston Fork Assembly Slave Pistons External Hose Assembly Housings Fuel Pipes Hold Down Bolts Accumulator Springs Solenoid Harness Solenoid Seal Rings Control Valve Springs Control Valves Oil Seal Rings Master Piston Return Springs Terminal Lead Out Crosshead Pin Assembly 2 5 Inspect and replace as required A Adjust R Replace contained in tune up kits Severe driving conditions types of roads and driving areas will affect the length of time between scheduled maintenance Engine brakes which are exposed to severe applications and operating environments may require more frequent preventive maintenance Jacobs Engine Brake Operator s Manual 13 Warranty Coverage and Procedures The unrivaled reliability of the Jacobs Engine Brake makes it unlikely that you will need to file a warranty claim Jacobs Vehicle Systems Inc and the engine manufacturers back the Jacobs Engine Brake with limited warranty coverage Refer to the appropriate section of your engine manufacturer s warranty for specific engine brake warranty information The Jacobs Engine Brake warranty is2. t re quired place the progressive braking switch in the Low position If you find that you are still using the service brakes move the switch to a higher position until you do not need to use the service brakes When you are carrying a heavier load or de scending a grade and the pavement is dry and traction is good your progressive braking switch should be in the High position Jacobs Engine Brake Operator s Manual 7 Descending a Grade Before beginning a long steep descent determine if your Jacobs Engine Brake is operating properly This can be done by lifting your foot briefly off the throttle You will feel the Jacobs Engine Brake CONTROL SPEED WITHOUT JACOBS ENGINE BRAKE HO activate An explanation of control speed is helpful in understanding how to use the Jacobs Engine Brake while descending a grade Control speed is the constant speed at which the forces pushing the vehicle forward on a grade are equal to the forces holding it back without using the service brakes In other words the speed the vehicle will maintain without using the service brakes or the throttle Note The following road speeds and grades are given as examples only Actual conditions and engine braking performance will vary Depending on road and load conditions without using your service brakes you may be able to descend a 6 grade safely at 10 mph without a Jacobs Engine Brake 8 Jacob
3. 0 mph and still expect to remain under control Get to know how much slowing power your engine brake can provide Never exceed a safe control speed Jacobs Engine Brake Operator s Manual 9 Slippery Pavement Since the operation of any vehicle under slippery conditions is unpredictable be sure you have plenty of distance when testing service brakes or your Jacobs Engine Brake The Jacobs Engine Brake will not affect the operation of ABS Anti lock Braking System on vehicles so equipped The ABS systems should deactivate the engine brake when wheel slip occurs and traction is lost and will reactivate the engine brake when the ABS system has disengaged If the Jacobs Engine Brake is new to you it is recommended that you do not attempt to use it on slippery roads until you have some experience with it on dry pavement When you have that experience you may use the following operation sequence as a guideline Do not use the Jacobs Engine Brake when bobiailing or pulling an empty trailer on wet or slippery pavement especially when operating a single drive axle vehicle Slippery Pavement Driving Procedures When driving on wet or icy pavement start with the master switch in the Off position and use the same gear you would normally use under these conditions Before activating the engine brake be sure that you have plenty of distance between your vehicle and other vehicles and that traffic conditions allow for testi
4. 00 rpm or when the transmission shifts from lock up to converter operation usually about 10 25 mph depnending on the transmission type NOTE With Autoshift type transmissions the engine brake may actuate to help the transmission upshift This is done automatically through the transmission control module and can happen even if the engine brake dash switch is in the off position 6 Jacobs Engine Brake Operator s Manual Driving with Your Jacobs Engine Brake Since the engine brake is most Braking Horsepower effective at higher engine speeds vs Engine RPM gear selection is very important You obtain maximum retarding power when you use the lowest possible gear without exceeding the recommended engine speed for engine braking Best retarding performance is obtained at engine Engine RPM speeds between 1800 rpm and high idle Below 1700 rpm retarding power may be significantly reduced Braking Horsepower The Jacobs Engine Brake must be turned on at the dash switch in order to operate Once it is turned on merely take your foot off the throttle to slow your vehicle The Jacobs Engine Brake goes into action providing retard ing power to the vehicle Apply the service brakes when it s time to come to acomplete stop See the sections below for driving procedures for specific conditions Flat Dry Pavement If you are driving on flat open stretches with a light load and greater slowing power isn
5. Contents Introduction BERR ERR RRR RRR RRR ERR ERR 2 Using Your Jacobs Engine Brake 3 The COntrols a e a a arrea ma aeara ea a Aae aaa a ia aaao stasis ee aaraa ia is 3 Jacobs Engine Brake Operation 8 7 4 Driving with Your Jacobs Engine Brake 7 Flat 7 Descending a Grade 8 Slippery 10 Maintenance and 7 12 Recommended Preventive Maintenance 5060116 9 13 Warranty Coverage and Procedures 14 4 10 For More Jacobs Engine Brake Operator s Manual 1 Introduction Congratulations Your vehicle is equipped with the original Jacobs Engine Brake The Jacobs Engine Brake also known as the Jake Brake engine brake is widely recognized throughout the trucking industry for its quality reliability and performance This manual contains useful information on the operation and maintenance of your Jacobs Engine Brake Read this manual thoroughly and fully understand the engine brake system before you drive your Jacobs Engine Brake equipped vehicle The Jacobs Engine Brake is a diesel engine retarder that uses the engine to aid in slowing and controlling the vehicle When activated the engine brake alters the operation of the engine s exhaust valves so that the engine works as a power absorbing air compressor This provides a retarding or slowing action to the vehicle s drive wheels enabling you to have improved vehicle control wi
6. administered through vehicle or engine dealers as an engine component For More Information If you would like more information or have specific questions please ask your local vehicle dealer or engine dealer or visit us on the Internet at www jakebrake com 14 Jacobs Engine Brake Operator s Manual 15 Notes Jacobs Engine Brake Operator s Manual
7. commended operating procedure when using your trailer brakes If your tractor is equipped with tandem axles and a power divider the Jacobs Engine Brake will not change the normal usage of this equipment on icy roads See the manufacturer s recommendations for the proper use of this equipment Jacobs Engine Brake Operator s Manual 11 Maintenance and Service Jacobs Engine Brakes are recognized as one of the most reliable components on today s diesel powered vehicles However inspections and routine maintenance are necessary to ensure proper operation In addition periodic service will help reduce maintenance costs unscheduled service and downtime With every routine engine maintenance have your engine brake inspected and serviced If for some reason the engine brake will not shut off when your foot is on the throttle immediately pull off the road and call for service Maintain your Jacobs Engine Brake with genuine Jacobs replacement parts Use of other than Jacobs approved parts may result in reduced performance serious engine damage and loss of warranty protection 12 Jacobs Engine Brake Operator s Manual Recommended Preventive Maintenance Schedule The service intervals presented here are intended as a guide for establishing a routine of Jacobs Engine Brake inspection and maintenance in conjunction with scheduled engine maintenance Reference your engine manufacturer s service manual for specific maintenance
8. ng of vehicle braking Also make sure that the vehicle is maintaining traction and stability using the natural retarding of the engine alone If the retarding of the engine alone without the engine brake causes any loss of traction do not attempt to use the engine brake until road conditions improve 10 Jacobs Engine Brake Operator s Manual If the vehicle is maintaining traction you may then activate the Jacobs Engine Brake by HIGH turning the switch to the Low position If the tractor drive wheels begin to lock or there A is a fishtail motion immediately turn the switch off and don t turn the Jacobs Engine Brake on until road conditions improve power move the braking switch to the next highest position If the drive wheels tend to lock or there is a fishtail motion immediately switch the engine brake into the low position Do not attempt to use a higher position until road conditions improve If there was no tendency for the drive wheels to lose traction and you desire greater slowing HIGH Check your progressive braking switch for proper position often since road conditions can change quickly Remember never skip a step when operating the progressive braking switch Always go from off to low position and then to a higher position On single trailers or combinations a light air application of the trailer brakes may be desirable to help keep the trailer stretched out Follow the manufacturer s re
9. on the free flow of engine oil for operation so be sure to let the engine reach full operating temperature before switching on the engine brake Normally the engine brake is then left in the On position whenever you are driving The exception is when roads are slippery due to bad weather conditions Refer to the section entitled Slippery Pavement for specific operating instructions The operation of the Jacobs Engine Brake is fully automatic once it is turned on When your foot is off the clutch and you remove your foot completely from the throttle the engine brake is automatically activated There are some systems that will activate only once the brake pedal is depressed When you apply pressure to the throttle the Jacobs Engine Brake is deactivated 4 Jacobs Engine Brake Operator s Manual While shifting gears the engine brake is automatically deactivated when you depress the clutch pedal If the engine brake is on shifting without using the clutch or double clutching to use the engine brake to reduce engine rpm also known as Jake Shifting is strongly discouraged Serious powertrain damage or engine stalling loss of vehicle control can result Note that the Jacobs Engine Brake will also remain activated after the brake pedal has been depressed giving the combined power of both the engine brake and the service brakes to the drive wheels ABS Anti Lock Braking System e
10. quipped vehicles have the ability to turn the engine brake off if a wheel slip condition is detected The engine brake will automatically be turned back on when wheel slip is no longer detected On vehicles equipped with electronic engine controls the controls will deactivate the engine brake when engine speed falls below approximately 1000 rpm or when the vehicle slows down to a pre set speed which varies depending on the vehicle and engine configuration This prevents stalling the engine On vehicles equipped with mechanical engine controls and manual transmissions depress the clutch pedal at low speeds to prevent stalling the engine Alternatively a low speed cutoff control may be installed to ensure deactivation of the engine brake at low vehicle speeds Be sure to turn off the engine brake dashboard switch CAUTION when you shut the engine down This will prevent the switch from being in the on position at engine cold start Jacobs Engine Brake Operator s Manual 5 Automatic Transmissions If you have an automatic transmission operation of the Jacobs Engine Brake functions basically in the same manner for vehicles with manual transmissions The engine brake is activated when you move your foot off the throttle and deactivated when you apply pressure to the throttle A pressure sensing switch or the electronic engine controls will deactivate the Jacobs Engine Brake when the engine speed falls below approximately 10
11. s types of switches that you may find in your vehicle Note Switches supplied by Jacobs Vehicle Systems may be different from the ones installed in your vehicle physical appearance varies but function should not The operations tied to these switches are as follows for a typical in line 6 cylinder engine Se Low High Switch The low setting activates ON three cylinders yielding approximately 50 HIGH braking horsepower The high setting will OFF activate all six cylinders providing full braking oe horsepower Low Med High Switch The Low setting activates two cylinders yielding approximately one third total braking horsepower The Medium setting activates four cylinders yielding approximately two thirds braking horsepower The high setting will activate all six cylinders providing full braking horsepower Additionally a foot operated switch may be offered to give you control of the on off function of the Jacobs Engine Brake Some vehicle manufacturers offer a gear lever selector switch for the engine brake Jacobs Engine Brake Operator s Manual 3 Engine Controls All Jacobs Engine Brakes have two additional controls one activated by the position of the clutch pedal and the other by the position of the throttle The two controls can provide for fully automatic operation of the Jacobs Engine Brake Jacobs Engine Brake Operation The Jacobs Engine Brake depends
12. s Engine Brake Operator s Manual With the Jacobs Engine Brake CONTROL SPEED WITH set to the High position you JACOBS ENGINE BRAKE might be able to descend that same grade at 25 mph and still remain under control without using your service brakes The engine brake can be kept on for as long as needed without any risk of engine overheating or damage Under some circumstances you may want to come down a grade at a faster rate than the control speed This can be done by selecting a higher gear or a lower position on the progressive braking switch However you may have to apply your service brakes intermittently to prevent overspeeding the engine and to keep the vehicle at a safe speed Frequent use of the service brakes will cause them to heat up reducing their stopping ability The result can be dangerous brake fade FASTER THAN CONTROL SPEED WITH JACOBS ENGINE BRAKE There may be circumstances in which you might want to descend a grade at a rate slower than the control speed This is done by selecting a lower gear one that will not overspeed the engine You may have to apply the service brakes to obtain the desired lower speed Like any product the Jacobs Engine Brake can be abused Take for instance the above example of the 6 grade which you could descend under control only at 10 mph without an engine brake but at 25 mph with an engine brake You could not descend that same hill at 5
13. thout using the service brakes This results in reduced service brake maintenance shorter trip times and lower overall operating costs Statements marked with this symbol indicate potentially dangerous conditions including the possibility of personal injury Statements marked with this symbol are important for the safe use and care of the Jacobs Engine Brake Please refer to the operator s manual provided by the manufacturer of your vehicle for additional information and operations that may differ from those described in this manual 2 Jacobs Engine Brake Operator s Manual Using Your Jacobs Engine Brake The Jacobs Engine Brake is a vehicle slowing device not a vehicle stopping device It is nota substitute for the service braking system The vehicle s service brakes must be used to bring the vehicle to a complete stop However by appropriately using the engine brake for your slowing needs the service brakes remain cool and ready to provide their maximum stopping power Driver Controls It is important to familiarize yourself with the Jacobs Engine Brake controls in your vehicle The controls will vary slightly depending on the engine brake configuration and cab design as discussed below However basic operator controls will be similar for all models All vehicles with manual transmissions will allow the driver to turn the engine brake on and off and select a level of braking Below are illustrations of the variou
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