ex3116/3126, ex3126b, and tm3126b · b. mount the exhaust brake in a vertical orientation with the...

16
EX3116/3126, EX3126B, And TM3126B Jacobs Exhaust Brake INSTALLATION FOR APPLICATION ON 3116, 3126, AND 3126B CATERPILLAR ® ENGINES

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Page 1: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

EX3116/3126,

EX3126B, And TM3126B

Jacobs Exhaust Brake™

INSTA

LLA

TIO

N

FOR APPLICATION ON 3116, 3126, AND 3126B CATERPILLAR® ENGINES

Page 2: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

2 JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL

Information in this manual was current at the time of printing and is subject to change without notice or liability.See the Jake Brake Product Reference Guide for Caterpillar Engines, Manual Form RENR 1370, and Jacobswebsite - www.jakebrake.com - for more information.

Table of Contents1.Exhaust Brake Assembly Installation ........ 3

A. Turbo-mount Applications ........................ 3B. In-pipe Applications.................................. 4

2.Pneumatic Group Installation .................... 6

3.Controls Installation

A. 3116 Mechanical Engines ........................ 8B. 3126B Electronic Engines ....................... 10C. 3126 Electronic Engines ........................ 11

4. Final Test ................................................. 12

Appendix A

Installing the Jacobs Exhaust Brake withAllison Automatic Transmissions ........... 13

Application NotesA. Engine application:

For Caterpillar 3126B engines there are twoaftermarket kits available: a turbo-mount designand a standard "in-pipe" design. The turbo-mount design eliminates cutting and welding ofexhaust pipes, simplifying installation. Theexhaust brake housing, however, extendsapproximately 3" from the turbo outlet. Beforeinstalling this type of exhaust brake, ensure therewill be at least 3" of clearance between anyexhaust component and the vehicle chassis andfirewall after exhaust brake installation.

For Caterpillar 3116 and 3126 engines, astandard "in-pipe" kit is available.

For kit part numbers and further information, seethe Brake Application Guide in the Jake BrakeProduct Reference Guide for Caterpillar Engines,Manual Form RENR 1370.

Installation is approved for all 3126 and 3126Bengines. Installation on 3116 engines is limited toengines with S/N 2BK29931 and higher (allhorsepower ratings) and 200 - 275 horsepowerratings built after August, 1992. Some earlier3116 engines can be converted for higher backpressure. See Jacobs Product Advisory 94-2 fordetails (included in the Form RENR 1370).

B. Vehicles equipped with hydraulic brakes:Vehicles that do not have an on-board air supplyrequire the installation of an auxiliary air supplysystem. When an air supply is required, order thePneumatic Group with Air Supply and Electricalharness Group. Follow the installation instructionsincluded with the Pneumatic Group with AirSupply. See the Brake Application Guide forcorrect part numbers.

C. Vehicles with Allison Transmissions: Forvehicles equipped with an Allison transmission,refer to Appendix A, Installing the Jacobs ExhaustBrake with Allison Automatic Transmissions. Forinformation on the use of the exhaust brake onthese vehicles, see Jacobs Exhaust Brake™Application Note 93-1, available in the JakeBrake Product Reference Guide (see note at thetop of this page).

Safety PrecautionsThe following symbols in this manual signal potentiallydangerous conditions to the mechanic or equipment.Read this manual carefully. Know when theseconditions can exist. Then, take necessary steps toprotect personnel as well as equipment.

THIS SYMBOL WARNS OFPOSSIBLE PERSONAL INJURY.

THIS SYMBOL REFERS TOPOSSIBLE EQUIPMENT DAMAGE.

NOTE: INDICATES AN OPERATION, PROCEDUREOR INSTRUCTION THAT IS IMPORTANTFOR CORRECT SERVICE.

Fuels, electrical equipment, exhaust gases andmoving engine parts present potential hazards thatcould result in personal injury. Take care wheninstalling a compression brake. Always use correcttools and proper procedures as outlined in thismanual.

THE JACOBS EXHAUST BRAKE™COMPRESSION BRAKE IS AVEHICLE SLOWING DEVICE, NOT A

VEHICLE STOPPING DEVICE. IT IS NOT ASUBSTITUTE FOR THE SERVICE BRAKINGSYSTEM. THE VEHICLE’S SERVICE BRAKESMUST BE USED TO BRING THE VEHICLE TO ACOMPLETE STOP.

Page 3: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL 3

Section 1: Exhaust Brake Assembly Installation

FIG. 1

1A. Turbo-mount Installation

Refer to Figure 1 for the following procedures.

1. Loosen the “V” clamp holding the originalexhaust pipe to the turbo. Remove the exhaustpipe. Inspect the exhaust pipe for any sign ofrust or damage. Replace if necessary.

2. In most installations, the exhaust pipe must beshortened to allow installation of the exhaustbrake housing. The most convenient method isto modify the exhaust pipe length at a slip joint.Using a torch, heat the pipe sufficiently todisassemble the slip joint. Then remove therequired length of exhaust pipe.

3. The exhaust brake assembly is mounted to theturbo outlet using the gasket and clampprovided (see Figure 1). The gasket is coatedwith an adhesive to ease installation. Removethe backing from the adhesive and apply thegasket to the turbo outlet, taking care to centerthe gasket.

NOTE: ENSURE THE GASKET IS CENTEREDDURING INSTALLATION OF THE EXHAUSTBRAKE. GASKETS NOT CENTEREDCORRECTLY DURING INSTALLATION CANCAUSE UNNECESSARY RESTRICTION OFEXHAUST FLOW AND POSSIBLE LOSS OFPOSITIVE POWER, OR A LEAK DURINGBRAKING AND LOSS OF BRAKING POWER.

4. Position the exhaust brake assembly so the aircylinder is either above the exhaust brakehousing or on the side of the housing oppositethe engine, and mount to the turbo using theclamp provided.

TO PREVENT EXPOSURE TOEXCESSIVE HEAT, DO NOTINSTALL THE EXHAUST BRAKE

ASSEMBLY WITH THE AIR CYLINDER FACINGTHE ENGINE SIDE OF THE HOUSING. TOPREVENT ACCUMULATION OF WATER IN THESOCKET JOINT, DO NOT INSTALL THE EXHAUSTBRAKE ASSEMBLY WITH THE AIR CYLINDERLOCATED BENEATH THE MAIN HOUSING.

5. When the exhaust brake assembly is properlypositioned, torque the clamp bolts to 70 - 80lb-in. (8 - 9␣ N•m).

6. Connect the original exhaust pipe to theexhaust brake housing. Use the clampprovided in the kit. No gasket is requiredbetween the exhaust brake assembly and theexhaust pipe. Tighten the clamp enough toloosely hold the parts in place.

7. Make the connection to the muffler using theparts (flex pipe and clamp) removed when theinstallation began. With the clamps still loose,align the exhaust system. Ensure that there isproper clearance between the exhaust system,including the exhaust brake components, andthe engine and chassis. Now torque all the “V”clamps to 70 - 80 lb-in. (8 - 9␣ N•m).

Proceed to Section 2, Pneumatic GroupInstallation.

For turbo-mount models, follow the procedure in 1A. For in-line models, follow theprocedure in 1B.

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4 JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL

1B. In-pipe Installation

Important Notes on the Positioning ofthe Jacobs Exhaust Brake™

A. Exhaust pipe arrangements vary from vehicle tovehicle. Install the exhaust brake no further than48” (122 cm) from the turbocharger.

NOTE: INSTALLING THE EXHAUST BRAKEASSEMBLY DOWNSTREAM FROM A FLEXPIPE OR NON-SEALED JOINT, ORINSTALLING THE ASSEMBLY FURTHERTHAN 48" FROM THE TURBOCHARGERWILL RESULT IN POOR BRAKINGPERFORMANCE.

B. Mount the exhaust brake in a vertical orientationwith the exhaust brake air cylinder facing thefront of the vehicle (refer to Fig. 2). This willensure a flow of air over the cylinder.

C. When vertical orientation is not possible, theexhaust brake can be mounted in the horizontalposition. Position the exhaust brake with the airactuator facing the side of the exhaust pipe butaway from the engine(refer to Fig. 2).

DO NOT POSITION THE EXHAUST BRAKE SOTHAT THE ACTUATOR IS ABOVE OR BELOWTHE EXHAUST PIPE.

Installing the exhaust brake assembly

1. Figure 1 indicates a typical arrangement of theexhaust brake and mounting hardware. Loosenthe “V” clamps holding the original exhaust pipearrangement in place. Remove the exhaustpipe, inspect for any sign of rust or damage.Replace if necessary.

2. Lay the exhaust pipe on the ground or bench

with the exhaust brake and exhaust pipesleeves, (see Fig.␣ 2) and mark the pipe sectionto be replaced with the sleeves. Cut out thenecessary pipe section and weld the sleeve tothe two exhaust pipe lengths.

NOTE: BE SURE TO CUT THE PIPE STRAIGHT ANDWELD THE SLEEVES IN PLACE CAREFULLYTO ENSURE THAT NO LEAKS OCCUR INTHE SYSTEM. THE SECTION OF THEEXHAUST PIPE BETWEEN THE TURBO ANDTHE EXHAUST BRAKE ASSEMBLY WILL BEUNDER SIGNIFICANT INTERNALPRESSURE, AND ANY LEAKS WILLSERIOUSLY AFFECT RETARDINGPERFORMANCE.

3. Reinstall the exhaust pipe on the turbochargerusing Jacobs gasket. The gasket is coated withan adhesive to ease installation. Remove thebacking from the adhesive and apply the gasketto the turbo outlet, taking care to center thegasket.

NOTE: ENSURE THE GASKET IS CENTEREDDURING INSTALLATION OF THE EXHAUSTBRAKE. GASKETS NOT CENTEREDCORRECTLY DURING INSTALLATION CANCAUSE UNNECESSARY RESTRICTION OFEXHAUST FLOW AND POSSIBLE LOSS OFPOSITIVE POWER, OR A LEAK DURINGBRAKING AND LOSS OF BRAKING POWER.

4. Install the exhaust brake assembly at the otherend of the section of pipe just installed usingthe gasket and the “V” clamp. Orient theexhaust brake assembly so the air cylinderbracket points away from the turbocharger.Make sure that the gasket is centered on theexhaust brake inlet. Install the “V” clamp andtighten enough to temporarily hold the parts inplace.

FIG. 3FIG. 2

ORIGINALEQUIPMENT

ORIGINALEQUIPMENT

WELD

HORIZONTALORIENTATION (OPTIONAL)

VERTICALORIENTATION (PREFERRED)

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JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL 5

5. Install the second section of exhaust pipe withthe sleeve attached and clamp to the exhaustbrake outlet using the “V” clamp provided. Nogasket is needed between the exhaust brakeand this pipe section.

6. Make the connection to the muffler using theparts (flex pipe and clamp) removed when theinstallation began. At this point, with theclamps still loose, align the exhaust system.Ensure that there is proper clearance betweenthe exhaust system (including the exhaustbrake components) and the engine andchassis. Torque all the “V” clamps to 70 - 80lb.-in. (8 - 9␣ N•m).

7. One support boss is cast into the exhaustbrake housing to facilitate the attachment of asupport bracket. This support bracket is thenfastened to a suitable engine, bell housing ortransmission mounting point. The actualconfiguration of this support bracket andfasteners depends on the specific vehicleconfiguration. Failure to support the exhaustbrake and exhaust system properly can causedamage to the exhaust system.

NOTE: MAKE SURE THAT THE GASKETS AREINSTALLED BETWEEN THE TURBOOUTPUT AND THE EXHAUST PIPE ANDBETWEEN THE EXHAUST PIPE AND THEEXHAUST BRAKE INLET. FAILURE TOCORRECTLY INSTALL THESE GASKETSCORRECTLY WILL RESULT IN ASIGNIFICANT LOSS OF RETARDINGPERFORMANCE.

Page 6: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

6 JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL

Ill.

No. Description1 Pipe tee, 1/2 NPT2 Reducer bushing, 1/2 - 1/4 NPT3 90° street elbow, 1/4 NPT4 Nipple, 1/4 NPT5 Protection valve6 Compression fitting assembly7 Air brake tube

Ill.

No. Description8 Compression fitting assembly9 Solenoid valve

10 45° flared, 90° elbow, 1/8 NPT11 Hose fitting assemblies (2)12 Air brake hose13 45° flared, 90° elbow, 1/4 NPT14 Nipple, 1/4 NPT

FIG. 4

Section 2: Pneumatic Group InstallationRefer to Figure 4 when installing the pneumatic group.

To Vehicle Air Tank

2

34

5

6

7

89

10

11

11

13

12

14Exhaust BrakeAssembly

1

Page 7: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL 7

BLEED THE AIR TANK OF THEVEHICLE BEFORE STARTING THISINSTALLATION.

1. Install the protection valve at the outlet of thevehicle's existing air tank using the proper pipefittings as indicated in Figure 3.

USE OF THE PROTECTION VALVEWILL MAINTAIN THE INTEGRITY OFTHE ORIGINAL PNEUMATIC

SYSTEM. UNDER NO CIRCUMSTANCESSHOULD THE PROTECTION VALVE BE OMITTEDFROM THE INSTALLATION OF THE EXHAUSTBRAKE.

NOTE: IF A FITTING IS NOT AVAILABLE ON THEAIR TANK AND A “TEE” FITTING ISEMPLOYED TO TAP INTO THE ORIGINALPNEUMATIC CONNECTIONS, ENSURETHAT THE ORIGINAL AIR CONNECTIONSARE CORRECTLY RETORQUED.

2. Install the solenoid valve on the chassis railusing existing predrilled holes. If no suitablelocation is available on the chassis rail, thenmount the solenoid valve to the body sheetmetal. Position the solenoid valve with its airexhaust port facing downward. Avoid excessiveheat coming from the exhaust system. Thedistance from the solenoid valve to the aircylinder of the exhaust brake should be withinthe length of the supplied air hose.

3. Using the 1/4 - 18 NPT compression fittings,connect the solenoid port marked “1” or “P” tothe air tank using the air tubing. Whenassembling compression fittings, cut the tubingends squarely, then insert the tubing into thefitting until it bottoms on the seat. Tighten thenut until one thread remains visible on thefitting.

4. The supplied air hose, connects the solenoidport marked “2” or “A” to the exhaust brake aircylinder. Shorten the hose to the requiredlength. Ensure that the minimum bend radius is

2” (51 mm). Install the end fittings on both endsof the hose according to the following steps:

a. Cut the hose squarely with a fine toothhacksaw or cutoff wheel.

b. Put the socket in a vise.

c. Screw the hose counterclockwise intosocket until it bottoms, then back off 1/4turn.

d. Lubricate the nipple thread and inside of thehose liberally with a heavy oil or Aeroquiphose assembly lube, Aeroquip P/N 222070.

e. Screw the nipple clockwise into socket andhose. Leave 1/32” (0.8 mm) to 1/16” (1.6mm) clearance between the nipple hex andsocket.

5. Route the air tubing carefully and clamp usingthe clamps provided. Avoid tight bends,excessive heat coming from the exhaustsystem (+200° F/93° C) and ensure there is nopossibility of abrasion through contact withchassis components.

6. If there is a plug in the exhaust port of thesolenoid valve, remove it. Use the hoseassembly to connect the solenoid port marked“2” or “A” to the exhaust brake air cylinder.

Page 8: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

8 JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL

Section 3: Installation of the Controls

4. Install the provided switch in the switch bracketas shown. Orient the switch bracket so that theswitch contact face is perpendicular to theswitch axis (see Fig. 6). Once this adjustmenthas been made, torque the throttle lever bolt to15 - 25 lb.-ft. (21 - 35 N•m). Reinstall thethrottle linkage springs.

3.A. 3116 Mechanical Engines

3. Reinstall the throttle linkage bracket. Torquethe two M10 bolts to 33 - 47 lb.-ft. (45 - 65N•m) and the M8 bolt to 15 - 25 lb.-ft. (21 - 35N•m). Discard the throttle lever bottom washerand replace with the bracket included in the kit.Reinstall the throttle lever along with the upperwasher (see Fig. 5). Do not torque the throttlelever bolt at this time.

FIG. 4

FIG. 5

FIG. 6

Dash and Clutch Switches

1. Install the dash switch in a convenient locationon the dashboard.

2. Install the clutch switch using the instructionsincluded in the Clutch switch group.

Fuel Pump Switch Installation

1. Remove the two throttle return springs, throttlelever, bolt and washers. Note there is onewasher on top and one below the throttle lever.

2. Remove the three bolts that attach the throttlelinkage bracket to the engine. Using thetemplate supplied in the kit, mark and drill thebracket with a “V” size (0.377”) or an M10 drillbit (see Fig. 4).

Page 9: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL 9

FIG. 8

FIG. 7

Wiring Diagram, 3116 Engines

5. Adjust the position of the switch so that theswitch plunger is depressed when the throttlelever is at its low idle position. At the properadjustment, there should be a 0.010 - 0.015”(0.254 - 0.381 mm) gap as shown in Fig. 7. Inthis position, the throttle lever must be stoppedagainst the idle speed stop bolt.

6. Hold the switch in position and torque thelocknuts to 5 lb.-ft. (7 N•m).

NOTE: ADJUST (IF NECESSARY) THE LOW IDLERPM ACCORDING TO THE ENGINE SHOPMANUAL. NOTE THAT EVERY IDLE SPEEDADJUSTMENT WILL REQUIRE A FUELPUMP SWITCH POSITION ADJUSTMENT.

Wire Harness Installation

Use the harness group supplied and make theconnections shown in the wiring diagram in Fig. 8.

ABgreen

yellow

018899wire harness

black

white

blue

red

red

gre

en

blu

e

yello

w

Exhaust Brake

Dashboard switch

01

75

94

po

we

r le

ad

NOTE: Connect allgrounds to a

common bolt or agood chassis

ground.

Key-switchedpower

10A fuse or enginecircuit breaker(required for

installation - notincluded)

Clutch switch

ExhaustBrake

FUEL PUMP SWITCH

0.010 - 0.015”

SWITCH

BRACKET

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10 JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL

Wiring Diagram, 3126B Engines

FIG. 9

3.B. 3126B Electronic Engines

4. Connect the brown wire to Pin 12 on theEngine Control Module (ECM) P1 connector(see Fig. 9).

5. Plug the connector on the Solenoid harness tothe corresponding connector on the Solenoid.

6. Connect the gray wire on the Solenoid harnessto the dash switch as shown in Figure 9.Connect the green wire on the Solenoidharness to a good chassis ground.

1. Install the dash switch in a convenient locationin the dashboard.

NOTE: THE SWITCH GROUP USES LOW-RESISTANCE GOLD-PLATED CONTACTSAS REQUIRED BY THE ENGINE CONTROLMODULE. ANY SUBSTITUTE SWITCH MUSTHAVE GOLD-PLATED CONTACTS.

2. Connect the green and gray wires on the Relayharness to the back of the switch as indicatedin Figure 9.

3. Connect the pink/white wire to keyed ignition.

P2 P1

2-positionON/OFF switch

Back side of switchmodule

A B

silvercontacts

10A fuse or enginecircuit breaker(required for

installation - notincluded)

12V Relay base

pin

k/w

hite

gray

green

Pin 86

Pin 87

Pin 85

Pin 30

bro

wn

green

graygold

contactsgreen

Exhaustbrake

solenoid

To PIN 12 of ECMConnector P1

EngineECM

Key-switchedpower

ExhaustBrake

Page 11: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL 11

FIG. 10

Wiring Diagram, 3126 Engines

3.C. 3126 Electronic Engines4. Connect the brown wire to Pin 40 on the

Engine Control Module (ECM) P1 connector(see Fig. 10).

5. Plug the connector on the Solenoid harness tothe corresponding connector on the Solenoid.

6. Connect the gray wire on the Solenoid harnessto the dash switch as shown in Figure 10.Connect the green wire on the Solenoidharness to a good chassis ground.

1. Install the dash switch in a convenient locationin the dashboard.

NOTE: THE SWITCH GROUP USES LOW-RESISTANCE GOLD-PLATED CONTACTSAS REQUIRED BY THE ENGINE CONTROLMODULE. ANY SUBSTITUTE SWITCH MUSTHAVE GOLD-PLATED CONTACTS.

2. Connect the green and gray wires on the Relayharness to the back of the switch as indicatedin Figure 10.

3. Connect the pink/white wire to keyed ignition.

ENGINEE.C.M.

A B

P2

P1

IGNITION

ExhaustBrake

12V Relay base

pin

k/w

hite

gray

2-positionON/OFF switch

OEMharness

(Back side of switchmodule)

Caterpillarharness

Key-switchedpower

10A fuse or enginecircuit breaker(required for

installation - notincluded)

gray green

Exhaustbrake

solenoid

NOTE: Connect allgrounds to a

common bolt or agood chassis ground.

To PIN 40 of ECMConnector P1

green

Pin 86

Pin 87

Pin 85

Pin 30

bro

wn

green

goldcontacts

silvercontacts

Page 12: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

12 JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL

Final Test1. Start the engine and run at low idle speed with

the transmission in neutral and the parkingbrake set.

2. Turn on the dash switch. The exhaust brakeshould come on within 0.25 seconds. Step onthe accelerator pedal and increase enginespeed. The exhaust brake must turn off at900␣ ± 50 RPM. Take your foot off the pedaland the exhaust brake should turn on againwithin 0.25 seconds.

3. With the engine at idle, step on the clutchpedal. Again, the exhaust brake must turn offimmediately. Take your foot off the clutch pedaland the exhaust brake should turn on again.

NOTE: ON ELECTRONIC ENGINES, THE EXHAUSTBRAKE WILL ONLY OPERATE ABOVE 900RPM WHEN DECELERATING.

4. Check for exhaust gas leakage around the “V”clamps at the turbo outlet and exhaust brakeinlet. No leakage is allowed as this will reducethe effectiveness of retarding performance.

5. Before returning the vehicle to service, make afinal check of wiring and air tubing/hose routingto make sure that it does not run against hotsurfaces or is abraded or kinked. Take thevehicle out for a road test to ensure that thesystem is functioning correctly.

NOTE: UNDER NORMAL OPERATINGCONDITIONS, DO NOT USE THE EXHAUSTBRAKE AT IDLE ENGINE SPEED.

Page 13: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL 13

Appendix A - Installing the Jacobs Exhaust Brake™ onvehicles equipped with Allison Automatic TransmissionsWhen installing the Jacobs Exhaust Brake™ on vehicles equipped with Allison Automatic transmissions, somemodification of the wiring provided in the kit may be required. For specific information by model, refer to theprocedures below.

For additional information on the use of the Jacobs Exhaust Brake with automatic transmissions, see ApplicationNotes 93-1 (P/N 021163).

Allison AT and MT Series Transmissions

When installing the Jacobs Exhaust Brake Model 3116 on vehicles equipped with the Allison AT or MTtransmissions, follow the installation instructions included in this manual with the following exception: splicetogether the two wires connected to the clutch switch. Refer to the wiring diagram on page 9 for wireidentification.

When installing Models 3126 or 3126B on vehicles equipped with Allison AT or MT transmissions, noModifications to the installation are required.

Allison MD Series ("World") Transmissions

Use of the Jacobs Exhaust Brake on Allison MD Series transmissions requires special programming of the AllisonTransmission. Refer to Application Notes 93-1 for more information. Application Notes 93-1 is available in theJake Brake® Product Reference Guide for Caterpillar Engines, Manual Form RENR 1370, or from Jaoobs website(www.jakebrake.com).

Wiring of the exhaust brake with the Allison MD transmission requires interfacing with the Allison transmissioncontrols. Modification of the wiring harness included in the kit must be made by the installer. Refer to the wiringdiagrams below and on the next two pages when wiring the exhaust brake.

ABgreen

yellow

018899wire harness

blue

red

red

gre

en

blu

e

yello

w

Exhaust Brake

Dashboard switch

0175

94 p

ow

er le

ad

NOTE: Connect allgrounds to a

common bolt or agood chassis

ground.

Key-switchedpower

10A fuse or enginecircuit breaker(required for

installation - notincluded)

Alternative installationfor vehicles equipped

with the Allison VehicleInterface Module (VIM)

Pin 86

Pin 87A

Pin 30

Pin 85installer

relay(not

included)

Pin D2

AllisonVIM

Pin E2

To Pin 119 ofAllison ECU

To Allison ECUPin 132

ExhaustBrake

FUEL PUMP SWITCH

Wiring Diagram: Model EX3116 with the Allison World Transmission

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14 JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL

Wiring Diagram: Model EX3126B with the Allison World Transmission

P2 P1

12V Relay basep

ink/

whi

te

gray

2-positionON/OFF switch

(Back side of switchmodule)

Key-switchedpower

10A fuse or enginecircuit breaker(required for

installation - notincluded)

green

gray

goldcontacts

green

Flybackdiode

(prewired torelay base)

Exhaustbrake

solenoid

NOTE: Connect allgrounds to a

common bolt or agood chassis

ground.

A B

silvercontacts

To PIN 12 of ECMConnector P1

green

To Allison ECMwire 119

Pin 86

Pin 87

Pin 85

Pin 30

ExhaustBrake

Pin 86

Pin 87A

Pin 30

Pin 85installer

relay(not

included)

To Allison ECUPin 132

Pin D2

Pin E2

AllisonVIM

Alternative installationfor vehicles equipped

with the Allison VehicleInterface Module (VIM)

bro

wn

EngineECM

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JACOBS EXHAUST BRAKE™ EX3116/3126, EX3126B, AND TM3126B INSTALLATION MANUAL 15

Wiring Diagram: Model EX3126 with the Allison World Transmission

12V Relay base

pin

k/w

hite

gray

2-positionON/OFF switch

ENGINEE.C.M.

OEMharness

(Back side of switchmodule)

Caterpillarharness

Key-switchedpower

10A fuse or enginecircuit breaker(required for

installation - notincluded)

green

gray

goldcontacts

green

Flybackdiode

(prewired torelay base)

Exhaustbrake

solenoid

NOTE: Connect allgrounds to a

common bolt or agood chassis

ground.

A B

silvercontacts

P2

P1

To PIN 40 of ECMConnector P1

green

To Allison ECMwire 119

Pin 86

Pin 87

Pin 85

Pin 30

ExhaustBrake

Pin 86

Pin 87A

Pin 30

Pin 85installer

relay(not

included)

To Allison ECUPin 132

Pin D2

Pin E2

AllisonVIM

Alternative installationfor vehicles equipped

with the Allison VehicleInterface Module (VIM)

bro

wn

Page 16: EX3116/3126, EX3126B, And TM3126B · B. Mount the exhaust brake in a vertical orientation with the exhaust brake air cylinder facing the front of the vehicle (refer to Fig. 2). This

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