BLUE OX EXHAUST BRAKE

Transcription

1 BLUE OX EXHAUST BRAKE EXHAUST BRAKING SYSTEM FOR FOUR STROKE DIESEL ENGINES INLINE PIPEMOUNT SIZES 2 /2 TO 5 INCHES FLANGEMOUNT TURBOMOUNT DESIGNER & MANUFACTURER OF EXHAUST BRAKES MADE IN THE USA MANUFACTURED BY BRAKE SYSTEMS INC. 222 NE HOYT, PORTLAND, OR PH: FAX: TOLL FREE: brakesystems@brakesystemsinc.com WEBSITE: REVISED

2 TABLE OF CONTENTS INTRODUCTION TO BLUE OX APPLICATION TABLE 3-5 VEHICLE APPLICATION GUIDE 7-8 BRAKE ASSEMBLIES 9-20 CONTROL KITS 2 MOUNTING KITS 22 MISCELLANEOUS KITS WARRANTY PAGE 39 LINE CARD Back Cover MADE IN THE USA MANUFACTURED BY BRAKE SYSTEMS INC. 222 NE HOYT, PORTLAND, OR PH: FAX: TOLL FREE: brakesystems@brakesystemsinc.com

3 WHY AN EXHAUST BRAKE? Increases safety by reducing load on foundation brakes. Faster engine warm up. Improves cold weather operation, reduces thermal stress on intake valves and allows prolonged idling in Aids in shifting of some engine / transmission combinations. Increases brake lining life. Less expensive option for an exhaust brake. Less n oise / no special muffling necessary. WHY A BLUE OX? Nodular iron housing, 50 years of testing. Stainless shaft and butterfly, no rusting here. Butterfly design minimizes weight and envelope size. Guillotine design for heavy duty industrial application. Adjustable opening stop a llows system tuning to your engine and exhaust system. Actuating cylinder assembled with Hi -temperature components. Cylinder shells for Guillotine units is hard anodized aluminum and for butterfly models in stain less steel. Available w ith in stallation kits to cover several, ) pipe sizes, 2) various control kit options and 3) various operating voltages, including 2 & 24 volt. Guillotine and butterfly types available in several pipe sizes. 38

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5 EXHAUST BRAKE APPLICATION TABLE BY ENGINE CAUTION: ADJUST TO MANUFACTURER S BACK PRESSURE SPECIFICATIONS. Exhaust brake, control kit and mounting kit required for installation. Important: Automatic transmissions must have a lock-up torque converter for exhaust brake to be operational.. Note: On any engine 2006 or newer design, please specify if the engine is equipped with a VGT. ENGINE MAKE Caterpillar ENGINE MO DEL 36 Manufactured after 8/92*** Caterpillar 326 (439) Caterpillar 326B Dual intake valves /98 (439) EXHAUST BRAKE MODEL GUILLOTINE or BUTTERFLY - WM77A WM77A WM790A WM77A WM790A CONTROL KIT WM90L WM90L WM90M WM90M WM90M WM90M WM90M WM90M MOUNTING KIT MAXI MUM BACK** PRESSURE EXHAUST PIPE DIAMET ER 55 P SI 4.0 IN. WM904B WM904B 55 P SI 4.0 IN. 40 P SI 4.0 IN. Caterpillar 326E-2 WM790A WM90M WM904B 40 P SI 3.5 IN. SPECIAL INSTRUCTIONS Caterpillar 376 & 376B WM77A WM90M WM90M 33 P SI 4.0 IN. Caterpillar 3208T & ATAAC WM77A WM90K WM90K -2 For Ford trucks For all others 25 P SI 4.0 IN. Approval limited to engines w/steel camshaft and roller followers Caterpillar 3406A (893) WM77A WM90J WM90J WM902A WM902A 35 P SI 5.0 IN. Caterpillar 3406B Mechanical engine (893) WM77A WM90J WM90J WM902A WM902A 50 P SI 5.0 IN. Back pressure can be increased to 70 PSI w/ Caterpillar special kit #9Y672 Caterpillar 3406B mechanically fueled electronic engine (893) - WM77A WM90N WM90N WM902A WM902A 50 P SI 5.0 IN. Back pressure can be increased to 70 PSI w/ Caterpillar special kit #9Y672 Caterpillar 3406C (893) WM77A WM90M WM90M WM902A WM902A 50 P SI 5.0 IN. Back pressure can be increased to 70 PSI w/ Caterpillar special kit #9Y672 Caterpillar 3406E (893) WM77A WM90M WM90M WM902A WM902A 70 P SI 5.0 IN. Caterpillar C6.6 (402) WM780A WM78A WM90M WM90M WM903A WM904A 40 P SI 3.5 IN Caterpillar C7 (44) WM77A WM790A WM90M WM90M WM90M WM902D 40 P SI 4.0 IN. Caterpillar C9 (537) WM77A WM90M WM90M WM902B WM902B 60 P SI 5.0 IN. Caterpillar C0 (677) WM77A WM90M WM90M WM902B WM902B 40 P SI 5.0 IN. Caterpillar C (677) WM77A WM90M WM90M WM902B WM902B 40 P SI 5.0 IN. 23 / *Consult engine manufacturer. **Back pressure can be adjusted by repositioning the gate adjustment screw. *** For models before 8/92, consult engine manufacturer. Continued on next page 3

6 Note: On any engine 2006 or newer design, please specify if the engine is equipped with a VGT. ENGINE MAKE ENGINE MO DEL EXHAUST BRAKE MODEL GUILLOTINE or BUTTERFLY CONTROL KIT MOUNTING KIT MAXI MUM BACK** PRESSURE EXHAUST PIPE DIAMET ER SPECIAL INSTRUCTIONS Caterpillar C2 WM77A WM90MA WM90MA WM902B WM902B 40 P SI 5.0 IN. Caterpillar C3 (793) WM77A WM90M WM90M WM902B WM902B 40 P SI 5.0 IN. Caterpillar C5 (928) WM77A WM90M WM90M WM902B WM902B 40 P SI 5.0 IN. Caterpillar C8 (05) WM77A WM90M WM90M WM902B WM902B 40 P SI 5.0 IN. Cummins V/VT -903 WM77A WM90E WM90E WM902B WM902B 45 P SI 5.0 IN. Direct turbo mount not recommended Cummins 855 Series w/ Standard Engine Components WM77A WM90E WM90E WM902A WM902A 30 P SI 5.0 IN. Cummins 855 Series w/ Optional Heavy Duty Valve Springs (#78869) WM77A WM90E WM90E WM902A WM902A 45 P SI 5.0 IN. Cummins 855 Series Big Cam 400 WM77A WM90E WM90E WM902A WM902A 42 P SI 5.0 IN. Cummins ISC (506) WM780A WM78A WM90M WM90M WM903A WM904A 65 P SI 3.5 IN. Cummins ISM (66) WM77A WM90M WM90M 65 P SI 4.0 IN. Cummins SX (92) WM77A WM90M WM90M WM902A WM902A 65 P SI 5.0 IN. Cummins SL (540) WM77A WM90M WM90M 65 P SI 4.0 IN. Cummins L-0 Celect WM77A WM90M WM90M 65 P SI 4.0 IN. Cummins L-0 WM77A WM90E WM90E 65 P SI 4.0 IN. Cummins M- WM77A WM90M WM90M 65 P SI 4.0 IN. Cummins N-4 WM77A WM90M WM90M WM902A WM902A 45 P SI 5.0 IN. Cummins 5.9 B Series Not Equipped with catalytic converter WM780A WM78A WM90H WM90H WM903B WM904C 35 P SI 3.0 IN. Back pressure 60 PSI w/ Cummins springs *Higher pressure with Heavy Duty Valve Springs (78869) as standard on later engines. Continued on next page 4 REVISED

7 Note: On any engine 2006 or newer design, please specify if the engine is equipped with a VGT. ENGINE MAKE ENGINE MO DEL EXHAUST BRAKE MODEL GUILLOTINE or BUTTERFLY CONTROL KIT MOUNTING KIT MAXI MUM BACK** PRESSURE EXHAUST PIPE DIAMET ER SPECIAL INSTRUCTIONS Cummins 5.9 B Series Equipped with catalytic converter WM780A WM78A WM90H WM90H WM903B WM904C 35 P SI 3.0 IN. Back pressure 60 PSI w/ Cummins springs Cummins 8.3 C Series Not Equipped with catalytic converter WM77A WM90H WM90H Bracket Bracket P SI 4.0 IN. Back pressure 65 PSI w/ Cummins springs Cummins 8.3 Series Equipped with catalytic converter WM77A WM90H WM90H WM902F Bracket WM902F Bracket P SI 4.0 IN. Back pressure 65 PSI w/ Cummins springs Cummins NH 220 / 250 all with four bolt flange WM728A WM90L PSI* 4.0 IN. Detroit Diesel Series WM77A WM90M WM90M 39 P SI 4.0 IN. Detroit Diesel Detroit Diesel Detroit Diesel. & 2.7 Series Liter Model Year 6.2 Liter984 Model Year to Dat e WM77A WM90M WM90M WM902B WM902B 40 P SI 5.0 IN. WM780A WM90L WM903C 33 P SI 2.5 IN. WM780A WM90L WM903C 42 P SI 2.5 IN. Ford 6.6 Liter WM77A WM90L WM90L Ford 7.3 Liter See Vehicle / Engine Application Table P SI 4.0 IN. Exhaust brake must be minimum of 5.5ft. From turbocharger Ford 7.8 Liter WM77A WM90L WM90L P SI 4.0 IN. Exhaust brake must be minimum of 5.5ft. From turbocharger Ford FD. 060 (B) WM780A WM78A WM90H WM90H WM903B WM904C 35 P SI 3.0 IN. Back pressure 60 PSI w/dual exhaust valve spring Ford FD. 460 (C) WM77A WM90H WM90H Bracket P SI 4.0 IN. Back pressure 65 PSI w/dual exhaust valve spring GMC Isuzu Duramax 6.6 V8 WM780A WM78A WM90M WM90M WM903A WM904A 3.5 IN. GMC Isuzu Duramax I6 WM77A WM90M WM90M 4.0 IN. Komatsu/ Cummins Komatsu/ Cummins QST30 - WM90M WM902B (2) 55 P SI 5.0 IN. KT 38C (2) - WM90M WM902B (2) 55 P SI 5.0 IN. Mack E6 WM77A WM90M WM90M 40 P SI 4.0IN. REVISED Continued on next page 5

8 Note: On any engine 2006 or newer design, please specify if the engine is equipped with a VGT. ENGINE MAKE ENGINE MO DEL EXHAUST BRAKE MODEL GUILLOTINE or BUTTERFLY CONTROL KIT MOUNTING KIT MAXI MUM BACK** PRESSURE EXHAUST PIPE DIAMET ER SPECIAL INSTRUCTIONS Mack E-6 w/4 Valves Per Cylinder WM77A WM90E WM90E 45 P SI 4.0 IN. Mack E-2 w/2 Valves Per Cylinder WM77A WM90E WM90E 40 P SI 4.0 IN. Engine must have heavy duty valve springs Mack E7 & E9 WM77A WM90E WM90E 45 P SI 4.0 IN. Mack Midliner 200 & 250 WM780A WM78A WM90L WM90L WM903B WM904C 40 P SI 3.0 IN. Mack Midliner 300 WM77A WM90L WM90L 40 P SI 4.0 IN. Mack Midliner 300 WM780A WM77A WM78A WM90L WM90L WM90L WM903A WM902E WM904A 40 P SI 3.5 IN. Mercedes MBE WM77A WM90MB WM90MB 42 P SI 4.0 IN. Fl 70 Electronic engine add 540A Mercedes MBE 4000 (78)(2.8) WM77A WM90MB WM90MB WM902B WM902B 60 P SI 5.0 IN. Navist ar DT-360 & DTA-360 WM780A WM77A WM78A WM90L WM90L WM90L WM903A WM902E WM904A 38 P SI 3.5 IN. Navist ar DT-466 & DTA-466 w/bosch Fuel Pump WM WM77A WM78A WM90H WM90H WM90H WM903A WM902E WM904A 28 P SI 3.5 IN. Navist ar DT-466 after 988 WM780A WM77A WM78A WM90H WM90H WM90H WM903A WM902E WM904A 5 P SI 3.5 IN. Approval limited to engines w/steel camshaft and roller followers Navist ar DT 466E WM780A WM77A WM78A WM90M WM90M WM90M WM903A WM902E WM904A 53 P SI 3.5 IN. Navist ar DT-466-NGD 9/93 and after WM780A WM77A WM78A WM90H WM90H WM90H WM903A WM902E WM904A 53 P SI 3.5 IN. Approval limited to engines w/steel camshaft and roller followers Navist ar 530E WM780A WM77A WM78A WM90M WM90M WM90M WM903A WM902E WM904A 52 P SI 3.5 IN. Navist ar 530H WM780A WM77A WM78A WM90H WM90H WM90H WM903A WM902E WM904A 52 P SI 3.5 IN. 6

9 VEHICLE / ENGINE APPLICATION TABLE CAUTION (a): ADJUST TO MANUFACTURERS BACK PRESSURE SPECIFICATIONS. Pressure listed herein are suggested from industry input. CAUTION (b): Vehicles with automatic transmissions must have a lock-up feature to enable retarding torque to pass through the transmission. If you have a question please contact BSI T echnical Support personnel. VEHICLE YEAR ENGINE BRAKE MO DEL CONTROL KIT & COMBI KIT* MOUNTING KIT MAX PRES- SURE PIPE SIZE NOTES Dodge PU 998½ Cummins 5.9 WM78A WM734C 533A WM904A 55 P SI 3.5 IN. WM78 AK20 Dodge PU 2003 & Up Dodge PU 2003 & Up Cummins 5.9 Cummins 5.9 WM78A WM734C WM904A 60P SI 3.5 IN. WM78 AK8 WM77A WM734C 60P SI 4.0 IN. WM77 AK9 Ford F Series 2004 & Up 6.0 WM78A WM734D WM904A 50P SI 3.5 IN. *** Ford F Series 999 & Up 7.3 WM78A WM734D WM904A 40 P SI 3.5 IN. WM78 AK9 Ford F Caterpillar C7 WM77A WM90L 55 P SI 4.0 IN. Ford Excursion Powerstroke WM78A WM734D WM904A 40 P SI 3.5 IN. Note: On any engine 2006 or newer design, please specify if the engine is equipped with a VGT. *Combi Kit includes necessary control items, plus air supply and idle validation device (switch or ECU pins). **For Idle Validation ) tap into electronic system per WBO 2, or 2) add 540A switch to throttle 5 / ***Special mounting instructions. 7

10 VEHICLE / ENGINE APPLICATION TABLE CAUTION (a): CAUTION (b): ADJUST TO MANUFACTURERS BACK PRESSURE SPECIFICATIONS. Pressure listed herein are sug gested from industry input. Vehicles with automatic transmissions must have a lock-up feature to enable retarding torque to pass through the transmission. If you have a question please contact BSI Technical Support personnel. Note: On any engine 2006 or newer design, please specify if the engine is equipped with a VGT. VEHICLE YEAR ENGINE BRAKE MO DEL Freightliner FL CONTROL KIT & COMBI KIT* MBE 900 WM77A WM90MB ** MOUNTING KIT MAX PRES- SURE PIPE SIZE NOTES WM902B 43P SI 5.0 IN. Freightliner FL Caterpillar 326E WM77A WM90M ** 55 P SI 4.0 IN. Freightliner FL Mercedes MBE900 WM77A WM90MB ** 43P SI 4.0 IN. Freightliner FL Caterpillar 326 WM790A WM90M WM904B 55P SI 3.5 IN. Freightliner FL & Up Series 50 GMC WM77A WM90S 2 39 P SI 4.0 IN. GM Hummer 200 & Up 6.5 I6 WM78A WM734D WM904C 38 P SI 3.0 IN. Use Torqloc GMC Isuzu ALL Duramax 6.6 V8 WM780A WM78A WM90M WM90M WM903A WM904A 3.5 IN. GMC Isuzu ALL Duramax 7.8 Inline 6 WM78A WM90M WM90M 4.0 IN. IH 4300/ & Up DT 466E WM78A WM734C 544A WM904A 5 P SI 3.5 IN. IH 4700/ & Up DT 466E WM78A WM77A WM736C 544A WM904A 5 P SI 3.5 IN. 4.0 IN. Komat su ALL QST30 WM IN. Komat su ALL KT 38C WM (x2) 5.0 IN. St erling 2004 & Up Cummins 5.9 WM78A WM90H WM904C 60 P SI 3.0 IN. Air on board *Combi Kit includes necessary control items, plus air supply and idle validation device (switch or ECU pins). **For Idle Validation ) tap into electronic system per WBO 2, or 2) add 540A switch to throttle 8 ***Special mounting instructions.

11 WM728A BUTTERFLY WEIGHT-3lb, 8oz Blue Ox exhaust brake devices provide downhill retarding horsepower as well as cold weather protection for the engine in both highway & idling modes. This is a bolt on retarder unit designed to mate with certain naturally aspirated or super charged diesel engines. This unit fits the four bolt, 4 exhaust flange popular on some Cummins 855 cubic engines Item Description Part Number Quantity Item Description Part Number Quantity Housing Assembly, 728-0C 0 Lock Washer consists of: Housing Stop Screw Shaft A 2 Jam Nut Butterfly Bushing Rivet Bushing Collar B 2 5 Mounting Screw Seal Ring Hex Nipple 3325X2 2 Bracket Assembly 77-04B 7 Shaft Nut Cylinder Assembly C Clip Link Mounting Hardware: 5 Clevis Assembly Gasket QR Valve Mounting Bolt Breather Mounting Bolt Snap Ring Mounting Nut Lock Washer

12 WM728A KIT DETAILS Item Kit Number Size Control Kit Install Kit Application WM728AK A 736A NHB WM728AK L - NHB WM728AK A - COMPLETE INSTALLATION KITS INCLUDE: WM728 AK Brake kit without controls. 2 WM728 AK2 2 volt manual type foot operated. 3 WM728 AK4 2 volt automatic type throttle rod actuated. 4 WM728 AK6 2 volt automatic type electronic engine control. 0

13 WM760A BUTTERFLY Blue Ox exhaust brake devices provide downhill retarding horsepower as well as cold weather protection for the 4 stroke engine in both highway and idling modes. This unit is designed to mount inline and downstream of the turbo or manifold flange. The WM760A is the smallest of the Blue Ox family and will mate with pipe sizes from two to three inches, including 58mm outer diameter as well as engine displacements up to 300 cubic inches (5 L)

14 WM760A KIT DETAILS Item Kit Number Size Pipe Kit Control Kit Install Kit Application WM760AK6 2.0 WM903E WM90M WM760AK8 58 mm WM903D WM90M WM760AK0 58 mm WM903D - WM734C - 4 WM760AK2 2.5 WM903C WM90M WM760AK4 2.5 WM903C - WM734C - COMPLETE INSTALLATION KITS INCLUDE: WM760 AK6 2.0 inches 2 volt DC electronic engine control. 2 WM760 AK8 58 millimeters 2 volt DC electronic engine control. 3 WM760 AK0 58 millimeters 2 volt DC electronic engine control with air supply kit. 4 WM760 AK2 2.5 inches 2 volt DC electronic engine control. 5 WM760 AK4 2.5 inches 2 volt DC electronic engine control with air supply kit. 0/05 2

15 , WM780A GUILLOTINE SERIES A B C D E WEIGHT WM (54 ) 2.2 (54 ) 4.53 (5 ) 7.8 (436 ) 4.00 (02 ) 9.5 lbs 8.8 kg WM (459 ).62 (4 ) 3.76 (96 ) 5.72 (399 ) 2.75 (70 ) 5.5 lbs 7.0 kg The Blue Ox exhaust brake is an engine retarder for fourstroke diesel engines. models fit engines with exhaust system diameters of 4 to 5 inches. WM780A models are used on engines with exhaust system diameters under 3 /2 inches. ITEM DESCRIPTION 839 WM780A 802 QTY. ITEM DESCRIPTION 839 WM780A 802 QTY Snap Ring Screen Filter Air Cleaner Body Washer Nut Pipe Nipple Quick Release Male Connector Brake Body Slide Gate Nut Waste Gate Waste Gate Seal Gasket Screw Spring Washer Packing Screw fo r fo r Cylinder Adapter Spring Spring Spring Retainer Piston Seal Retainer Piston Rod Cylinder Shell Nut Packing Cup Nut Base Cap Screw Bushing Pipe Plug I.D. Tag Screw Screw Washer Item is included in cylinder assembly kit 842 Item is included in cylinder / waste gate assembly kit Item is included in repair kit R770D/780 (86). 3

16 , WM780A /05

17 WM77A BUTTERFLY WEIGHT-2lb, 2oz Item Description Part Number Quantity Item Description Part Number Quantity Housing Assembly, 77-0C 4 Link consists of: Housing Clevis Assembly Shaft Cap Screw Butterfly Breather Rivet A 3 8 Snap Ring Collar B 3 9 Lock Washer Seal Ring Shaft Nut Bushing Stop Screw Bushing Stop Nut Bracket Assembly 77-04B 3 QR Valve Cylinder Hex Nipple 3325X2 5

18 WM77A KIT DETAILS Item Kit Number Size Pipe Kit Control Kit Install Kit Air Kit Application WM77AK C 532A 736A WM77AK C - 90E WM77AK C - 736A WM77AK B 532A 736A Wm77AK B - 90E WM77AK B - 736A WM77AK E - 736B 734A Dodge 8 WM77AK C - 736B 734A Dodge 9 WM77AK C - 736A 734A Ford 0 WM77AK C 540A 90R - FL50 / FL70 WM77AK E - 736A 734A Ford COMPLETE INSTALLATION KITS INCLUDE:. WM77 AK2 4 2 volt manual type foot operated. 2. WM77 AK4 4 2 volt automatic type throttle rod actuated. 3. WM77 AK6 4 2 volt automatic type electronic engine cotrolled. 4. WM77 AK2 5 2 volt manual type foot operated. 5. WM77 AK4 5 2 volt automatic type throttle rod actuated. 6. WM77 AK6 5 2 volt automatic type electronic engine controlled. 7. WM77 AK8 3 /2 2 volt electronic engine air supply kit. 8. WM77 AK volt electronic engine air supply kit

19 WM78A BUTTERFLY Blue Ox exhaust brake devices provide downhill retarding horsepower as well as cold weather protection for the 4 stroke engine in both highway and idling modes. This unit is designed to mount in-line and down stream of the turbo or manifold flange. The WM78A is the smaller of the Blue Ox family and will mate with pipe sizes up to 3 /2 as well as engine displacements up to 470 cubic inches Item Description Part Number Quantity Item Description Part Number Quantity Housing Assembly, 78-0C 5 Clevis Assembly 5383 consists of: Housing Cap Screw Shaft Breather WMC Butterfly Snap Ring Rivet Lock Washer Collar B 2 0 Shaft Nut Seal Ring Stop Screw Bushing Jam Nut Bushing Pin 57 2 Bracket Hair Clip Cylinder WM635B3B 5 Clevis Pin Link

20 WM78A KIT DETAILS Item Kit Number Size Pipe Kit Control Kit Install Kit Air Kit Application WM78AK A 532A 736A - Manual 2 WM78AK A - 90E - Throttle Rod 3 WM78AK A - 736A - Electric Engine 4 WM78AK D 532A 736A - Manual 5 WM78AK D - 90E - Throttle Rod 6 WM78AK D - 736C 734A Ford WM78AK A - 736A 734A Air Kit 8 WM78AK A - 90L 734A Whisker 9 WM78AK A - 736B 734A Dodge 98 0 WM78AK A - 736A 734A Electric WM78AK G - 736C 734A Ford COMPLETE INSTALLATION KITS INCLUDE: WM78 AK2 3 /2 2 volt manual type foot operated. 2 WM78 AK4 3 /2 2 volt automatic type throttle rod actuated. 3 WM78 AK6 3 /2 2 volt automatic type electronic engine control. 4 WM78 AK8 3 /2 2 volt automatic type electronic engine control (with air supply kit)

21 WM790A BUTTERFLY Blue Ox exhaust brake devices provide downhill retarding horsepower as well as cold weather protection for the 4 stroke engine in both highway and idling modes. This unit is designed to mate directly with the turbo charger for several engines including the Caterpillar 326. Usually the downstream exhaust pipe is 3 /2 diameter but other size flange kits are also available Item Description Part Number Quantity Item Description Part Number Quantity Housing Assembly, 790-0C 5 Clevis Assembly 5383 consists of: Housing Cap Screw Shaft Breather WMC Butterfly Snap Ring Rivet Lock Washer Collar B 2 0 Shaft Nut Seal Ring Stop Screw Bushing Jam Nut Bushing Hair Clip Bracket Pin 57 3 Cylinder WM635B3B 5 Clevis Pin Link

22 WM790A KIT DETAILS Item Kit Number Size Pipe Kit Control Kit Install Kit Application WM790AK B 540A 736A 326T 2 WM790AK D 540A 736A 326T COMPLETE INSTALLATION KITS INCLUDE: WM790 AK2 3 /2 2 volt 326T, FL 2 WM790 AK4 3 /2 2 volt 326T, FL

23 WM90 CONTROL KITS WM90 series kits provide the control circuit components for Blue Ox exhaust brakes. The WM90 control circuit is governed by an on/off electric switch mounted on the vehicle s dash. When the switch is in the on position, the exhaust brake is automatically applied whenever the throttle is returned to idle. When the operator moves the throttle from the idle position, the exhaust brake is released and completely withdrawn from the exhaust. For Butterfly Brakes, add the suffix after kit number (example: WM90E). Includes regulator assembly. DESCRIPTION WM90E 743 WM90H 9252 WM90J 947 WM90K 943 WM90L 9566 WM90M* WM90N QTY Microswitch Bracket Bracket Screw Washer Tinnerman Nut Lever Bolt Tee Saddle Clamp Lock Nut Solenoid Wire Fuse Holder Fuse Connector Toggle Switch Escutcheon Plate Connector Terminal Screw Screw Terminal Connector Connector Hose Adapter Swivel Connector Cable Ties Terminal Washer Screw Label Connector Connector Relay Wire Terminal Assy Switch Assy Actuator Switch Bracket Bracket WM779B for 90M 2 for others /05 *Includes ECU pin with w ire. 2

24 WM902/903/904 MOUNTING KITS WM902 series mounting kits are used to install and WM77A series exhaust brakes in exhaust systems with diameters between 3 /2 and 5 inches. A turbomount kit, WM902A, is available to mount the exhaust brake in the turbo outlet of some Cummins and Caterpillar engines. WM903 series mounting kits install the WM780A series exhaust brakes in exhaust systems with diameters of 3 /2 inches or less. WM904 series mounting kits install the WM78A and WM790A series exhaust brakes in exhaust systems with diameters between 3 and 4 inches. /77A MOUNTING KIT WM760A/780A MOUNTING KIT WM78A/790A MOUNTINGKIT ITE M DESCRIP. Q WM902A 7558 WM902B WM902E 7562 WM902F 3494 WM903A 7835 WM903B 7836 WM903C 7837 WM903D 7838 WM903H 3495 WM904A (78A) WM904B (790A) WM904C (78A) WM904 D (78A) ADAPTER U CLAMP V BAND CLAMP () GASKET () 8394 () 8394 () () () ADAPTER () () () GASKET PIPE SIZE 5.0 OD TURBO 5.0 ID 4.0 ID 4.0 OD 3.5 ID 4.0 ID * 3.5 ID 3.0 ID 2.5 ID 58 mm OD 3.0 ID * 3.5 ID 3.5 ID 2.5 & 3.0 ID 4.0 ID 22 * STAINLESS STEEL COMPONENTS 7 0/05

25 AIR SUPPLY KITS Supplies compressed air for engaging exhaust brakes. WM734A* AIR SUPPLY KIT, NO TANK For butterfly brakes only, demand only. The WM734A system uses the demand system for air. The compressor only turns on when the controls are in the ON position. This takes from 3 to 4 seconds for the compressor to pressurize the line and also the control cylinder. When the pressure is at the governor setting it then shuts off. This system does not use an air tank therefore the compressor is not required to keep up a full tank and also with the various air leaks that often plague a more conventional system. WM734AK2 The ON-OFF signal in the WM734AK2 system comes from the whisker switch or other device which senses throttle idle position to compete the circuit. All of the required circuitry is enclosed in control box Hook the three wires (red, white and black) and two air hoses to their respective terminals. 24A /29/ 23

26 WM734AK The ON-OFF signal in the WM734AK system comes from the on board ECU and usually uses pins 39 and 42 to complete the circuit. The relay turns on the compressor when the control circuit is completed by a ground through the ECU. (See dwg. WM734AK; 24B). All of the required circuitry is enclosed in the control box Hook the three wires (red, white and black) and two air hoses to their respective terminals. WM734AK 24 /29/

27 AIR SUPPLY KITS Complete air kit designed for light to medium duty vehicles that do not already have an onboard air system. *WM734B AIR SUPPLY KIT includes air tank. ITEM QTY. DESCRIPTION REF. # COMPRESSOR 2 AIR TANK 2 3 PRESSURE SWITCH 3 4 FUSE 20 A 4 5 FUSE HOLDER 5 6 EXTENSION HOSE 25 7 INFLATION VALVE 7 8 BRASS T FITTING 8 9 WIRE KIT 0 AIR FILTER 0 COILED HOSE W/ CHUCK REV

28 WM734BK COMPLETE AIR KIT ITEM QTY. PART # DESCRIPTION REF. # WM734B SUPPLY KIT W/ TANK 2 WM779B WHISKER SWITCH KIT A SOLENOID/REGULATOR 2, DASH SWITCH ESCUTCHEON PLATE X4 SERVICE TEE X4X4 HOSE END C ELECTRICAL KIT 9 BLUE OX CATALOG PG. 22A AND 22B CATALOG SHEET 26 REV

29 WM734C,D AIR CONTROL/SUPPLY KIT A complete supply and control kit for butterfly type exhaust brakes on vehicles without an air supply. Kit includes the (on demand) air compressor, mounting bracket and preassembled circuitry with two variations for idle validation. The WM734C kit includes pins to plug into the engine ECU. The WM734D kit includes a whisker switch with bracket to validate pedal position. ITEM QUANTITY 734C 734D PART NUMBER DESCRIPTION 728-2B Switch, 2V B Electrical Package Cap Screw Lock Nut A DWG B-02 Union, / Escutcheon Plate Compressor Bracket ECU Pin Control Assembly X2 Elbow 3 - WM779B Whisker Kit AIR CONTROL ASSEMBLY Pre-plumbed wire and sealed control system, all ready to install. Add the compressor, dash switch and idle validation switch to make up the complete unit listed above as WM734C, D. ITEM QUANTITY PART NUMBER DESCRIPTION 0390 Connector Cap Screw Connector Wire, Red, 4ga Wire, Green, 8ga Wire, Black, 8ga Wire, Red, 8ga Wire, White, 8ga Wire, Black, 4ga Connector Relay, 4 Pin Manifold Assembly Doubler Blade Enclosure Box Retainer Roll Loom, /2 7 4 H004 Roll Hose, /4 24A 07/05 27

30 CONTROL KITS Control kits for exhaust brake applications. WM736A, GENERIC N.C. SIGNAL ITEM QUANTITY PART NUMBER DESCRIPTION 0345 Escutcheon Plate Relay Breather B Solenoid, 2V B Switch, 2V B Electrical Package 7 24B Catalog Page WM736B, DODGE 5.9 ITEM QUANTITY PART NUMBER DESCRIPTION 0345 Escutcheon Plate Relay Breather Terminal B Solenoid, 2V B Switch, 2V B Electrical Package 8 24B Catalog Page D Wiring Program WM736C, FORD 7.3 ITEM QUANTITY PART NUMBER DESCRIPTION 0345 Escutcheon Plate Blade Receptacle Blade Receptacle Relay Relay N.C Breather B Solenoid, 2V B Switch, 2V B Electrical Package 0 24B Catalog Page 54 Catalog Page 24B 07/05 28

31 4R 8 + 2V DC 7 0 DASH SWITCH BATTERY OR IGN. SWITCH A R 4 3 8G CRUISE CONTROL FORD I.V.S. WM734A AIR SUPPLY KIT WM736C WIRING KIT () COMPRESSOR - 2V. (2) SOLENOID (3) GOVERNOR (4) DASH SWITCH (5) IDLE VALIDATION SYSTEM (6) EXHAUST BRAKE (7) RELAY - N.C. (8) FUSE OR BREAKER (9) SAFETY POP-OFF 24B 07/05 29

32 IDLE VALIDATION via IDLE VALIDATION SWITCH (I.V.S.) This acronym is used in modern technology to describe what was at one time called a throttle interlock. The idea is to insure that an exhaust brake (or other device) will only be activated when the engine throttle is in the idle mode. The brake must never be turned on (exhaust shut off) when a throttle setting is telling the engine to put out horsepower. This is a conflict that may harm the engine. Throttle technology has gone from:.) Throttle rods including clevis and ball joints, to 2.) Air throttles using variable air pressure, and currently, 3.) Electronic throttle positioning using variable voltage. For I.V.S., it is possible to use a whisker switch, a micro switch on the throttle pedal. Or, simplest of all, use a plug to connect into the electronic engine control (ECU, ECM). Some military installations use yet another solution. The brake is activated with a foot switch on the floorboard. Placement of the switch requires the operator to take his foot off of the throttle in order to press on the switch, hence the term I.V.. Blue Ox offers a myriad of devices and wiring diagrams, so you can pick the one most suited to your engine/truck combinations, such as:.) Straight Air 2.) Electric/Air 3.) Electronic/Air Our technical service department can suggest a hook up that is simple and reliable /05

33 ENGINE IDLE KITS Energizes auxiliary circuit when electronic engines are in idle mode. 526B IDLE KIT For Williams floor mount pedals. ITEM QUANTITY PART NUMBER DESCRIPTION Bracket Spacer Switch Cap Screw Self Lock Nut Cap Screw Self Lock Nut Cap Screw Nut Washer, Big Washer, Small 2 29 Catalog Page 533A IDLE KIT For many Dodge pickup trucks with Cummins 5.9 electronic engines. ITEM QUANTITY PART NUMBER DESCRIPTION Mounting Bracket Striker Bracket Terminal Screw Washer Switch Tinnerman Nut Screw 9 29 Catalog Page TYPICAL USES FOR ENGINE IDLE KITS INCLUDE:.) Exhaust brake/engine retarder interlock circuit /05 2.) Bus door interlock when used in conjunction with brake interlock. 3.) Bus deceleration lighting programs. 3

34 540A IDLE KIT For Williams overhung (firewall) mount pedals. ITEM QUANTITY PART NUMBER DESCRIPTION Switch Bracket Idle Bracket Blade Connector Screw Switch Tinnerman Nut 7 29 Catalog Page 544A IDLE KIT For many International trucks including some 2000 and later models, such as 4300, 4700, 4900 and models with DT466 and other engines. ITEM QUANTITY PART NUMBER DESCRIPTION Switch Lock Nut Mounting Bracket Cap Screw Terminal, Elbow Terminal, Straight 7 29 Catalog Page TYPICAL USES FOR ENGINE IDLE KITS INCLUDE:.) Exhaust brake/engine retarder interlock circuit. 2.) Bus door interlock when used in conjunction with brake interlock /05 3.) Bus deceleration lighting programs. 32

35 MISCELLANEOUS CONTROL KITS 545B PUSH PULL CONTROL KIT Push Pull On-Off switch for shift lever mounting. ITEM QTY. PART NUMBER DESCRIPTION Connector Lock Nut Cap Screw Nylon Ties Roll Wire Switch Bracket Roll Loom 9 Blue Ox Sticker 0 Catalog Page 55 2/05 WM779B (958) SWITCH KIT Position sensing switch (whisker) in many cases used for idle validation (IVS) on a throttle pedal. ITEM QTY. PART NUMBER DESCRIPTION Terminal Screw Tinnerman Nut Switch Roll Wire Roll Loom Bracket 8 Catalog Sheet 33

36 MISCELLANEOUS CONTROLS 528A FOOT SWITCH A small compact foot switch used for a manual activation of exhaust brakes as well as other circuits up to 2, 24, or 42DC volts. Comes with 8 pigtail and mounting ears. Circuits up to 4 amps. 530A WHISKER SWITCH A small micro switch mounted on a universal bracket with a 3 activation whisker used to validate throttle or clutch pedal position. Used on automotive systems of 2, 24, or 42DC volts. Circuits up to 4 amps. 532A FOOT SWITCH Momentary contact foot switch assembly with mounting bracket for floor board mount. Capacity 60 AMP, 5/6 stud terminal /05

37 30379/30657 SOLENOID A small special purpose three-way solenoid with /8 NPT ports, up to 25 PSI supply pressure, 0 watts of electric draw with a 3/32 orifice; 2 or 24V DC (2V DC) (24V DC) DASH SWITCH Dashboard mount (7/6 hole) for automotive applications. /4 blade connections. For illuminated toggle version, the extra blade needs to be grounded to provide a circuit for the LED in the handle which glows when the switch is turned on (24V DC Illuminated) 728-2B (2V DC Illuminated) MANIFOLD ASSEMBLY Manifold assembly including all necessary components of a Blue Ox air supply system. Designed for smaller vehicles without an air supply system. Add a 2 volt compressor (6005) and the system will supply air on demand and limited to 70 PSI. WM25A MOTION VALVE A small 3-way N.C. air valve (/8 NPT) with a push rod actuator. Originally designed to sense motion in the throttle mechanism of diesel engines. 75 0/09 35

38 SOLENOID REGULATOR ASSEMBLY W/ MOUNTING BRACKET 697A 24V 0379A 2V MICRO SWITCH 7785 DASH TOGGLE SWITCH 0384 Standard Lighted Toggle 24V 728-2B Lighted Toggle 2V RELAY 2V, 30 AMP W/ MOUNTING BRACKET /09 36

39 WM224H COMPENSATING HAND VALVE, SMALL Used as a Blue Ox dash control on some older type of control systems (aka WM90P). It is a combination of an on-off dash valve and a pressure regulator and usually used in conjunction with a WM25A motion valve to detect throttle position. It provides a full air/mechanical control system without the need for electrical input. 37

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41 WARRANTY Brake Systems Inc. warrants to the Original Purchaser that all exhaust brake products manufactured by Brake Systems Inc. will be free from defects in materials and workmanship under normal use and service. This warranty also provides an unlimited lifetime warranty on the: NODULAR IRON EXHAUST BRAKE BODY Brake Systems Inc. also warrants a Limited Lifetime Warranty extended to the original purchaser of the components of the Blue Ox Exhaust Brake under the following limitations: FOR HIGHWAY VEHICLES Two (2) years from date of installation or 00,000 miles, whichever shall occur first. FOR OFF-HIGHWAY VEHICLES 50,000 miles FOR S TATIONARY EQUIPMENT 2000 hours of operation WARRANTY DEFINITION The exhaust brake is factory tested and preset for most normal installations.. If the brake assembly is field adjusted the user accepts responsibility for the consequences of the change. 2. The brake kit must include a factory of field designed throttle interlock. In no case shall the brake assembly be closed at the same time as the throttle control is above idle. This can harm your engine with so much heat with nowhere to go 3. Warranty requests must include verification of the above requirements 4. Warranty shall not apply to units that have been subject to misuse, misapplication, fire or accident, or to units which have been improperly installed or have been subject to unauthorized.alteration. NO OTHER WA RRA NTY, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR OTHERWISE (INCLUDING ANY WARRANTY OF MERCHANTABILITY, FITNESS OR PERFORMANCE), SHALL EXIST IN CONNECTION WITH THE SALE OR USE OF EXHAUST BRAKE UNITS SOLD BY BRAKE SYSTEMS INC. In the event that claims are made with regard to defective materials or workmanship, Brake Systems Inc. shall have the option to repair, replace or grant a credit for any unit which Brake Systems Inc. in its sole discretion determines to be defective at time of sale. THE FOREGOING STATES BRAKE SYSTEMS INC. S SOLE RESPONSIBILITY FOR BREACH OF THIS WARRANTY. IN NO EVENT SHA LL BRAKE SYSTEM S INC. BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. To make a claim against the warranty, all claim units must be reviewed by Brake Systems Inc. All warranty claims must be presented within 30 days of discovery of defect. To make a warranty claim, the purchaser must ship the unit freight prepaid along with the invoice number, purchaser s name, address, and vehicle mileage (at the time of failure) to: Brake Systems Inc., Warranty Dept., 222 NE Hoyt St. Portland, Oregon / 06/ 2 The reasonable cost of returning merchandise will be reimbursed, if it is subsequently determined that the unit was defective at the time of sale 39

42 BRAKE SYSTEMS, INC. 222 N.E. HOYT PORTLAND, OR FAX TOLL FREE / 0 37 DISTRIBUTOR OF: AIR CYLINDERS BENDIX - POWER BRAKES HYDRAULICS & COMPRESSORS BLUE OX EXHAUST BRAKES C/R,SKF AIR DRYERS, BEARINGS CARLISLE INDUSTRIAL BRAKE PRODUCTS CHICAGO RAWHIDE AIR DRYERS DELCO BOOSTERS & VACUUM PUMPS DEL HYDRAULIC ELECTRONIC THROTTLE CONTROLS EUCLID / SEALCO/ARVIN-MERITOR FIRESTONE - RIDE RITE GROVER AIR HORNS HAYES LEMMERZ CONTROLLERS HORTON FAN CLUTCHES KIP SOLENOIDS LOCKTITE PRODUCT LINES SUPER STORE MAGNETEK / PATRIOT / GEMCO / WAGNER INDUSTRIAL BRAKE PRODUCTS MGM SPRING BRAKES BRAKE PRODUCTS brakesystems@brakesystemsinc.com MIDLAND HALDEX BRAKE PRODUCTS PBD REPLACEMENT AIR VALVES REXROTH INDUSTRIAL CONTROLS WABCO TSE SPRING BRAKES VELVAC BRAKE & ELECTRIC PRODUCTS WAGNER / FEDERAL MOGUL WEATHERHEAD HOSE & FITTINGS WILLIAMS CONTROLS - AIR VALVES & ELECTRONIC THROTTLES ZERO-RUST MANUFACTURER OF: SPECIALTY ELECTRONIC THROTTLE & BRAKE PRODUCTS EXHAUST BRAKES - BLUE OX AIR CYLINDERS - BSI & WILLIAMS AIR VALVES BSI & WILLIAMS REMANUFACTURER OF: BRAKE BOOSTERS LUCAS/GIRLING BACKING PLATES AIR VALVES, FAN HUBS PRESSURE CONVERTERS INDUSTRIAL CALIPERS AIR COMPRESSORS