NO.

: 03 TS - 51
October 22, 2003

TO: All Distributors, U.S. and Canada

ATTN. Service Managers

FROM: Evandro Silva

SUBJECT: MBE4000 – Turbo Brake – Troubleshooting

The information enclosed in this letter provides diagnostics procedures on the MBE4000 engines
equipped with a turbo brake. For additional information on the turbo brake, refer to the following TS
Letters:

• 03 TS-39: MBE4000 – Turbo Brake – Installation Diagrams

• 03 TS-40: MBE4000 – Turbo Brake – Operation

CAUTION

To avoid injury when working near or on an operating engine,

remove loose items of clothing, jewelry, and tie back or contain
long hair that could be caught in any moving part causing injury

CAUTION

Diesel engine exhaust and some of its constituents are known to

the state of California to cause cancer, birth defects, and other
reproductive harm.
o Always start and operate an engine in a well-ventilated area.
o If operating an engine in an enclosed area, vent the exhaust
to the outside.
o Do not modify or tamper with the exhaust system or
emission control system.

NOTE:
For additional safety precautions, refer to the MBE4000 Service Manual
(6SE412) – General Information – page 15.

Detroit Diesel Corporation 13400 Outer Drive, West / Detroit, Michigan 48239-4001 / Telephone: 313-592-5000
DaimlerChrysler Powersystems
1. Visual inspections performed with the vehicle in neutral, parking brake engaged and wheels
blocked.

1.1. Constant Throttle Valve (CTV) Operation:

• Condition: Engine at operating temperature.
• Activation: Switch on the low engine brake level, then raise engine rpm and allow it
to fall again. The engine speed drop should be twice as fast than without
the CTV. An increase in noise from the exhaust system should also be
audible.
1.2. Turbo Brake Operation:
• Condition: Engine at operating temperature. Switch on the medium engine brake
level.
• Activation of the waste gate valve (this step requires an operator for the engine brake controls
in the cab and an observer for the engine compartment):
When the engine is started it should be easy to see the waste gate valve
plunger rod extending. When the engine is turned off the plunger rod
should retract all the way into the waste gate valve.
• Activation of the sliding sleeve:
Start the engine, and then raise the engine rpm up to rated speed and
allow it to fall again. The semi-circle lever must switch back all the way.

2. Operating Characteristics.

Operation Condition Specification

Minimum: 90,000 rpm

Checking the turbocharger
speed*
Under full load (engine speed
above 1500 rpm)
Maximum: 100,000 rpm
With Turbo brake on and at Minimum: 85,000 rpm
maximum braking power
(engine speed above 2000 rpm) Maximum: 90,000 rpm

Pressure at the sliding sleeve

Above 116 PSI (8 bar)
actuator (pneumatic cylinder)
Checking air control
pressures Pressure at the Electronic
Above 73 PSI (5 bar) at idle
Proportional Valve (EPV) – air
and under full load.
supply line

* Note: this feature will be available at DDDL version 6.0.

2
3. Basic Troubleshooting Table

Complaint Possible Cause Corrective Action

Turbo brake fails to work Check fault code and

Fault code in the PLD/VCU
conduct inspection/repair

Check parameter set (use

Incorrect parameter set on the that parameter set table from
PLD / VCU 03TS-39). Perform the proper
adjustments.

Sliding Sleeve fails to work Check input signal at VCU,

No electrical signal to the
out put signal from PLD and
solenoid valve.
wiring.

Remove the ball joint from

Control bracket and sliding the pneumatic actuator to the
sleeve sticking or blocked. control bracket and check the
control bracket movement.

Remove the ball joint from

the pneumatic actuator to the
Pneumatic actuator sticking or
control bracket and check the
seized
pneumatic actuator
movement.

Insufficient air pressure supply Check pressure at the circuit

to the pneumatic actuator. (see specs page 2).

Insufficient air pressure supply Check pressure at the circuit

to the solenoid valve (see specs page 2).

Waste gate valve and by- Check wiring and signal to

pass valve fail to work No electrical signal to the the EPV.
Electronic Proportional Valve
(EPV) Check parameter set on the
PLD.

Disconnect the waste gate

By-pass valve sticking or seized valve rod and check the by-
pass valve for movement.

Check pressure at the circuit

(see specs page 2).
Insufficient air pressure supply
to the waste gate valve. Check for leaks at the circuit
and waste gate valve.

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 Complaint Possible Cause
Waste gate valve and by- Insufficient air pressure supply
pass valve fail to work to the EPV.
EPV Valve fails to work.
Low braking power
Engine speed not high enough
Insufficient air pressure supply
to the waste gate valve.
Insufficient air pressure supply
to the EPV.
EPV Valve fails to work.
Constant Throttle Valve fails to
open, no electrical signal for the
solenoid valve at the oil filter
housing.
Constant Throttle Valves fail to
open, no oil pressure
Any further questions, please contact DDC Technical Support for MBE4000.
Evandro Silva
Technical Support
cc: Regional Vice Presidents, U.S. & Canada
Regional Product Support Managers, U.S. & Canada
Corrective Action
Check pressure at the circuit
(see specs page 2).
Replace the EPV Valve.
Engine speed must be >
2000 rpm.
Check pressure at the circuit
(see specs page 2).
Check for leaks at the circuit
and waste gate valve.
Check pressure at the circuit
(see specs page 2).
Replace the EPV Valve.
Check parameter set (use
that parameter set table from
03TS-39). Perform the proper
adjustments.
Coolant temperature must be
higher than 140°F (60°C)
Check the solenoid valve
(opening and closing).
Check for pressure at the oil
supply line.