Trucks • Engine

Turbobrake Code MZ4

Advanced Training
Information Module

As at 05/03

Trucks • Engine Turbobrake Code MZ4

Advanced Training Information Module
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1511 1281 02 - 1 edition 05.03 20 As at 05/03
 Inhaltsverzeichnis 19.05.2003

Titel Seite

Turbo brake - Component layout .............................................................................................................................................................................................................1

Turbo brake - Components and operation...............................................................................................................................................................................................2
Turbo brake - Comparison with other braking systems...........................................................................................................................................................................4
Turbo brake - Flow plate location, design and operation.........................................................................................................................................................................5
Turbo brake - Location, design and operation of air-discharge element .................................................................................................................................................6
Turbo brake - Turbine speed sensor location and operation ...................................................................................................................................................................7
Turbo brake - Electropneumatic transducer (EPW) location, design and operation ................................................................................................................................8
Turbo brake - Engine brake demand......................................................................................................................................................................................................10
Turbo brake - Problem diagnosis, operating functions ..........................................................................................................................................................................11
Turbo brake - Problem diagnosis ...........................................................................................................................................................................................................12
 Turbo brake - Component layout 13.05.03

1 Exhaust-gas turbocharger
2 Aneroid capsule
3 Turbo brake
A6 MR/PLD control module
B104 Turbine speed sensor
Y87 Electropneumatic transducer (EPW)

W09.40-1061-06

05/03 Trucks • Engine Turbobrake Code MZ4 Advanced Training Information Module
Turbo brake - Component layout 1
 Turbo brake - Components and operation 13.05.03

The turbo brake replaces the engine brake valve.

It consists of a flow plate (4) that moves axially
within the turbocharger. When higher levels of
engine braking are required, the flow plate (4)
slides into the radial passage in the turbine
induction channel. This reduces the radial
passage's effective flow aperture as well as the
incidence angle at which the exhaust gas impacts
against the turbine. The ultimate result is to
accelerate the exhaust gas and rise the turbine
speed, causing an increase in induction pressure.

This boost pressure enhances the engine's

braking effect – the rise in effective compression
ratio translates into more braking.

The control cylinder (1) operates the flow plate.

As with the engine brake valve, ultimate control
resides with the FR Drive Control system. Driver
demand is transmitted through the engine control
/ continuous brake lever. The constant throttle
also assumes operation at engine oil
temperatures of > 60 °C. W09.40-1066-09

1 Working cylinder 5 Control bracket 8 Aneroid capsule

2 Cam lobes 6 Matrix 9 Air-discharge element
3 Housing 7 Turbine spiral 10 Rotating slide valve
4 Flow plate

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Turbo brake - Components and operation 2
To prevent the turbocharger from self-destructing owing to excessive rotation
rates, the turbine rpm sensor (B 104) monitors its speed for relay to the MR
Engine Control ECU (A6), which limits turbocharger speed to 90,000 rpm.

The MR Engine Control ECU regulates and limits braking power via the
electropneumatic converter (Y87), which then activates the aneroid capsule
(2) for the rotating slide valve (4).
A bypass valve serves as a wastegate by diverting gas flow around the turbine.
This places a limit on boost pressure and turbine speed.

The turbo brake responds with a lag of 1 to 10 seconds, depending upon

initial engine speed and instantaneous load factor.
When the system is activated the constant throttle acts with almost no delay
to start applying braking pressure. The driver will note this as a gradual initial
braking application which leads into the phase of higher braking force
furnished by the turbo brake.

W09.40-1062-06

2 Aneroid capsule 7 Rotary slide valve housing

4 Rotary sliding valve A6 MR Engine Control ECU
5 Bypass line B104Turbine rpm sensor
6 Turbine Y87 EPW valve

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Turbo brake - Components and operation 3
 Turbo brake - Comparison with other braking systems 13.05.03

Diagram comparing turbo brake with engine

brake valve

A Engine brake valve, constant throttle and retarder

B Turbo brake and constant throttle
C Engine brake valve and constant throttle

W09.40-1067-75

Advantages of the turbo brake:

· 50% more braking power than with standard engine brake (brake valve and constant throttle) at engine speed of 2500 rpm
· Lower weight (roughly 85 kilos less than a hydraulic retarder)
· Does away with loads on cooling system generated by the hydraulic retrader
· Braking performance remains constant with no variations caused by shifts in coolant temperature
· Maintenance-free system
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Turbo brake - Comparison with other braking systems 4
 Turbo brake - Flow plate location, design and operation 13.05.03

Location:
The flow plate (1) is installed in the matrix (2)
within a general layout designed for axial travel.

Operation:
When extended the flow plate (1) reduces the
effective flow aperture within the passage while
also shifting the impact angle at which the
exhaust gases hit the turbine, increasing the force
that the turbine generates.

W09.40-1065-09

1 Flow plate 3 Turbocharger A Flow plate retracted

2 Matrix B Flow plate extended

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Turbo brake - Flow plate location, design and operation 5
 Turbo brake - Location, design and operation of air-discharge element 13.05.03

Design:
The air-discharge element (1) consists of the
rotary slide valve (4) mounted in the turbocharger
housing and connected to the aneroid capsule
(2).

Location:
The air-discharge element (1) is located on the
turbocharger (3) in the supply port to the turbo
spiral.

Operation:
The air-discharge element (1) governs the flow of
exhaust gas into the turbine, redirecting it
through the channels (4) in the rotary slide valve
(4) and into the discharge line as required.

1 Air-discharge element
2 Aneroid capsule
3 Turbocharger
4 Rotary valve

W09.40-1063-06

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Turbo brake - Location, design and operation of air-discharge element 6
 Turbo brake - Turbine speed sensor location and operation 13.05.03

Location:
The turbine speed sensor (B104) is screwed into the housing of the turbocharger (1).

Operation:
As the turbine shaft rotates adjacent to the turbine speed sensor (B104) it generates an inductive voltage
signal. This signal is registered by the turbine speed sensor (B 104) for relay to the MR/PLD control
module.

1 Turbocharger
B104 Turbine speed sensor

W07.04-1024-03

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Turbo brake - Turbine speed sensor location and operation 7
 Turbo brake - Electropneumatic transducer (EPW) location, design and operation 13.05.03

Location:
The electropneumatic transducer (EPW) (Y87) is screwed into the engine block on the right side of the
below the turbocharger.

Function:
The MR/PLD control module triggers the electropneumatic transducer (EPW) (Y87) to govern the opening
ratio of the air-discharge element.

Y87 Electropneumatic transducer

W07.17-1002-03

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Turbo brake - Electropneumatic transducer (EPW) location, design and operation 8
Electropneumatic transducer design and operation

W07.17-1003-12 W07.17-1004-12

1 Air-discharge element control line The electropneumatic transducer (Y87) responds to the modulated input
2 Pneumatic supply line signal from the MR/PLD control module by regulating pressure in the air-
3 Aluminum housing
4 Air-discharge line
control line (1) for the discharge element.
5 Plug-in electrical connection The electronic control circuitry (8) compares the specified pressure with the
6 Valve actual conditions in the air-discharge element control line (1), which is
7 Pressure sensor monitored by a pressure sensor (7). The control parameter generated in the
8 Electronic control circuitry electronic control circuit (8) relies on the proportional-control valve (9) to
9 Proportional-control solenoid
provide air supply or discharge at the valve (8). This process continues until
the pressure in the air-discharge element control line (1) reaches the specified
level.

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Turbo brake - Electropneumatic transducer (EPW) location, design and operation 9
 Turbo brake - Engine brake demand 13.05.03

3-stage selector lever in AXOR

Switch position 1: The constant throttle is activated and the turbo brake supplies 50% of its maximum power.
The braking force generated by the turbo brake is regulated by the air-discharge system.
Switch position 2: Constant throttle and 100% of braking power from turbo brake. The rotary valve closes.
The valve sleeve is extended all the way in both cases.

6-stage selector lever in AXOR

The individual braking levels correspond to 20%, 40%, 60%, 80% and 100% of maximum braking force. The valve sleeve is always fully extended. The rotary valve
governs to the individual force graduation levels.

Tempomat cruise control

The valve sleeve is also fully extended in the Tempomat cruise control's braking mode. The rotary valve provides infinitely-variable regulation of braking force.

Braking levels for Freightliner, USA

Switch position 1: Constant throttle only, no activation of the turbo brake mechanism
Switch position 2: Constant throttle + 50% turbo brake power Switch position 3: Constant throttle + 100% turbo brake

Remark: Braking force and/or braking torque may need to be reduced when the system is used together with some transmissions (such as Allison, etc.).

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Turbo brake - Engine brake demand 10
 Turbo brake - Problem diagnosis, operating functions 13.05.03

Flow plate activation:

Can be verified externally by observing the motion of the control bracket activated by the pneumatic control cylinder. The process is governed by an electro-
pneumatic 3/2 proportional – control valve. In MB vehicles this, in turn, is governed by the FR Drive Control. Yet another option is to control this mechanism
manually using Star diagnosis.
In OM 460 (Freightliner) the MR Engine Control uses proportional-control valve 6 to control the control bracket.

Activating the rotary valve:

Operation can be verified from the outside by watching the process in which the rod from the aneroid capsule turns the rotary valve. The EPW valve controls the
aneroid capsule pneumatically in an infinitely-variable process. The EPW valve is controlled by the MR Engine Control via proportional-control valve 1. The
process can also be initiated manually using Star diagnosis. The rotary valve should move into its closed position when the engine is started.

Controlling the constant throttle valve:

An electrohydraulic 3/2 control valve installed above the oil filter manages the constant throttle valves. This hydraulic process is not visible from the outside. The
MR Engine Control governs the 3/2 control valve via proportional-control valve 2. The activation process can also be initiated manually using Star diagnosis. To
verify valve operation, start by briefly accelerating the engine from idle. Activation of the constant throttle should produce a more rapid rpm drop than occurs
when the unit is not activated. The constant throttle valve produces a gentle sound of rushing air. If a problem is suspected, it is possible to use a pressure gauge
to check pressurization in the control or to open a banjo bolt in the fluid line by a small increment (Caution: Hazard of considerable fluid discharge).
The constant throttle operates only at water temperatures above 60°C.

Turbocharger rpm sensor

The turbocharger rpm is monitored to protect the turbine against excessively high rotation rates during braking. The MR Engine Control governs rpm by
intervening via the air-discharge valve.

Notice: When Star diagnosis is employed to operate the proportional-control valves manually during testing, it is important to switch the ignition off completely
following testing. Failure to observe this instruction will allow the engine to remain in its test mode.

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Turbo brake - Problem diagnosis, operating functions 11
 Turbo brake - Problem diagnosis 13.05.03

General catalog of visual inspections performed with vehicle stationary

Operation of constant throttle valves

Condition: Vehicle with engine warmed to normal operating temperature.
Activation of constant throttle valves: Switch on braking at level 1, then raise engine rpm and allow it to fall again. The drop in engine speed should be
substantially quicker than without the constant throttle. A conspicuous noise from the exhaust system should also be
audible.

Turbo brake operation

Condition:
Activation of air-discharge valve:
Activating sleeve with flow plate:
Vehicle with engine warmed to normal operating temperature. Switch on the engine and engage brake at level 2. Tilt
the cab.
Use start button to start engine. When the engine is started it should be easy to see the aneroid capsule' s plunger
rod extending. When the engine is switched off again the plunger rod should retract all the way into the aneroid
capsule.
Engage braking at level 1 or 2 and use start switch to raise engine speed. Engine speed will start to run up and down.
The fork on the valve sleeve with flow plate must switch back all the way to its other position.

General catalog of operational tests to conduct during vehicle operation

Checking turbocharger speeds

Under full load n> 1,500 /min: Turbo speed >90,000 /min, max. 110,000 /min
With turbo brake at maximum capacity n> 2,000 /min: Turbo speed >85,000 /min to max. 90,000 /min

Checking control pressures

Line pressure at control cylinder: Specified: >8 bar
Line pressure at EPW valve: Specified: >5 bar at idle and under full load
(Notice: Future engines will also respond to the rotary valve when pulling loads.)

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Turbo brake - Problem diagnosis 12
Problem diagnosis table
Problems and malfunctions Possible problem sources
Turbo brake fails to operate Current error code in FR, MR or other systems
Clutch status "engaged" is not recognized.
Incorrect parameters entered in FR or MR
Control bracket for valve sleeve fails to No electrical trigger signal to solenoid valve
operate
Control bracket, cam lobe or valve sleeve sticking or
blocked mechanically
Control cylinder sticking or mechanically seized
No or inadequate supply of compressed air to
control cylinder
No or inadequate supply of compressed air to
solenoid valve
Rod on air-discharge mechanism fails to No electric trigger signal to EPW valve
operate
Rotary valve sticking or seized
No or inadequate supply of compressed air at
aneroid capsule
No or inadequate supply of air to EPW valve
EPW valve fails to operate
05/03 Trucks • Engine Turbobrake Code MZ4 Advanced Training Information Module
Turbo brake - Problem diagnosis
Remedial action
Access error codes and repair problems
Initialize clutch
Check parameters and correct as indicated
Check parameter entries in FR.
Detach control cylinder and check control bracket to ensure
that it moves without stiction.
Check operation of control cylinder
Check supply of compresed air from solenoid valve to control
cylinder
Check, measure air supply of compressed air to solenoid valve
Check air pressure in circuit 4
Open circuit in control wire for PWM signal (PWM signal 0 is
OK).
Check parameter entries in MR
Detach control cylinder and check rotary valve for mechanical
stiction.
Notice: Aneroid capsule rod is under tension
Check hose from EPW valve to aneroid capsule for compressed
areas and leakage
Check aneroid capsule for leakage
Specified test pressures in hose: 5 bar at idle, at least 2 bar
with engine brake operating
Check air pressure to EPW valve, measure as indicated
Check pressure in circuit 4
Replace EPW valve
13
Problem/malfunction Possible problem sources
Inadequate braking force Engine speed not high enough
Inadequate supply of compressed air to aneroid
capsule
No or inadequate supply of compressed air to EPW
valve
EPW valve malfunction
Constant throttle valves fail to open, no electrical
trigger signals to 3/2 control valves
Constant throttle valves fail to open, inadequate air
pressure at 3/2 control valve
05/03 Trucks • Engine Turbobrake Code MZ4 Advanced Training Information Module
Turbo brake - Problem diagnosis
Remedial action
Driver instruction: RPM > 2,000 when possible
Check hose from EPW valve to aneroid capsule for compressed
areas and leaks
Check aneroid capsule for leaks
Specified test pressures in hose: 5 bar at idle, at least 2 bar
with engine brake operating
Check, measure supply of compressed air to EPW valve
Check supply pressure in circuit 4
Replace EPW valve
Check parameter entries in MR Engine Control.
Coolant temperature must be > 60°C.
Check, measure compressed air supply to 3/2 control valve
Check supply pressure in circuit 4
14
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