User Manual

3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
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Air Brake Troubleshooting Guide
This guide assumes that your exhaust brake system is using a DFIV and a BD air compressor. If you system uses a
microswitch for throttle activation, the operation of the air solenoid and pump are the same as with the DFIV. If you are
using existing on-board air, check that system as appropriate.
When I let off the throttle
nothing happens.
No
Yes
Is the DFIV powering its “brake”
output when the throttle is at idle
and brake switch and ignition are
both on?
Check if DFIV has good power, ground
and throttle signal. Check DFIV
adjustment. If these things check out,
but the DFIV won’t power the “brake”
output, the DFIV is likely faulty.
Also check power & ground at pump
relay and make sure the air solenoid
has a good ground.
Check that when air solenoid is
powered it will allow air to flow from
the #2 port out the #1 port.
Check that pump relay is powering
pump. If pump has power but does
not run, pump is likely faulty. Check
for power & ground at pump relay, if
these are good but relay does not
click or does not power pump, relay
is likely faulty.
The brake comes on but
there’s little or no holdback
No
Yes
See if torque converter is staying
locked up during deceleration. If
not, the engine RPM will fall to idle
when the throttle is released. The
brake will be ineffective without the
torque converter locked up.
Check off idle brake pressure.
(See back pressure chart)
Are you getting maximum allowable
backpressure?
Check for exhaust leaks. A small leak
can result in a significant decrease in
back pressure. If no leaks are found try
adjusting air regulator. Check for air
leaks in brake system.
Try down shifting more aggressively.
More RPM will give more holdback.
Transmission or torque converter
could be slipping internally.
Everything seems to work, but
the brake valve won’t close.
No
Yes
Check that air is reaching brake air
cylinder?
Air solenoid or quick release valve are
likely stuck, plugged or faulty. Clean or
replace as required.
Cylinder or brake valve are seized.
Remove the clevis pin on the end of
the cylinder rod & see if the valve
lever can be moved freely.
The valve lever can be moved
freely?
Try dismounting the brake & cleaning
the carbon out of it. If this does not
work the brake valve will need to be
replaced.
The cylinder is stuck and will need to
be replaced.
Problem
Solution
Air compressor runs in short bursts
and brake is slow to apply.
There is a restriction in the air system, normally in the regulator or air solenoid.
Remove the fittings from the regulator and air solenoid, you will likely find some
corrosion or debris caught in them. Clean this out with a pick, small brush,
compressed air and WD40 or similar lubricant.
Air compressor runs continually.
Pump relay is likely stuck on. Check operation of relay & replace as required.
Brake is slow to release.
Debris or corrosion is restricting the quick release valve or air solenoid. Clean
as required. Air solenoid could be too far from brake.
Thank you and happy motoring.
BD Engine Brake, Inc.