BD Diesel Performance 1036703 Instructions Manual Download | Manualshive

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21 October 2011

Ford 6.7L 2011-2012 Positive Air Shutoff

5

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: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com

MAINTENANCE

No maintenance is needed other then check to make sure the valve is acting correctly.
Please see the testing section later in the manual for the correct procedure.

INSTALLATION with OVER SPEED ELECTRONICS (1036703)

VEHICLE

SHOULD

BE

SAFELY

SECURED

BEFORE

INSTALLATION.

1.

Block the wheels of the vehicle to prevent the vehicle from rolling.

Open the hood.

2. Remove the charge air cooler

pipe  using  a  flat  screwdriver  to
release the spring clips on both
sides  of the  turbo  intake,  and  a
7/16”  socket  and  ratchet  to
loosen both T clamps to release
the  pipe  from  the  water  to  air
cooler.

NOTE:

Keep all spring clamps

as you will be reusing them.

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Summary of Contents for 1036703

Page 1: ...sford 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 604 853 6096 Fax 604 853 8749 Internet www bd power com 2011 2012 Ford 6 7L Powerstroke Positive Air Shutoff P N 1036703 P N 1036703 M UPLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION ...

Page 2: ...ower com K I T C O N T E N T S Please check to make sure that you have all the parts listed in this kit before you start the disassembly of your truck 1036703 Kit Contents 1302300 1302258 1302274 Air Shutoff Valve Wiring Harness 3 3 Silicone Boot Qty 1 Qty 1 Qty 2 1302280 1302282 1407030 1405211 3 PAS Bead Ring PAS Drill Template 0350 Clamps 0325 Clamps Qty 2 Qty 2 Qty 2 Qty 2 1800060 1301381 1306...

Page 3: ... Harrison St Sumas WA 98295 U S Mailing Address P O Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com 1036703 M Kit Contents 1302300 1302249 1302274 Air Shutoff Valve Wiring Harness 3 3 Silicone Boot Qty 1 Qty 1 Qty 2 1302280 1405211 1407030 1302282 3 PAS Bead Ring 0325 Clamps 0350 Clamps PAS Drill Template Qty 2 Qty 2 Qty 2 Qty 2 ...

Page 4: ...ntents 3 REQUIRED TOOLS 4 MAINTENANCE 5 INSTALLATION with OVER SPEED ELECTRONICS 1036703 5 INSTALLATION without OVER SPEED ELECTRONICS 1036703 M 18 BEAD RING AND DRILL JIG INSTALLATION 29 WIRING DIAGRAM with OVER SPEED ELECTRONICS 1036703 30 WIRING DIAGRAM without OVER SPEED ELECTRONICS 1036703 M 31 RESETTING THE VALVE 32 SETUP TESTING AND VERIFICATION with OVER SPEED ELECTRONICS 33 Automatic Mode...

Page 5: ...he valve is acting correctly Please see the testing section later in the manual for the correct procedure INSTALLATION with OVER SPEED ELECTRONICS 1036703 VEHICLE SHOULD BE SAFELY SECURED BEFORE INSTALLATION 1 Block the wheels of the vehicle to prevent the vehicle from rolling Open the hood 2 Remove the charge air cooler pipe using a flat screwdriver to release the spring clips on both sides of th...

Page 6: ...St Sumas WA 98295 US Mailing Address PO Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com 3 Once the pipe is removed from the truck you can make your first cut at 4 1 2 from the factory pipe benders grip start on the C A C side IMPORTANT Ensure all cuts are straight 4 Then make the second cut from the grip start at 1 1 4 GRIP START CAC SIDE ...

Page 7: ...ower com When both pipes are cut they should look like this WATER TO AIR PIPE TURBO PIPE 5 Remove backing from drill Jig sticker and wrap around pipe The edge of the sticker should line up with the edge of the pipe For the 3 pipe the sticker should wrap perfectly around the pipe the start of the sticker should meet the end of the sticker NOTE Refer to the Bead Ring and Drill Jig Installation secti...

Page 8: ...l bit and drill a hole in the center of the holes marked For 3Ø There will be two holes and they should be perfectly 180 inline with each other through the pipe DO NOT DRILL COMPLETELY THROUGH THE PIPE AND OUT THE OTHER END YOU WILL NEED TO DRILL ONE SIDE THEN ROTATE AND THEN DRILL THE OTHER SIDE 7 Once the pilot holes are drilled you will need to drill an Ø11 32 hole through the pilot holes You c...

Page 9: ...ower com 8 Once the holes are drilled install the ring bead around the pipe Lock each end of the ring bead into each hole You can use needle nose pliers to tweak or adjust the ring fit slightly Be careful not to bend the ring bead to much as you will weaken it Note the ring bead does not have to be perfectly tight or snug around the pipe as we will be installing a silicone boot over top of it With...

Page 10: ...he bead rings are on the pipes install the boots 1302274 onto the valve using the supplied spring clamps 0350 1407030 then connect the pipes to the valve assembly ensuring the arrow on the valve points away from the pipe that connects to the turbo Secure the boot with the provided 0325 clamps 1405211 Note that there should be about 3 4 1 of silicone material after the bead ring Note leave clamps l...

Page 11: ...com 10 Install the assembly into the truck clock pipe sections and valve for clearance Tighten all clamps until spring is bound 11 Lay out supplied harness over top of the driver s side of the engine You will then need to route the switch wires through the firewall on the driver s side note you will need to remove the switch from the harness to accomplish this See wiring diagram on page 30 Choose ...

Page 12: ...g Address PO Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com 12 Using a 1 8 drill drill a pilot hole in the location you have selected for the switch to be mounted Finally using a 1 2 UNIBIT drill bit drill an exact 1 2 round hole 13 Once you have the mounting hole drilled insert the switch from the backside Reinstall the correct wires to the correct switch ter...

Page 13: ...ne 604 853 6096 Fax 604 853 8749 Internet www bd power com 14 Mount the switch so that the groove on thread boss is facing down Adjust the HEX washer nut so that the switch threads do not protrude an unsightly amount Then apply the supplied sticker and finally install the round plastic nut 15 Now underneath the hood locate and connect the weather pack connector on the wiring harness to the solenoi...

Page 14: ...ng Address 88 446 Harrison St Sumas WA 98295 US Mailing Address PO Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com 16 You will now need to locate the crankshaft position sensor wire pin 33 at the PCM connector on the passenger side of the firewall Year PCM Pin Wire Color 2011 33 Yellow Orange 2012 33 Yellow Orange ...

Page 15: ...trippers create a 1 window gap in insulation of the wire Then strip about 1 of insulation of the RPM signal wire of the BLUE wire from the PAS wiring harness Wrap the copper wire around the factory RPM signal wire and solder this connection Then use electrical tape to wrap this connection so that it is water tight You can also cut the factory crank signal wire and use heat shrink tubing if you wou...

Page 16: ...ou will need to locate ignition power This will power the automatic over speed control box LED switch Note that the unit can still be activated manually with the switch at any time Locate the fuse box under the hood driver s side in front of firewall Remove junction box cover and locate the appropriate fused ignition power circuit See table below Install fuse tapper onto fuse 49 and reinstall fuse...

Page 17: ...8749 Internet www bd power com 20 Mount the electronic control unit on to the junction box Be sure to clean the mounting surface with alcohol before applying the supplied Velcro Connect the wiring harness to the electronic control unit Double check all wiring connections and ensure wires are routed away from any heat sources and moving parts and continue to the Setup Testing and Verification secti...

Page 18: ...ATION without OVER SPEED ELECTRONICS INSTALLATION without OVER SPEED ELECTRONICS 1036703 M VEHICLE SHOULD BE SAFELY SECURED BEFORE INSTALLATION 1 Block the wheels of the vehicle to prevent the vehicle from rolling Open the hood 2 Remove the charge air cooler pipe using a flat screwdriver to release the spring clips on both sides of the turbo intake and a 7 16 socket and ratchet to loosen both T cl...

Page 19: ...Mailing Address PO Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com INSTALLATION without OVER SPEED ELECTRONICS 3 Once the pipe is removed from the truck you can make your first cut at 4 1 2 from the factory pipe benders grip start on the C A C side IMPORTANT Ensure all cuts are straight 4 Then make the second cut from the grip start at 1 1 4 GRIP START CAC SIDE...

Page 20: ...without OVER SPEED ELECTRONICS When both pipes are cut they should look like this WATER TO AIR PIPE TURBO PIPE 5 Remove backing from drill Jig sticker and wrap around pipe The edge of the sticker should line up with the edge of the pipe For the 3 pipe the sticker should wrap perfectly around the pipe the start of the sticker should meet the end of the sticker NOTE Refer to the Bead Ring and Drill ...

Page 21: ...d then use a Ø1 8 drill bit and drill a hole in the center of the holes marked For 3Ø There will be two holes and they should be perfectly 180 inline with each other through the pipe DO NOT DRILL COMPLETELY THROUGH THE PIPE AND OUT THE OTHER END YOU WILL NEED TO DRILL ONE SIDE THEN ROTATE AND THEN DRILL THE OTHER SIDE 7 Once the pilot holes are drilled you will need to drill an Ø11 32 hole through...

Page 22: ...pliers to tweak or adjust the ring fit slightly Be careful not to bend the ring bead to much as you will weaken it Note the ring bead does not have to be perfectly tight or snug around the pipe as we will be installing a silicone boot over top of it With the ring bead in place you should not be able to pull the ring bead off axially from the tube 9 Once the bead rings are installed connect the pip...

Page 23: ... ELECTRONICS 10 Once the bead rings are on the pipes install the boots 1302274 onto the valve using the supplied spring clamps 0350 1407030 then connect the pipes to the valve assembly ensuring the arrow on the valve points away from the pipe that connects to the turbo Secure the boot with the provided 0325 clamps 1405211 Note that there should be about 3 4 1 of silicone material after the bead ri...

Page 24: ...hout OVER SPEED ELECTRONICS 11 Install assembly into the truck clock pipe sections and valve for clearance Tighten all clamps until spring is bound 12 Lay out supplied harness over top of the driver s side of the engine You will then need to route the switch wires through the firewall on the driver s side note you will need to remove the switch from the harness to accomplish this See wiring diagra...

Page 25: ...Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com INSTALLATION without OVER SPEED ELECTRONICS Using a 1 8 drill drill a pilot hole in the location you have selected for the switch to be mounted Finally using a 1 2 UNIBIT drill bit drill an exact 1 2 round hole 13 Once you have the mounting hole drilled insert the switch from the backside Reinstall the correct wires to th...

Page 26: ...R SPEED ELECTRONICS 14 Mount the switch so that the groove on thread boss is facing down Adjust the HEX washer nut so that the switch threads do not protrude an unsightly amount Then apply the supplied sticker and finally install the round plastic nut 15 Now underneath the hood locate and connect the weather pack connector on the wiring harness to the solenoid on the PAS valve See page 31 for more...

Page 27: ...ernet www bd power com INSTALLATION without OVER SPEED ELECTRONICS 17 For the last connection you will need to locate ignition power Locate the fuse box under the hood driver s side in front of firewall Remove junction box cover and locate the appropriate fused ignition power circuit See table below Install fuse tapper onto fuse 49 and reinstall fuse Connect the pink lead wire with flag connector ...

Page 28: ...ss PO Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com INSTALLATION without OVER SPEED ELECTRONICS 18 Double check all wiring connections and ensure wires are routed away from any heat sources and moving parts Then install the loom with the supplied tee connector and clips for the loom ends and continue to the testing flow chart without over speed electronics in...

Page 29: ...E BRAKE INC Plant Address A10 33733 King Rd Abbotsford BC Canada V2S 7M9 US Shipping Address 88 446 Harrison St Sumas WA 98295 US Mailing Address PO Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com BEAD RING AND DRILL JIG INSTALLATION ...

Page 30: ... INC Plant Address A10 33733 King Rd Abbotsford BC Canada V2S 7M9 US Shipping Address 88 446 Harrison St Sumas WA 98295 US Mailing Address PO Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com WIRING DIAGRAM with OVER SPEED ELECTRONICS 1036703 ...

Page 31: ...C Plant Address A10 33733 King Rd Abbotsford BC Canada V2S 7M9 US Shipping Address 88 446 Harrison St Sumas WA 98295 US Mailing Address PO Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com WIRING DIAGRAM without OVER SPEED ELECTRONICS 1036703 M ...

Page 32: ...33 King Rd Abbotsford BC Canada V2S 7M9 US Shipping Address 88 446 Harrison St Sumas WA 98295 US Mailing Address PO Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com RESETTING THE VALVE Valve Activated Closed Valve Reset Open Rotate lever and lock in position to reset ...

Page 33: ...Test Mode 1320 1200 PAS Switch Position 3 Manual Mode User Configured User Configured Automatic Mode Pre Configured RPM Action Failure Fix Notes 1 Turn the ignition key to the on position You should see the RED light illuminate on the toggle switch If the LED does not illuminate check the wiring to the back of the switch first Then check entire circuit 2 Next start the engine 3 With the engine idl...

Page 34: ...ntrol module There are two locking tabs on the sides of the enclosure 6 Change the position selection switch to position 2 Auto Test Slide enclosure cover over circuit board 7 Start the vehicle with the vehicle in park step on the throttle increasing the engine RPM At 1320 RPM the PAS should engage itself automatically and the engine should stall Like with all activations the If the engine did not...

Page 35: ...n switch to position 1 You are now complete and the unit should function correctly This test cycle should be completed once a year Manual Mode User Configured RPM Setup With the control unit the user installer has the ability to set their own activation RPM It is necessary that you chose a low activation RPM first to test the units is operating correctly Once it has you will need to set the high l...

Page 36: ...on the unit will store the RPM 25 So for this example the unit has stored 1320 RPM 25 1650 RPM Set Button PRESS HOLD RPM Set RELEASE TO STORE RPM RPM Set You should see the RPM signal flash proportionally to engine RPM 7 Now increase the RPM of the engine to test the activation circuit is working correctly As in this example the valve should activate at 1650 RPM You should see the ACTIVATION LED f...

Page 37: ...mple the unit has stored MAXIMUM engine RPM 25 Set Button PRESS HOLD RPM Set RELEASE TO STORE RPM RPM Set 12 You can now put the electronic enclosure back together and secure it to the fuse box 13 With the engine running you will need to test to make sure the manual activation switch is functioning correctly 14 With the engine running lift the activation switch and the engine should die 15 Reset t...

Page 38: ...id engine stall Raise engine RPM 1200 RPM Did Valve Activate Did engine stall Reset Valve and return electronics to Position 1 Check Wiring Check valve Check Wiring Check Valve Testing Complete Manual Mode Ensure Electronic Module is set to Position 3 Start Vehicle Activate PAS valve using manual switch Did Valve Activate Did engine stall Check Wiring Check valve N N N N N N Depress RPM SET Button...

Page 39: ... INC Plant Address A10 33733 King Rd Abbotsford BC Canada V2S 7M9 US Shipping Address 88 446 Harrison St Sumas WA 98295 US Mailing Address PO Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 Internet www bd power com TESTING FLOW CHART without OVER SPEED ELECTRONICS ...

Page 40: ...he activation line or the solenoid is disconnected Activation Flashes when a valve activation is command manually switch or automatically Toggle Switch LED The LED will flash indicating either a problem with the system Loss of RPM or Power or an activate valve activation If you have any technical difficulties concerns comments or complaints please phone our Technical Support hotline at 800 887 503...

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