BD Diesel Performance 1036700 Manual de usuario

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 1

BD ENGINE 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

1999.5-2003 Ford 7.3L Powerstroke

Positive Air Shutoff

P/N#

1036700

P/N#

1036700-M

PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 2

BD ENGINE 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

KIT CONTENTS:

Please check to make sure that you have all the parts listed in this kit before you start

the disassembly your truck.

1036700 Kit Contents

1302300

1407001

1302253

1405404

Air Shutoff Valve

3”-3” Upper Silicone

Boot

Wiring Harness 3”-3 ¼” Silicone Boot

Qty: 1

Qty: 2

1302268P

1302269P

1405212

1407030

Lower CAC Pipe

Upper CAC Pipe

3.78” HD Clamps

3.50” Clamps

Qty: 1

Qty: 2

1800060

1301381

1306700

1302285

Velcro strips Heat Shrink

Ford Electronic

Module

Solder

Qty: 2 x 4”

Qty: 3”

Qty: 1

Qty: 5”

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 3

BD ENGINE 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

1036700-M kit Contents

1302300

1407001

1302253

1405404

Air Shutoff Valve

3”-3” Upper

Silicone Boot

Wiring Harness

3”-3 ¼” Silicone

Boot

Qty: 1

Qty: 2

1302268P

1302269P

1405212

1407030

Lower CAC Pipe

Upper CAC Pipe

3.78” HD Clamps

3.50” Clamps

Qty: 1

Qty: 2

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 4

BD ENGINE 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

WELCOME

Thank you for purchasing a BD positive air shutoff. This manual is divided into different

areas to assist you with your installation and operation of your positive Air shutoff.

This product is a safety product and should be tested often.

Installation should occur on a vehicle properly secured to prevent rolling.

TABLE OF CONTENTS

1036700 Kit Contents.......................................................................................................2

1036700-M kit Contents....................................................................................................3

REQUIRED TOOLS..........................................................................................................4

MAINTENANCE................................................................................................................5

INSTALLATION with OVER SPEED ELECTRONICS (1036700)......................................5

INSTALLATION without OVER SPEED ELECTRONICS (1036700-M)...........................15

WIRING DIAGRAM with OVER SPEED ELECTRONICS (1036700).............................21

WIRING DIAGRAM without OVER SPEED ELECTRONICS (1036700-M).....................22

RESETTING THE VALVE...............................................................................................23

SETUP, TESTING AND VERIFICATION with OVER SPEED ELECTRONICS...............24

Automatic Mode (Pre Configured RPM)......................................................................24

Manual Mode (User Configured RPM) ........................................................................26

TESTING FLOW CHART with OVER SPEED ELECTRONICS......................................29

TESTING FLOW CHART without OVER SPEED ELECTRONICS.................................30

LED OPERATION...........................................................................................................31

REQUIRED TOOLS

•Frequency/Voltmeter (Optional)

•Drill

•1/8” Drill Bit

•½” Unibit

•7/16”, ½” Sockets

•Wire Strippers

•Electrical Tape

•Soldering Iron

•Air or Manual Ratchet

•Wire Cutters

•Heat Gun

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 5

BD ENGINE 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

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 (1036700)

VEHCILE SHO

ULD BE SAFELY SECURED BEFORE

INSTALLATION.

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

Open the hood.

2. Remove passenger’s

side

charge air cooler

(CAC) pipe and upper

silicone boot

using a

7/16” socket and

ratchet.

Keep all spring clamps

as you will be reusing

them.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 6

BD ENGINE 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

All springs should be tightened until springs binds.

3. First install the new BD lower Charge Air Cooler (CAC) tube (#1302268P) to the

CAC. You will utilize the stock clamps and silicone boot for the lower connection.

4. Next, insert the two 3-3¼”

boots (#1405404) over each end of the PAS valve.

Tighten this connection with 2 of the 3.78” (#1405212) spring clamps. Tighten

until spring bound.

5. Then install t

he PAS/Boot assembly to the lower CAC pipe you installed earlier.

Rotate the assembly as the valve our pipe do not contact any other components.

Secure this connection with the 3.5” (#1407030) spring clamp.

6. Finally install the upper CAC pipe (1302269P) to the PAS/Boot assembly. Again

secure this connection with 3.5” (#1407030) spring clamp.

Lastly, install the 3” boot (#1407001) to the upper CAC pipe and the stock

aluminum compressor manifold. You will utilize the factory clamps for this

location.

8. Ensure the assembly does not contact anything.

1302268P

1302269

1405404

1302300

AIRFLOW

1407001

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 7

BD ENGINE 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

9. L

ay out supplied harness

over top of the passenger’s

side of the engine.

10. You will then need to route

the switch wires as well as

the yellow ignition power

through the firewall

on the

driver’s side (note

you will

need to remove the switch

from the harness to

accomplish this).

Choose a highly visible

location for the switch and

mount it to the dash.

Recommended location

Switch end of wiring harness & yellow

wire should be routed through the kick

panel.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 8

BD ENGINE 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

11.

Using a 1/8” drill, drill a

pilot hole in

the location

you have selected for the

switch to be mounted.

Finally using a ½” UNIBIT

drill bit, drill an exact ½”

round hole.

12.

Once you have the

mounting hole drilled,

insert the switch from the

backside.

Reinstall the correct wires to

the correct switch terminals.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 9

BD ENGINE 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

13. 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.

14. Now underneath the

hood l

ocate and connect

the weather pack

connector on the wiring

harness

to the solenoid

on the PAS valve.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 10

BD ENGINE 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

15.

On the front of the

engine locate the

Camshaft Position

Sensor (#14 in diagram).

Once you have located the

sensor,

trace back the

wiring harness and locate a

long section that will be

easy to splice into. Locate

the correct wire color and

pull back loom and expose

wire.

Year

Wire Color

1999-2003

Dark Green

16.

As an alternate you can

lso connect to the CAM

position sensor wire at the

ECM. The ECM is located

at the rear of the fire wall

driver’s side. It is below the

master cylinder.

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